Xerox Phaser 6121 Service Manual

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Phaser® 6121MFP

Multi-Function Printer

Phaser® 6121MFP Service Manual

Phaser® 6121MFP

Warning

Service Manual

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: May 2009

Prepared By:

Xerox Corporation GPDG Worldwide Product Training and Information 26600 SW Parkway Wilsonville, OR 97070

Unpublished rights reserved under the copyright laws of the United States.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 and 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 technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied, or otherwise reproduced without prior written consent from Xerox Corporation.

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ii Phaser 6121MFP Service Manual

About this Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Service Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

1 General Information

Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Technical Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Front Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Media and Tray Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

First Print Output Time (FPOT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

First Copy Output Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Mounting Surface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Information Pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Contents

Phaser 6121MFP Service Manual iii

Contents

2 Theory of Operation

Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Print Engine Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Automatic Document Feeder (ADF) Print Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Main Engine Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Imaging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Toner Cartridge Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Transfer Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

System Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Waste Toner Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Media Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Tray 1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

Output Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Automatic Document Feeder (ADF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

500-Sheet Feeder Unit (Tray 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

3 Error Messages and Codes

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Accessing the Error Log History List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Jam Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Service Call Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Scan Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fax Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Other Error/Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Initial Actions for Jam Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Jam Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57

Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

iv Phaser 6121MFP Service Manual

Contents

Service Call Error Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

0001 Main Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69

001B Toner Rack Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

0045 Scanner Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71

004A Duplex Unit Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

004C Exhaust Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73

004E LVPS Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74

0092 Transfer Belt Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

0094 Transfer Roll Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

0300 Laser Motor Failure and 0310 Laser Unit Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77

0500 Fuser Failure and 0503 Thermistor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79

0502 Thermistor Failure, 0510 Fuser Failure, and 0520 Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

0650 Scanner Home Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81

0F51 Waste Toner Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82

1038 Interface Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-83

133C Fax Modem Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

13C0 Print Control Board Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

13DD Initial Toner Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85

13E2 Engine ROM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

14A3 Scanner Head Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

3FFF Control ROM Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

CF01 Controller Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-87

4 General Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Service Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

General Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2-Sided Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Changing the Duplexing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Multiple-Sheet Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Mis-Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Printer Does Not Come to a “Ready” State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Control Panel LED is On, Control Panel Display is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Fax Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Fax Protocol Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Transmission Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Reception Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Other Fax Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Fax Failure After Installation/Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Fax Failure After Continuous Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Power Supply Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Control Panel Indicators Do Not Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Abnormal Noise and Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Abnormal Noise During Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Operating System and Application Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Windows 2000, Windows XP, Windows Server Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Verify Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Verify Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Macintosh Troubleshooting (Mac OS 10.2 and Higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Phaser 6121MFP Service Manual v

Contents

5 Print-Quality Troubleshooting

Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Defects Associated with Specific Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Initial Actions for Troubleshooting Print-Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Check the Media and Media Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Check Printer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Environmental Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Print Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Printing Test Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Automatic Document Feeder (ADF) Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Blank Copy or Black Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Light Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Foggy Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

White or Colored Lines and Bands in Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

White or Colored Lines and Bands in Scan Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Black Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

Gradation Reproduction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Void Areas and White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

Colored Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Blurred Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

Incorrect Color Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

Poor Fusing Performance or Offset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

Brush Effect or Blurred Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Back Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Uneven Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29

Skew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31

Uneven Density in the Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

Uneven Density in The Scan Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

Print-Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

6 Adjustments and Calibrations

Adjust Function Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Using the Adjust Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Entering Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Service Mode Menu Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Service Mode Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Service’s Choice Function Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Adjustment Function Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Counter Function Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Fixed Zoom Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

Factory Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

Clear Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Maintenance Mode Entry Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43

vi Phaser 6121MFP Service Manual

7 Cleaning and Maintenance

Maintenance Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

RIP (Repair, Inspect, and Prevent) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Clean the Scanner Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Laser Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

ADF Retard Roller and Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

ADF Pick Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

500-Sheet Feeder Paper Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Duplexer Transport Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

8 Service Parts Disassembly

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Imaging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

Separation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

ADF Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13

ADF Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

ADF Pick Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

Toner Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28

Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28

Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

ADF Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31

ADF Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Lifting Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-50

Contents

Phaser 6121MFP Service Manual vii

Contents

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54

Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56

High Voltage Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-57

Engine Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

Fax Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-66

USB Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-72

Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-79

Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-79

Developing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-84

Power Supply Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89

Fan Duct Guide Assembly/Ventilation Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95

Exit Tray Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96

Paper Path Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-98

Front Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-99

Solenoids and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Tray 1 Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Registration Roller Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101

Image Transfer Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103

Cleaning Blade Solenoid (SD5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104

Humidity Sensor/Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106

Duplex Unit Transport Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108

500-Sheet Feeder Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109

500-Sheet Feeder Tray (PL15.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110

Duplex Unit (PL14.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110

9 Parts List

Serial Number Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Part Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-40

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Parts List Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Part List 1.1 Automatic Document Feeder (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Part List 1.2 Automatic Document Feeder (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Part List 2.0 Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

Part List 3.0 External Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

Part List 4.0 Main Frame Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14

Part List 5.1 Rack/Rack Drive Section (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16

Part List 5.1 Rack/Rack Drive Section (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18

Part List 6.0 Paper Take-up Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-20

Part List 7.1 Transfer Section (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22

Part List 7.2 Transfer Section (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24

Part List 8.0 Paper Exit Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26

Part List 9.1 Drive Section (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-28

Part List 9.2 Drive Section (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30

Part List 10.0 Right Guide Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-32

Part List 11.0 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34

Part List 12.0 Cooling Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-36

Part List 13.0 Electrical Components Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-38

Part List 14.1 Duplex Unit (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-40

Part List 14.2 Duplex Unit (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-42

Part List 14.3 Duplex Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-46

viii Phaser 6121MFP Service Manual

500-Sheet Tray Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-48

Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-54

10 Wiring

Plug/Jack Designations and Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Contents

Part List 15.1 500-Sheet Tray (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-48

Part List 15.2 500-Sheet Tray (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-50

Part List 15.3 500-Sheet Feeder Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-52

Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-54

Print Engine Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Notations Used in the Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Control Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Engine Control Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Imaging Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Image Processor Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

HVPS Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Reference

Phaser 6121MFP Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-15

Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16

Index

Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

System Menu - Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Copy Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Scan Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Fax Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Phaser 6121MFP Service Manual ix

Contents

x Phaser 6121MFP Service Manual

About this Service Manual

Warning

Caution

Replacement Note

Note

The Phaser 6121MFP Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the printer and attached options. Also included are detailed replacement procedures, parts lists, and wiring diagrams.

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.

A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life.

A caution indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment.

A replacement note provides important information related to parts replacement. When needed, replacement notes appear at the end of the dissasembly procedure.

A note indicates an operating or maintenance procedure, practice or condition that is necessary 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.

Phaser 6121MFP Service Manual xi

Manual Organization

The Phaser 6121MFP Service Manual contains these sections:

Introductory, Safety, and Regulatory Information: This section contains important safety information and regulatory requirements.

Chapter 1 - General Information: This section contains an overview of the printer’s operation, configuration, specifications, and consumables.

Chapter 2 - Theory of Operation: This section contains detailed functional information on the print engine components.

Chapter 3 - Error Codes and Messages: This section provides detailed troubleshooting procedures for error messages and codes generated by resident diagnostics.

Chapter 4 - General Troubleshooting: Troubleshooting discussions covering troubleshooting procedures not associated with a Service Call code or Control Panel error message.

Chapter 5 - Print-Quality Troubleshooting: This section focuses on techniques to correct image quality problems associated with the printer output.

Chapter 6 - Adjustments and Calibrations: This section provides procedures for the adjustment of print engine components.

Chapter 7 - Cleaning and Maintenance: This section provides periodic cleaning procedures for the printer.

Chapter 8 - Service Parts Disassembly: This section contains removal procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary.

Chapter 9 - Parts List: This section contains exploded views of the print engine and optional Field Replaceable Units (FRUs), as well as part numbers for orderable parts.

Chapter 10 - Plug/Jack and Wiring Diagrams: This section contains the plug/jack locations and the wiring diagrams for the printer.

Reference: This section provides an illustration of the printer’s menu structure, printer firmware update instructions, and a list of acronyms and abbreviations.

xii Phaser 6121MFP Service Manual

Symbols Marked on the Product

Danger invisible laser radiation when open. Avoid direct exposure to beam.

Hot surface on or in the printer. Use caution to avoid personal injury.

Use caution (or draws attention to a particular component). Refer to the manua l(s) for information.

It may take 30 minutes for the Fuser to cool down.

Product Terms

Do not touch the item.

Do not expose the item to sunlight.

Do not expose the item to light.

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.

Phaser 6121MFP Service Manual xiii

Power Safety Precautions

Warning

Power Source

For 115 VAC printers, do not apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. 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. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Disconnecting Power

Turning the power Off using the power switch does not completely de-energize the printer. You must also disconnect the power cord from the printer’s Alternating Current (AC) inlet. Disconnect the power cord 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 product,

• 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.

xiv Phaser 6121MFP Service Manual

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 reduce the occurrence of component damage caused by static electricity.

Ensure 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. To drain the electrostatic charge, touch an earth ground source or wear a wrist strap device connected to an earth ground source. Wearing a wrist strap also prevents accumulation of additional bodily static charges. 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 that the device is being installed in.

• Minimize body motions when handling unpacked 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 ICs and Erasable Programmable Read-Only Memories (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).

Phaser 6121MFP Service Manual xv

Service Safety Summary

General Guidelines

For qualified service personnel only: Refer also to the preceding “Power Safety

Precautions” on page xiv.

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.

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 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 6121MFP 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 product does not emit hazardous laser radiation; which 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 to minimize hazards from the laser.

xvi Phaser 6121MFP Service Manual

Servicing Electrical Components

Warning

Before starting any service procedure, switch the printer power Off 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.

Do not touch any electrical component unless you are instructed to do so by a service procedure.

Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate the Drive Assemblies, Rollers, and Gears.

Do not try to manually rotate or manually stop the drive assemblies while any motor is running.

Servicing Fuser Components

This printer uses heat to fuse the image to paper. When operating, the Fuser 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 or adjacent components.

Phaser 6121MFP Service Manual xvii

Regulatory Specifications

Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.

United States (FCC Regulations)

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential environment. This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with these instructions, it may cause harmful interference to radio communications. 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 equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that which

• Consult the dealer or an experienced radio/television technician for help.

Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.

Canada (Regulations)

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

the receiver is connected.

xviii Phaser 6121MFP Service Manual

European Union

The CE mark applied to this product symbolizes Xerox’s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated:

December 12, 2006: Low Voltage Directive 2006/95/EC

December 15, 2004: Electromagnetic Compatibility Directive 2004/108/EC

March 9, 1999: Radio & Telecommunications Terminal Equipment Directive 1999/ 5/EC

This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment.

To ensure compliance with European Union regulations, use shielded interface cables.

A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

Phaser 6121MFP Service Manual xix

xx Phaser 6121MFP Service Manual

General Information

In this chapter...

• Printer Introduction and Overview

• Printer Configurations

• Parts of the Printer

• Maintenance Items

• Consumables

•Specifications

Chapter

General Information

Printer Introduction and Overview

The Xerox Phaser 6121MFP combines a color laser print engine, scanner, copier, and Fax. The print engine uses a four-pass color laser architecture producing 20 page per minute (ppm) monochrome or 5 ppm color prints on Letter or A4 media. The system connects to the host with USB or 10/100baseT Ethernet ports and provides a 35-sheet Automatic Document Feeder (ADF) and the standard 200-sheet input Tray. The Output Tray holds 100 (75.2 gsm) sheets facedown. Available options include a 500-Sheet Feeder (Tray 2) to add input capacity, and the Duplex Unit enables auto-duplexed (2-sided) printing.

Copy speed is 3 copies per minute (cpm) at a resolution of 600x300 dpi, monochrome copies at10cpm (600x300 dpi) or 20cpm (300x300 dpi). The Fax portion of the system incorporates a resolution of up to 203 dpi by 392 dpi. Fax features include a modem speed of up to 33.6 Kbps using V.34 standard transmission, print capability of up to a maximum of 250 printed pages. The Fax includes a phone book, real time clock, and auto redial.

Technical Support Information

The Xerox Phaser 6121 MFP 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 6121MFP Service Training is strongly recommended. To service this product, Xerox certification for this product is required.

For updates to the Service Manual, Service Bulletins, knowledge base, etc., go to:

• Xerox Global Service Net: https://www.xrxgsn.com/secure/main.p

• Service Partners: http://www.office.xerox.com/partners/

For further technical support, contact your assigned Xerox Technical Support for this product.

1-2 Phaser 6121MFP Service Manual

Printer Configurations

General Information

The Phaser 6121MFP is available in three configurations. The 3-in-1 version connects to the host by USB and provides platen scan. The 4-in-1 versions are expandable with both the options Tray 2 and Duplex Unit to enable 2-sided printing. The following table lists shared features of all configurations.

Fea tures Specification

Processor Speed 120 MHz

Max Print Speed (ppm) color/mono 5/20

Memory 128 MB

USB Port Yes

Print Resolutions (dpi): Draft Enhanced

600x600 1200x600

Copy Speed with auto document feeder

Scan speed (Phaser 6121MFP/N or /D printer configurations only.)

Scan Resolutions 150 x 150 dpi

The following table lists printer features by configuration.

Fea tures

10/100 Ethernet Port No Yes Yes

ADF No Yes Yes

Duplex Unit No Optional Yes

Color: 3 cpm (600 x 300 dpi) Monochrome: 10 cpm (600 x 300 dpi) Monochrome: 20 cpm (300 x 300 dpi)

Color: 600 x 600 dpi: 9.94 mm/second 600 x 300 dpi: 19.88 mm/second Monochrome: 600 x 600 dpi: 29.81 mm/second 600 x 300 dpi: 59.62 mm/second 300 x 300 dpi: 119.5.25 mm/second

300 x 300 dpi

Configuration

6121/S 6121/N 6121/D

500-Sheet Feeder (Tray 2) No Optional Yes

Phaser 6121MFP Service Manual 1-3

General Information

s6121mfp-017

Parts of the Printer

Front Views

Item Description Item Description

1 Document Output Tray 9 Document Cover

2 ADF (Auto Document

Feeder) Cover

3 ADF Guides 11 Tray 1

4 ADF Tray 12 Tray 1 Dust Cover

5 Document Stopper 13 Front Door

10 Output Tray

6 Printer Top 14 Tray Extension

1-4 Phaser 6121MFP Service Manual

7Power Switch 15Control Panel

8 USB Drive Port 16 Document Glass

Rear View

s6121mfp-173

2 3

4 5

General Information

Item Description

1Power switch

2 Power cord connection

3 Fax Phone line out (Phaser 6121MFP/N and /D only)

4 Line out jack (Phaser 6121MFP/N and /D only)

5USB cable port

6 Network/Ethernet connections (Phaser 6121MFP/N and /D only)

Phaser 6121MFP Service Manual 1-5

General Information

s6121mfp-175

Options

Duplex Unit

Item Description

1Duplex Unit Optional Base

2 Release Lever

3Duplex Unit

1-6 Phaser 6121MFP Service Manual

Lower Feeder Tray

s6121mfp-176

General Information

Item Description

1 Lower Feeder Unit

2 500-Sheet Feeder with Tray Cover

Phaser 6121MFP Service Manual 1-7

General Information

s6121mfp-177

15149 131276

Control Panel

The Control Panel consists of multiple LEDs, a display, and several function buttons. These buttons are used to navigate the menu system, perform functions, and select modes of operation.

Control Panel Button Descriptions

Left side: Fax Controls Middle Right side

1. Auto Receive LED

Remains lit while the automatic receive function is on. Blinks when there is a stored fax in memory.

2. Address Book button

Press to access the printer’s address book, fax numbers, and E-mail addresses.

3. Redial / Pause button

Recalls the last number dialed. Inserts a pause when a fax number is dialed.

4. On Hook button

When the fax line is shared with a telephone, pressing On Hook before sending or receiving disables the telephone extension.

5. Menu Display window

Displays settings, menus, and messages

6. Navigation / Menu buttons Up / Down arrow buttons

move through menus, options. Back / Forward arrow buttons move left and right through menus, options.

7. OK (confirm) button Press to select the setting

that is currently displayed.

8. Alert indicator When lit, indicates an error

condition or warning.

9. Back/Menu button Press to go to the System

Menu, cancel an entered character, or return to the previous screen.

10.Alphanumeric keypad Use to enter information.

11.Mode buttons Press to select Fax, Scan, or

Copy mode.

12.B&W Start button Starts a fax or B&W copy

or scan.

13.Ready indicator Lights up when it is OK to

press the Start button to copy, scan, or fax.

14.Color Start button Starts a color copy or scan.

15.Stop/Reset button Press to return to the

default mode main menu; cancel current print/copy/ fax job.

1-8 Phaser 6121MFP Service Manual

Maintenance Items

Note

s6121mfp-172

General Information

Routine maintenance items are parts or assemblies that require periodic replacement. These items are typically customer replaceable (CRU).

The listed items have limited life and require periodic replacement.

Maintenance Items

Item Print Life

Transfer Roller Up to 50,000 pages

Fuser Up to 50,000 pages

Imaging Unit Approximately 30,000 pages

Tray Separator Pad Up to 50,000 pages

ADF Feed Roller Up to 35,000 pages

ADF Separator Pad Up to 35,000 pages

Print life is based on “typical” office printing and 5% coverage per color on 24 lb. paper. Print life figures are not guaranteed and varies depending on usage habits. Imaging Unit print life is based on 3-page jobs using letter-size paper.

Item Description

1Transfer Roller

2Fuser

3Imaging Unit

Phaser 6121MFP Service Manual 1-9

4 Toner Cartridge

General Information

Consumables

Consumables consist of 4 Toner Cartridges.

Each Toner Cartridge has a CRUM (Customer Replaceable Unit Meter) to record toner usage information. A CRUM counts the amount of remaining toner. When toner empty is detected, Life End status is displayed to indicate toner empty.

CMY Toner is not consumed when printing in monochrome mode or when printing Gray scale. Internal counters track consumables and maintenance life.

Life ratings are based on A-size sheets at 5% coverage.

Print Life

Toner Cartridge

Standard Capacity 1,500 pages 1,000 pages

High Capacity 2,500 pages 2,500 pages

C,M,Y Black

1-10 Phaser 6121MFP Service Manual

Specifications

Printer Specifications

General Information

Characteristic Description

Type Desktop full-color laser beam printer

Printing system Laser and electrostatic image transfer to plain paper

Exposure system 2 laser diodes and polygon mirror

PC drum type OPC (organic photo conductor)

Photoconductor cleaning

Resolution 1200 x 600 dpi, 600 x 600 dpi

Media feeding 6121MFP/S Tray 1: 200 sheets

Developing system Single-element developing system

Charging system DC comb electrode Scorotron system

Image transfer system

Media separating Curvature separation + Charge-neutralizing system

Fusing system Roller fusing

Media exit system Face down (Output tray capacity: 100 sheets)

Warm-up time Average 30 seconds (return to Ready from Energy Saver)

Print resolution 600 x 600 dpi x 1 bit (Standard)

Custom media sizes Paper width: 92 to 216 mm (3.6" to 8.5")

Blade cleaning system

6121MFP/N/D Tray 1: 200 sheets

Expandable to a two-tray system by adding optional 500-Sheet Lower Feeder Unit.

Intermediate transfer belt system

1200 x 600 dpi x 1 bit (Enhanced)

Paper length: 195 to 356 mm (Plain paper) 184 to 297 mm (Thick paper)

Media types Plain paper (60 to 90 g/m2)

Thin card stock 1 (91 to 163 g/m2) Thick card stock 2 (164 to 209 g/m2) Postcards Envelopes Letterhead Label stock

Tray capacities Plain paper and letterhead: 200 sheets

Thick stock, postcards, labels, and glossy stock: 50 sheets Envelopes: 10 sheets

Phaser 6121MFP Service Manual 1-11

General Information

Performance Specifications

Characteristic Specification

Copy speed with auto document feeder (Phaser 6121MFP/N and /D printer configurations only.)

Copy resolution 600 x 600 dpi x 1 bit

Scan speed (Phaser 6121MFP/N or /D printer configurations only.)

Scan resolution 150 x 150 dpi

Fax M ode m spe ed (Phaser 6121MFP/N or /D printer configurations only.)

Fax T X speed (Phaser 6121MFP/N or /D printer configurations only.)

Color: 3 cpm (600 x 300 dpi) Monochrome: 10 cpm (600 x 300 dpi) Monochrome: 20 cpm (300 x 300 dpi)

Color: 600 x 600 dpi: 9.94 mm/second 600 x 300 dpi: 19.88 mm/second Monochrome: 600 x 600 dpi: 29.81 mm/second 600 x 300 dpi: 59.62 mm/second 300 x 300 dpi: 119.5.25 mm/second

300 x 300 dpi

V.34 (up to 33.6 k bps)

3 seconds/page (at V.34)

1-12 Phaser 6121MFP Service Manual

Controller

General Information

The following table lists controller functionality for the Phaser 6121MFP/S.

Characteristic Description

Memory RAM (128 MB)

Flash ROM (4 MB for F/W)

Interface USB 2.0 compliant

Hard Disk Not supported

Support Microsoft Windows Vista, Windows XP (Service Pack 2 or

later), Windows XP Professional x64, Windows Server 2003, Windows Server 2003 x64 Edition, Windows 2000 (Service Pack 4 or later)

Mac OS X (10.2.8 or later; We recommend installing the latest patch)

The following table lists controller functionality for the Phaser 6121MFP/N/D.

Characteristic Description

Standard memory RAM (128 MB)

Flash ROM (4 MB for F/W) Fax (6 MB )

Hard Disk Not supported

Interface USB 2.0 (High Speed) compliant, 10Base-T/100Base-T

Ethernet, Host USB (for scan to USB memory)

PSTN (Fax) Connector Two RJ11 (Phone and Line) for US models; phone port is

closed in European models

Support Microsoft Windows Vista, Windows XP (Service Pack 2 or

later), Windows XP Professional x64, Windows Server 2003, Windows Server 2003 x64 Edition, Windows 2000 (Service Pack 4 or later)

Mac OS X (10.2.8 or later; We recommend installing the latest patch)

Phaser 6121MFP Service Manual 1-13

General Information

Electrical Specifications

Characteristic Specification

Power Supply Voltage/Frequency

Line Voltages 110 – 127 VAC

220 – 240 VAC

Frequency Range 50 – 60 Hz

Current Capacity 110 V Engine: < 9 A

220 V Engine: < 5 A

Power Consumption (with all options, 110 or 220 V)

Power Saver Mode 10W or less

Standby Mode (Fuser On) 80W or less

Color Continuous Printing 300W or less

B/W Continuous Printing 396W or less

Maximum Value 1060 W or less

Environmental Specifications

Characteristic Specification

Te mp e ra tu re

Operating 10 to 35° C (50 to 95° F)

Storage -20 to 55° C (-4° to 131° F)

Humidity (% RH)

Operating 10 to 85% RH

Storage 35 to 85% RH

Operating Altitude

Acoustic Noise LWA(B) Sound Pressure (dBA)

0 to 2,500 meters (8,000 feet)

Printing 52

Standby 35

1-14 Phaser 6121MFP Service Manual

Media and Tray Specifications

Auto Document Feeder

Characteristic Specification

Paper Size A4 (210 x 297 mm / 8.2 x 11.5 in.)

Paper Type (Weight) Plain (50 – 110 gsm / 16 – 34 lb.)

Loading Capacity Holds up to 35 standard sheets

Paper Tray 1 – Multi-purpose

Characteristic Specification

General Information

Letter (8.5 x 11 in.) Legal (8.5 x 14 in.)

Custom size range: W: 140 – 216 mm, H: 148 mm – 356 mm

Paper Size A4 (210 x 297 mm / 8.2 x 11.5 in.)

A5 (148 x 210 mm / 5.8 x 8.2 in.) B5 (ISO) (176 x 250 mm) Envelopes C6 (114 x 162 mm) Envelopes DL (110 x 220 mm) Executive (7.25 x 10.5 in.) Foolscap (8 x 13 in.) Government Legal (8.5 x 13 in.) Government Letter (8 x 10.5 in.) Letter (8.5 x 11 in.) Letter Plus (8.5 x 12.69 in.) Legal (8.5 x 14 in.) SP Folio (210 x 330 mm) Statement (5.5 x 8.5 in.) UK Quarto (203 x 254 mm / 8 x 10 in.)

Custom size range: W: 92 – 216 mm (3.6 – 8.5 in.) H: 184 – 356 mm (7 – 14 in.)

Paper Type (Weight) Plain (60 – 90 gsm / 16 – 24 lb.)

Letterhead Thin Card Stock (91 – 162 gsm / 30 – 60 lb. Cover) Thick Card Stock (164 – 209 gsm / 61 – 80 lb. Cover) Envelopes (DL and C6 sizes only) Labels

Loading Capacity 200 sheets (20 lb.)

Phaser 6121MFP Service Manual 1-15

General Information

First Print Output Time (FPOT)

500-Sheet Feeder (Tray 2)

Characteristic Specification

Paper Sizes A4, Letter

Paper Type (Weight) Plain (60 – 90 gsm / 16 – 24 lb.)

Loading Capacity 500 sheets (20 lb.)

Duplex Unit

Characteristic Specification

Paper Sizes A4, Letter

Paper Type (Weight) Plain, Letterhead (60 – 90 gsm / 16 – 24 lb.)

First Print Output Time is defined as a time from when the engine receives a Start signal in Ready state, until a single page is printed and delivered to the output tray.

The following conditions are applied:

• The Controller does not keep the print engine waiting

• The printer is at Ready mode

• Paper is A size Short Edge Feed (SEF)

• Process control time is not included

Tray 1

Size

A4/Letter Simplex

A4/Letter Duplex

Legal Simplex < 33 sec. < 11 sec. N/A N/A N/A N/A

Legal Duplex N/A N/A N/A N/A N/A N/A

Normal paper

color mono color mono color mono

< 21 sec. < 11 sec. < 21 sec. < 11 sec. < 28 sec. < 19 sec.

< 33 sec. < 23 sec. < 33 sec. < 23 sec. N/A N/A

Tray 2

Normal paper

Tray 1

Thick paper

1-16 Phaser 6121MFP Service Manual

First Copy Output Time

10 cm

(3.9 in.)

10 cm

(3.9 in.)

27.8 cm

(10.9 in.)

71 cm

(27.9 in.)

67.3 cm

(26.5 in.)

60.5 cm

(23.8 in.)

s6121mfp-178

First Copy Output Time (FCOT) is defined as the time when the Start button is pressed until the trail edge of the first copied media passes the printer Exit Roller.

The following conditions are applied:

• The Controller does not keep the print engine waiting.

• The printer is at Ready mode (Laser Unit Motor Off, Fuser Ready).

• Paper is A size Short-Edge Feed (SEF).

• Media: Media feed from the standard media tray.

Mode FCOT (second) Platen FCOT (second) ADF

Color 57.0 sec. 45.0 sec.

Mono 23.0 sec. 19.0 sec.

Physical Dimensions and Clearances

General Information

Minimum Clearances

Minimum clearances for the Phaser 6121MFP/S.

Phaser 6121MFP Service Manual 1-17

General Information

(

)

s6121mfp-180

2°2°

Minimum clearances for the Phaser 6121MFP/N

81.4 cm

(32.0 in.)

60.5 cm

(23.8 in.)

79.4 cm

(31.3 in.)

10 cm

(3.9 in.)

Mounting Surface Specifications

These specifications apply to any printer used as a table-top printer.

Mounting surface flatness must be within the specified range. The printer must not be tipped or tilted more than 2 degrees.

10 cm

3.9 in.

25.4 cm

(10.0 in.)

s6121mfp-179

1-18 Phaser 6121MFP Service Manual

Information Pages

Configuration Page

General Information

Known problems that occur as a result of exceeding the mounting surface specifications are:

• Color-to-Color mis-registration, primarily in the horizontal (laser scan) direction.

• A smear or line of toner approximately 40 mm from the trailing edge of the print.

Print the Configuration Page from the Control Panel, System Menu > Print Config

Page. The Configuration Page includes this information.

Configuration Page Information

General Description Detail Description

Title Prints Title of the document

Supplies Status Shows the status of toner cartridges and Imaging

Unit, and displays the remaining life of each as a percentage.

Coverage Information Shows coverage information for each toner

cartridge as a percentage.

Counter Information Shows usage data by job type.

General Information Xerox Serial Number, Engine Serial Number,

Installation Date, Engine Firmware, Boot Code, Controller Firmware, Language, Energy Saver Mode, Toner Low Prompt, Toner Out Action, Initial Mode, Size Mismatch, Tray type and size

Machine Defaults Shows the default settings for copying, scanning,

and faxing.

Network Settings Network Interface, Host Name, DHCP/BOOTP,

IP Address, Subnet Mask, Gateway Address, MAC Address, DNS Addresses, and the status of Bonjour, HTTP, SNMP, FTP, and IPP

Fax Settings Fax Number, Tone/Pulse, No. of Ring, Line

Monitor, Header, Footer, Fax PTT Country, Send Speed, Receive Speed, ECM Mode

Email Settings Sender Name, Sender’s Email, SMTP Protocol,

SMTP Server Address, SMTP Port No., SMTP Authentication, POP Before SMTP, POP3 Server Address, LDAP Protocol, LDAP Server Address, LDAP Port No.

Phaser 6121MFP Service Manual 1-19

General Information

1-20 Phaser 6121MFP Service Manual

Theory of Operation

In this chapter...

• Operational Overview

• Paper Path of the Printer

• Major Assemblies and Functions

• Media Handling

Chapter

Theory of Operation

Operational Overview

Print Process

The Phaser 6121MFP is a full-color laser printer that utilizes electrophotographic recording principals to place a full color image onto the print media. The system contains a drum and developing unit that places the toner image of each color onto print media producing full-color prints.

The following illustration shows the Phaser 6121 print cycle.

Paper Separation

2nd Image Transfer

Transfer Belt Cleaning

1st Image Transfer

Photo

Developing

Printer Image Processing

The Phaser 6121 print process consists of these steps:

1. Exposure The surface of the Drum is irradiated with the laser light and an electrostatic latent image is formed.

2. Developing The toner, negatively charged, is attracted onto the electrostatic latent image formed on the surface of the Drum.

Conductor

Laser Exposure

PC Drum Cleaning

Photo Conductor Charging

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2-2 Phaser 6121MFP Service Manual

Theory of Operation

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Photo Conductor

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Transfer Belt

2nd Transfer Roller

Charge Neutralizing Cloth

A DC negative bias voltage is applied to the Developing Roller, thereby preventing toner from sticking to the background image portion.

3. Image Transfer to Belt A DC positive voltage is applied to the backside of the Transfer Belt to attract the visible, developed image from the surface of the Drum.

4. Image Transfer to Media A DC positive voltage is applied to the backside of the paper to attract the visible, developed image on the surface of the Transfer Belt to the media.

5. Paper Separation A Charge Neutralizing Cloth is provided on the guide plate to neutralize the charge.

Phaser 6121MFP Service Manual 2-3

Theory of Operation

Transfer Belt

2nd Transfer Roller

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Engine Control Board

Image Processor Board

CPU

Control Panel

Scanner

TC/Y TC/KTC/CTC/M

Image Processing

Fusing

Image Process

Paper Pick-Up/

Transport

Laser Unit

Image Bus Line

Control System Line

FAX

Power Supply/

High Voltage

6. Transfer Roller Cleaning The residual toner left on the surface of the Transfer Roller is removed by an alternating DC charge that transfers the waste toner back to the Transfer Belt for collection by the Transfer Belt cleaning blade.

7. Transfer Belt Cleaning A charge is applied to the Transfer Belt. By potential difference, residual toner on the surface of the Transfer Belt is collected for cleaning. The toner scraped off the surface of the photo conductor is collected in the Imaging Unit.

8. Fusing Toner is permanently fused to the paper by the combination of heat and pressure applied by the Fuser.

System Control

The following diagram shows the major operating components and their basic connection to each other.

2-4 Phaser 6121MFP Service Manual

Paper Path of the Printer

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Print Engine Paper Path

The print media is supplied from Tray 1 or the optional Tray 2, and is transported into the printer along the paper path as shown in the diagram.

Theory of Operation

Item Description

1Output Tray

2Tray 1 (MPT)

3 Tray 2 (Optional 500-Sheet Feeder)

Phaser 6121MFP Service Manual 2-5

Theory of Operation

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Automatic Document Feeder (ADF) Print Path

Sensors

The printer contains sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the paper path, and detects if a jam occurs. Other sensors detect the presence of the Toner Cartridges, stop printer activity if a door is open (interlock), detect the presence of media in the trays, and monitor the fusing temperature.

For an overview of sensors in the printer, see “Sensors and Switches” on page 2-11.

Sensor Types

The types of sensors used vary with function. In general, there are three types in use: photo sensors, microswitches, and thermistors.

Photo Sensors

Two types of photo sensors are used, photo-reflective and photo-receptive. Photoreflective sensors use light reflected back from an object to detect its presence. Photo-receptive sensors use an actuator or the object itself to block the light path to detect an object or condition.

Photo-reflective sensors have the light emitter and light receiver aligned on a single surface. Output of the photo-receptor is High (> +4.5 V) when light is being reflected back and Low (< +.3 V) when it isn’t. Photo-receptive sensors consist of a LED in one arm of a U-shaped holder, and a photo-transistor in the other arm. When the sensing area is vacant, nothing is between the arms of the sensor, light falls on the photo-receptor sending the signal High. If the light is interrupted, the photo-transistor goes Low.

Microswitches

Microswitches are used primarily as cover interlocks. They are in a normally open state, and close when actuated. Microswitches employ hooks or catches for retention in the bracket or frame.

2-6 Phaser 6121MFP Service Manual

Thermistors

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Thermistors have a known value of resistance whose value varies with temperature. Used primarily in the Fuser for temperature sensing.

Sensors in the Paper Path

The following illustration identifies the various sensors located along the paper path of a printer equipped with the Lower Feeder Unit and Duplex Unit. Error reporting is dependent on these designators. Error detection is based on paper transport timing through the sensing area.

Theory of Operation

Item Description

1Exit Sensor

2 2nd Image Transfer Retraction Position Sensor

3 Registration Sensor

4 Media Empty Sensor

Phaser 6121MFP Service Manual 2-7

Theory of Operation

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Automatic Document Feeder (ADF) Sensors

Item

Description

1 Paper Feed Sensor

2ADF Tray

2-8 Phaser 6121MFP Service Manual

Major Assemblies and Functions

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Scanner

Auto Document Feeder

Imaging Unit

Toner Cartridges

Laser Unit

Paper Feed Unit

2nd Image Transfer Section

Fuser

1st Image Transfer Section

The location of the system’s primary functional components is shown.

Theory of Operation

Phaser 6121MFP Service Manual 2-9

Theory of Operation

Scanner Control Board

LVPS

HVPS

Fax Board

Engine Control Board

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Main Engine Component Overview

Board Locations

2-10 Phaser 6121MFP Service Manual

Sensors and Switches

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Paper Feed Sensor

Registration Sensor

Exit Sensor

Temperature/Humidity Sensor

Registration Sensor

Rack Position Sensor

Front Door Switch

Main Power Switch

Contact Switch

Paper Full Sensor

2nd Image Transfer Retraction/Position Sensor

Theory of Operation

Phaser 6121MFP Service Manual 2-11

Theory of Operation

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Ozone Fan

LVPS Fan

Exit Tray Cooling Fan

Scanner Motor

Rack Motor

Developing Motor

Tray 1 Paper Feed Solenoid

Cleaning Blade Pressure/ Retraction Solenoid

Conveyance Solenoid

2nd Image Transfer Pressure/Retraction Solenoid

Main Motor

Motors, Fans, and Solenoids

2-12 Phaser 6121MFP Service Manual

Fuser

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Thermostat

Exit Sensor (PS7)

Pressure Roller

Thermistor (TH1)

Heater Lamp

Fusing Roller

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Theory of Operation

Functional components of the Fuser appears below.

Fuser Drive

The Fuser is driven by the Main Motor.

Phaser 6121MFP Service Manual 2-13

Theory of Operation

Fuser Temperature Control

To fuse the image on the media, the heater lamps are turned On and Off as necessary to bring the fusing temperature to an appropriate level. Thermistors are used to detect the surface temperature of the Fuser roller.

Warm-up Control Wait Control Print Control Wait Control

Printing Temperature

Warm-up Complete Temperature

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Warm-up Control

Control is provided until the Fuser roller reaches the predetermined level.

Control Start Timing

• The power switch is turned On.

• A malfunction or media misfeed is reset.

• The main body leaves the power save mode.

• A door is closed.

Control Termination Timing

• The Fuser roller reaches a predetermined temperature.

• A malfunction or media misfeed is reset.

•A door is opened.

2-14 Phaser 6121MFP Service Manual

Control Start Decision

Either of the following two control start decisions is made according to the temperature detected by the temperature/humidity sensor. The fusing temperature during the print cycle varies depending on the type of the start control carried out, either low temperature or ordinary start control.

Wait Control

Control is provided to ensure that the temperatures at different parts of the Fuser reach a constant level during the wait state.

Theory of Operation

Control Start Decision Environment on Start

Low temperature start control The temperature/humidity sensor detects a

temperature lower than the predetermined value.

Ordinary start control The temperature/humidity sensor detects a

temperature equivalent to, or higher than, the predetermined value.

Control Start Timing

• At the end of the warm-up control.

• At the end of the post-print cycle control (print start control).

Control Termination Timing

• The front cover is opened and closed.

• A malfunction or media misfeed occurs.

Print Control

To ensure a good fixing level and light transmission performance, the fusing speed and Fuser Roller temperature are controlled.

Control Start Timing

A print request is received.

Control Termination Timing

A malfunction or media misfeed occurs.

Phaser 6121MFP Service Manual 2-15

Theory of Operation

Print Control Temperatures

• The Fuser Roller temperature is set according to the type of media, main body interior temperature (as measured by the temperature/humidity sensor), and warm-up start decision.

• For types of media other than plain paper, the fusing speed is controlled at the 1/2 speed.

Print Control Temperature Adjustments

• The temperature during print control is adjusted using the menu available from the control panel.

• Adjustment steps are 0°C, -5°C, and -10°C.

Protection Against Abnormally High Temperature

The machine provides protection at three different stages to prevent abnormally high temperature of the Fuser.

Soft Protection

If the Thermistor (TH1) detects a temperature exceeding a predetermined value, the malfunction code representing abnormally high temperature is displayed. At this time, the power supply line is shut down.

If the temperature of the Fusing Roller does not reach a predetermined value within a predetermined period of time after the start of the warm-up cycle, the power supply line is shut down.

Hard Protection

If the CPU overruns and the output level of the CPU of the Mechanical Control Board becomes a HIGH or LOW level, and not a pulse output, and a predetermined temperature or higher is detected, a circuit within the Mechanical Control Board turns OFF the relay to shut down each power supply line.

Thermostat Protection

If a faulty Thermistor (TH) prevents detection of abnormally high temperatures by soft protect or hard protect, the thermostat operates at a predetermined temperature to shut down the power supply line.

2-16 Phaser 6121MFP Service Manual

PPM control

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Scanner Motor (M101)

Exposure Unit

PPM (page per minute) control prevents the edge temperature of the heating roller from increasing during a multi-print cycle using smaller sized media. The distance between fed sheets is increased according to the number of printed pages that are to be produced and the media length. This evens out the temperature of the heating roller and thus stabilizes fusing performance of the printed toner image.

The PPM control is provided at 20 ppm for a multi-print cycle of producing 20 pages. The number of printed pages per minute is established as detailed below for each media size for the 21st and subsequent pages.

No PPM control is provided for a multi-print cycle of color printing, as it is 1/4 of the monochrome printing.

Theory of Operation

Media Conditions PPM

A5, invoice 14 ppm

Media having a narrower width and longer length than above 8 ppm

Scanner

Scanner components include:

• Scanner Motor and Drive Belt

•Platen Glass

•Scanhead

Functional components of the Scanner are illustrated below.

Phaser 6121MFP Service Manual 2-17

The Scanner does not include sensors for determining the size of the original document. Original media size settings are made on the Control Panel.

Theory of Operation

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Home Position (Stand-by Position)

Reference Position

Original Reading Start Position

Original Reading Finish Position

Scanner Stop Position

Shading

Original Reading

Reference Position Detection

Scan from Platen

The Scanner performs these steps during a scan of an original placed on the platen.

• The exposure unit moves from the home position (stand-by position) reading the calibration sheet to make a shading compensation.

• The exposure units moves to the stand-by position.

• Original image reading starts from the start position of original reading.

• When the original reading completes, it moves to scanner stop position.

• After the reading completes, the exposure lamp lights OFF and it moves to the stand-by position.

• It moves again to detect the reference position.

• It moves to the stand-by position and stops there.

2-18 Phaser 6121MFP Service Manual

Scan from ADF

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ADF Reading Position

Home Position (Stand-by Position)

Reference Position

Shading

Reference Position Detection

Original Reading

The Scanner performs these steps during a scan of an original placed on the platen.

• The exposure unit moves from the home position (stand-by position) reading

• The exposure units moves to the stand-by position.

• It moves to ADF reading position and original image reading starts.

• After the reading completes, the exposure lamp turns OFF and moves to the

• After it moves again to detect the reference position, it moves to the stand-by

Theory of Operation

the shading sheet to make a shading compensation.

stand-by position.

position and stops.

Phaser 6121MFP Service Manual 2-19

Theory of Operation

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Semiconductor Laser

SOS Sensor

Polygon Mirror

G2 Lens

SOS Mirror

Return Mirror

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Photo

Conductor

Polygon Mirror

Laser Diode

Beam A

Photo Conductor Surface

Beam B

Return Mirror

G2 Lens

G1 Lens

Laser Unit

The Laser Unit in the Phaser 6121 printer has two laser diodes. The laser diode control circuitry adjusts the light intensity for each beam automatically. Image data is transmitted to the laser diodes in the Laser Assembly as digital signals. The laser diodes convert the image data from digital signals to optical signals. The Laser Assembly monitors and adjusts the intensity of the laser beams to attain a stable electrostatic image. The Laser Assembly is replaced as a complete assembly. Functional components within the Laser appear in the following.

Imaging Unit Exposure

The surface of the Imaging Unit is irradiated with laser light to form an electrostatic latent image. The polygon mirror has four faces. The two-beam laser array consists of two laser diodes arranged vertically. Two lines are scanned through a single face of the polygon mirror.

2-20 Phaser 6121MFP Service Manual

Laser Write Process

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Photoconductor

Semiconductor Laser

SOS Board

Polygon Motor

1. The laser light strikes the polygon mirror.

2. The four-sided polygon mirror rotates at high speeds driven by the Polygon Motor.

3. The Start-of-Scan (SOS) Sensor monitors laser light emission and initiates timing for each line of the scanning process.

Theory of Operation

Phaser 6121MFP Service Manual 2-21

Theory of Operation

Laser Write Timing

When a Ready signal is detected after the print cycle begins, a Laser On signal is output from the Engine Control Board. The Laser On signal triggers each laser diode illuminating the SOS Board and generating an SOS signal. The SOS signal is used to synchronize the timing at which the laser write each scan line.

The print start position in the CD direction is determined by the CD Print Start signal (/HSYNC) that is output from the Image Processor Board and the width of the paper.

The print start position in the FD direction is determined by the Image Write Start signal (TOD) that is output from the Image Processor Board and the length of the paper. The laser emission area is determined by the paper size. The area of 4 mm on both the leading and trailing edges of the paper is, however, the void image area.

/HSYNC

/VIDEO

4 mm

/VIDEO /TOD

4 mm

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2-22 Phaser 6121MFP Service Manual

Imaging Unit

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Transfer Belt

Cleaning Blade

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Theory of Operation

The Imaging Unit contains the photo-conductive drum, cleaning blade, transfer belt, transfer roller, and waste toner reservoir.

The photo-conductive drum is driven by the Main Motor through a series of gears. When the Main Motor is energized, it turns the drive gear, which in turn rotates the drum.

Phaser 6121MFP Service Manual 2-23

The cleaning blade is pressed against the drum to remove excess toner. Waste toner is stored in the Imaging Unit.

Theory of Operation

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Cleaning Blade

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Grid Mesh

An electrical charge is applied to the drum by an electrode mounted near the drum. This charge attracts toner from the Toner Cartridge developer roller. The image stabilization control process controls the grid voltage (Vg) applied to the electrode’s grid mesh.

Imaging Unit Life

A counter tracks the number of prints since the last detection of a new Imaging Unit. As this count nears its maximum value, the system generates a warning message. When the count reaches the maximum value, a replacement error is generated. The counter is reset following the detection of a new Imaging Unit.

The system checks for a new Imaging Unit when the Power Switch is turned On or the front door is closed. If a new Imaging Unit is detected, the image stabilization sequence is carried out.

The life counter is reset when a new Imaging Unit is detected. When a predetermined number of printed pages are produced after the life value has been reached, the machine displays a Imaging Unit replacement message.

2-24 Phaser 6121MFP Service Manual

Toner Cartridge

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Supply Section

Developer Roller

Supply Roller

Hopper Section

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Theory of Operation

The system employs four Toner Cartridges (CMYK) installed in a revolving Toner Cartridge Rack that positions each cartridge’s developer roller over the Drum. A cross section of the Toner Cartridge showing functional components follows.

1. Toner stored in the hopper is moved into the toner supply portion by the rotation of the Toner Cartridge rack

2. Toner in the toner supply portion is conveyed by the supply roller onto the developing roller.

3. Toner then sticks to the electrostatic latent image formed on the surface of the photo conductor drum. That part of toner left on the surface of the developing roller is returned to the toner supply portion.

Phaser 6121MFP Service Manual 2-25

Theory of Operation

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Bias Contact Point

4. To attract toner to the drum, a developing bias voltage (Vb) that includes both DC (-) and + AC components is applied to the developing roller during development. The AC component is applied only during development. The developing bias voltage (Vb) supplied by the High Voltage Power Supply is applied to the developing roller at the contact point shown below.

Developer Roller Drive

The Developer Roller is driven by the Developing Motor and intermediate gears.

Developing Roller

Intermediate Gear

Developing Roller Drive Gear

Developing Motor (M3)

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2-26 Phaser 6121MFP Service Manual

When the Toner Cartridge Rack is stationery at the developing position, the

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Developer Roller drive gear meshes with intermediate gears allowing the Developing Motor to engage the roller.

Toner Cartridge Rack

The Toner Cartridge Rack holds the four Toner Cartridges and rotates to position each cartridges’ Developer Roller in the developing position. The rack is driven by the Rack Motor.

Theory of Operation

The Toner Cartridge Rack has three stop positions driven by the Rack Motor: the standby (reference) position, the developing position, and the cartridge replacement position.

• The standby position is the Toner Cartridge Rack position when the system completes a warm-up cycle or waits for a print command.

• The development position is when the Toner Cartridge Rack stops during development of a specific color of toner.

• The cartridge replacement position refers to the position at which the Toner Cartridge Rack is stopped for replacement of the Toner Cartridge of a specific color of toner.

Phaser 6121MFP Service Manual 2-27

Theory of Operation

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0°

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90°

The standby position is 28° degrees before the developing position of the Magenta Toner Cartridge.

The developing position is where the Toner Cartridge Rack is rotated 62° degrees from the standby position.

The cartridge replacement position is where the Toner Cartridge Rack is rotated 90° degrees from the developing position.

2-28 Phaser 6121MFP Service Manual

Monochrome Process Operation

YYM

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The Toner Cartridge Rack follows these steps for monochrome prints.

1. The Toner Cartridge Rack is stationary at the standby position.

2. When a print request is received from the controller, the Toner Cartridge Rack is rotated to bring the K Toner Cartridge to its developing position.

3. Development of monochrome printing is started.

4. When the development is completed, the Toner Cartridge Rack is rotated and brought to a stop at the standby position.

Color Process Operation

The Toner Cartridge Rack follows these steps for color prints.

Theory of Operation

1. The Toner Cartridge Rack is stationary at the standby position.

2. When a print request is received, the Toner Cartridge Rack rotates to place the Y Toner Cartridge to its developing position.

3. Development of Y is carried out.

4. When development of Y is completed, the Toner Cartridge Rack is rotated to bring the M Toner Cartridge to its developing position.

5. Development of M is carried out.

6. Similarly, the Toner Cartridge Rack rotates and development of C is carried out, followed by K.

7. When the development of K is completed, the Toner Cartridge Rack rotates to the standby position.

Phaser 6121MFP Service Manual 2-29

Theory of Operation

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Rack Positioning Sensor (PS5)

Position Detection

The Toner Cartridge Rack stop position for each color of toner is detected by the Rack Positioning Sensor. Openings around the circumference of the Toner Cartridge Rack actuate the Rack Position Sensor at each stop position.

The Magenta Toner Cartridge includes a slit for detecting the standby position. When the Toner Cartridge Rack is rotated, the Rack Positioning Sensor (PS5) detects the standby position slit. To bring the toner cartridge rack to a stop at the corresponding developing position, the rack is rotated from the standby position 62° degrees by the Rack Motor.

2-30 Phaser 6121MFP Service Manual

Theory of Operation

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Detection Of M Developing Position

Detection Of Y Developing Position

Detection Of K Developing Position

Detection Of C Developing Position

Standby Position Detecting Position

Rack Positioning Sensor (In Standby Position)

Direction of Rotation of the Toner Cartridge Rack

Photo Conductor

When a replacement request is made for a Toner Cartridge, the Toner Cartridge Rack is rotated 70 degrees from the depleted cartridges’ developing position by the Rack Motor.

Phaser 6121MFP Service Manual 2-31

Theory of Operation

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Transfer Belt Drive Roller

Belt Positioning Sensor

Transport Belt

1st Transfer Roller

Driven Roller

Toner Collecting Auger

Cleaning Blade

IDC Sensor

2nd Transfer Roller

Pressure Slider

Pressure/Retraction Roller

Transfer Belt

The Transfer Belt serves to accumulate the images produced by the four developer rollers before transferring the composite image to the media with the Transfer Roller. Components of the Transfer Belt appear below.

In addition to the Transfer Belt, a Transfer Roller (sometimes referred to as the 2nd Transfer Roller) transfers the composite image to the media for fusing.

2-32 Phaser 6121MFP Service Manual

Transfer Drive

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Transfer Belt

Imaging Unit

Photoconductor

1st Transfer Roller

Driven Roller

Transfer Belt Drive Roller

Main Motor

The Transfer Belt and the 2nd Transfer Roller are driven by the Main Motor. The Transfer Roller Clutch at one end of the (2nd) Transfer Roller engages the Main Motor drive.

Theory of Operation

Phaser 6121MFP Service Manual 2-33

Theory of Operation

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Transfer Belt Cleaning

The Transfer Belt Cleaning Blade collects residual toner off the surface of the Transfer Belt, and a toner collecting auger transfers waste toner to the Imaging Unit reservoir. The prevention seal is affixed to prevent waste toner from leaking through a gap above the cleaning blade.

During color printing, an image is formed on the Transfer Belt for each color. The cleaning blade uses a retraction mechanism to lift off the belt during the printing process. However, no pressure/retraction sensor is used to trigger cleaning blade retraction. Instead, the IDC sensor detects a sample image on the Transfer Belt to control the pressure/retraction operation. During monochrome printing, no retraction sequence is needed. The cleaning blade is normally in contact with the Transfer Belt.

2-34 Phaser 6121MFP Service Manual

Theory of Operation

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234

Cleaning Blade retraction operations are driven by the Main Motor, Cleaning Blade Solenoid, pressure cam, and lever. When the Cleaning Blade Solenoid is energized, drive from the Main Motor is transmitted to the pressure cam.

The sequence of events to retract the cleaning blade are:

1. Drive from the Main Motor is transmitted to the drive gear.

2. Rotation of the drive gear is transmitted to the pressure cam.

3. When the cleaning blade pressure/retraction solenoid (SD5) is energized, the half-moon-shaped pressure cam rotates a half turn to push the lever forward.

4. When the lever is pushed forward, the cleaning blade is retracted.

Item Description

1 Cleaning Blade Pressure/Retraction Solenoid

2Cam

3Lever

4Cleaning Blade

Phaser 6121MFP Service Manual 2-35

Theory of Operation

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Belt Positioning Sensor

Detection Hole B

To return the cleaning blade to the Transfer Belt:

1. The cleaning blade pressure/retraction solenoid (SD5) is energized rotating the pressure cam a half turn. This pushes the lever backward.

2. When the lever is pushed backward, the cleaning blade is returned. Then, the cleaning blade is pressed against the transfer belt.

Image development requires the creation of a composite image on the surface of the Transfer Belt. The leading edge of each color component of the image must register correctly on the Transfer Belt’s surface. The position of the Transfer Belt is monitored by the Transfer Belt Position Sensor. The optical sensor detects holes in the Transfer Belt.

Two detection holes are punched in the Transfer Belt. The image write start position varies according to the media size. For A4 or smaller media, the image write start position, as determined by the sensor, is detection hole A. For a media sizes larger than A4, detection hole B is the reference for the image write start position.

2-36 Phaser 6121MFP Service Manual

Transfer Roller

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Theory of Operation

The Transfer Roller (sometimes referred to as the 2nd Transfer Roller) transfers the developed image from the Transfer Belt to the media. To allow development of the composite color image on the Transfer Belt, the Transfer Roller retracts from the belt while the image is developed.

The Transfer Roller retraction operation is performed by the Main Motor, Image Transfer Solen oid, and Transfer Roller C lutch. When the Image Transfer Solenoid is energized, drive from the Main Motor is transmitted to the Transfer Roller Clutch.

Phaser 6121MFP Service Manual 2-37

Theory of Operation

Pressure/Retraction Clutch

2nd Transfer Assembly

Ribs

Pressure Slider

2nd Image Transfer Pressure/ Retraction Solenoid (SD4)

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Transfer Roller Drive

The Transfer roller is driven through a set of intermediate gears by the Main Motor.

2nd Transfer Roller

Image Transfer

To apply pressure to the Transfer Roller (sometimes referred to as the 2nd Transfer Roller), the system follows these steps:

1. Drive from the Main Motor is transmitted to the drive gear.

2. Rotation of the drive gear is transmitted to the Transfer Roller Clutch.

3. When the 2nd Image Transfer Solenoid is energized, the Transfer Roller Clutch rotates a half turn. This moves the Pressure Slider.

4. When the Pressure Slider is moved, the ribs push against the Pressure Retraction Roller.

5. When the assembly is pushed up, the Transfer Roller presses against the Transfer Belt.

Main Motor (M1)

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2-38 Phaser 6121MFP Service Manual

Transfer Roller Retraction

Pressure/Retraction Clutch

2nd Transfer Assembly

Ribs

Pressure Slider

2nd Image Transfer Pressure/ Retraction Solenoid

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To retract the Transfer Roller from the Transfer Belt, the system performs the following steps:

1. When the Image Transfer Solenoid is energized, the Transfer Roller is presses against the Transfer Belt and the Transfer Roller Clutch rotates a half turn. This moves the Pressure Slider.

2. When the Pressure Slider moves, the Transfer Assembly, which has been pushed up by the ribs on the Pressure Slider, lowers.

3. When the Transfer Assembly lowers, the Transfer Roller retracts from the Transfer Belt.

Theory of Operation

Transfer Roller Cleaning

DC positive and negative transfer bias voltages are alternately applied to the Transfer Roller. These charges oppose those on the Transfer Belt attracting toner residue on the Transfer Roller back to the Transfer Belt. The Transfer Belt cleaning blade collects the waste toner from the belt and stores the waste in the Imaging Unit.

Transfer Roller cleaning occurs when:

• Power Switch is turned ON.

• Cover is opened and closed.

• A media error occurs during a print cycle.

• A paper empty condition occurs during a print cycle.

• A paper size error occurs during a print cycle.

Phaser 6121MFP Service Manual 2-39

Theory of Operation

Apply The Constant Current To

The 1st Transfer Roller

Apply The Constant Current To

The 2nd Transfer Roller

Measure The Resistance Of

The 1st Transfer Roller

Establish The 1st Transfer

Output Voltage

Measure The Resistance Of

The 2nd Transfer Roller

Establish The 2nd Transfer

Output Voltage

Constant

Voltage

Constant

Current

Measure

Resistance

Constant

Current

2nd Transfer Roller

Transfer Belt

Drive Roller

1st Transfer Roller

Transfer Belt

Photo Conductor

Ground

HVPS

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Process Control

For stable printing, the parameters related to forming both the electrostatic and toner image are continuously monitored and adjusted by the printer. Parameter correction and control over the entire printing process is called “process control”. Two primary process control mechanisms are used by the system, Automatic Transfer Voltage Control (ATVC) and Automatic Image Density Control (ADC).

Automatic Transfer Voltage Control (ATVC)

ATVC optimizes the transfer output. A constant current flows through each of the Transfer Rollers. The resistance of each of the 1st Transfer Roller, the Transfer Roller (sometimes referred to as the 2nd Transfer Roller), and Transfer Belt is measured. ATVC automatically adjusts the appropriate image transfer output voltage (bias) that is applied to each Transfer Roller and transfer belt during the print cycle.

Automatic Density Control (ADC)

ADC stabilizes image density to provide accurate tone reproduction. ADC uses the IDC Sensor and Temperature/Humidity Sensor to monitor system and environmental parameters to regulate the following:

• Leak detection control For the clearance between the Drum and Developing Roller, an optimum

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Theory of Operation

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OUT

Grid Bias Developing Bias

Developing

Charging

ADC Sensor

Temperature/

Humidity Sensor

ADC Control

1st Transfer Roller

2nd Transfer Roller

ATVC

developing bias voltage is established that prevents leak image or uneven density.

• IDC Sensor intensity control Adjustments are made to correct changes in IDC Sensor characteristics due to changes over time or contamination. The IDC Sensor is a photo-reflective sensor that emits light from an LED and detects the reflected light returning from the Transfer Belt. The light emitted from the LED is controlled so that the reflected light density is constant.

• Reflectance measurement control The reflectance of the Transfer Belt is measured using the IDC Sensor. The measurement is taken for one complete revolution of the Transfer Belt. The measured value is corrected during the intensity adjustment and G-correction control.

• Toner adherence control The developing bias voltage value is adjusted to keep constant the amount of toner sticking to the surface of the Drum with reference to the 100% solid image.

• Laser intensity adjustment control Characteristics of the Drum, developing, and charging processes are affected over time and by the environment. The intensity of the laser light is adjusted so that fine lines and gradations of a predetermined level are reproduced at all times.

• G-correction control A gradation pattern is produced on the surface of the Transfer Belt. The IDC Sensor measures the density of the pattern and sends the measured result to the controller for gradation adjustment.

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Theory of Operation

Depending on the state of the system, the process control mechanisms are activated. Factors for each state are listed in the following table.

Mode Process Control Criteria

Mode 1 ■ When the Power Switch is turned On, the current environmental

readings are different from when the Power Switch was turned Off.

■ The stored environmental readings taken when Energy Saver

mode was entered differ from those taken when the system woke from Energy Saver mode.

■ The Power Switch is turned Off and On or Energy Saver mode is

canceled after a predetermined number of printed pages have been produced.

■ A new Imaging Unit or Toner Cartridge is detected.

Mode 2 The Power Switch is turned Off and On, or Energy Saver mode is

canceled after a predetermined number of printed pages have been produced.

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Theory of Operation

Mode 2

ADC Intensity Control

Reflectance

Measurement Control

Laser Intensity Control

Mode 1

ATVC Control

Leak Detection Control

ADC Intensity Control

Reflectance

Measurement Control

Control Of The Maximum

Amount Of Toner Sticking

Control Of The Maximum

Amount Of Toner Sticking

Laser Intensity Control

G Correction Control

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The process controls invoked and the order in which they occur for each mode appears below.

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Theory of Operation

Note

Temperature/Humidity Sensor

The Temperature/Humidity Sensor monitors the internal temperature of the system. It is also used for image stabilization, transfer ATVC, and fusing temperature control.

There is a Control Panel command which obtains environmental temperature and humidity levels. However, this command is for internal use only and not available from the service menus.

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System Thermal Regulation

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Fans are the primary means used to limit the rise in internal temperature. Three fans are controlled by specialized circuity on the Main Board. The following illustration shows the location and airflow direction of these fans.

Theory of Operation

Item Description

Output Tray Fan Cools the Scanner and output media.

Power Supply Fan Draws cool air across the Power Supply.

Ventilation Fan Recovers toner powder in the Imaging Cartridge and

exhausts the ozone produced to the outside.

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Theory of Operation

Power Supply Fan

The Power Supply Fan cools the system Power Supply and operates at full-speed, half-speed, or stopped states.

The Power Supply Fan runs at full-speed for:

• A set period of time after the Power Switch is turned On.

• A set period of time after exiting Energy Saver mode.

• At the start of a print cycle (full-speed rotation after a set period of half-speed rotation).

The Power Supply Cooling Fan runs at half-speed:

• At the end of a print cycle (half-speed rotation following the predetermined period of time needed for full-speed rotation).

• During half-speed rotation under any condition other than above.

The Power Supply Fan stops when:

• The system enters the Energy Saver mode.

• The Power Switch is turned Off.

Ventilation Fan

The Ventilation Fan cools the system cabinet and operates at full-speed when the Main Motor is in operation.

Output Tray Fan

The Output Tray Fan cools the Scanner and operates at full-speed, half-speed, or stopped states according to these conditions:

The Output Tray Fan runs at full-speed:

• A set period of time after the Power Switch is turned On.

• A set period of time after exiting Energy Saver mode.

• At the start of a print cycle (full-speed rotation after a set period of half-speed rotation).

The Output Tray Fan runs at half-speed:

• At the end of a print cycle (half-speed rotation following the predetermined period of time needed for full-speed rotation).

•During standby.

The Output Tray Fan stops when:

• During Energy Saver mode.

• During firmware upgrade.

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Waste Toner Collection

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Waste toner removed from the Transfer Belt and drum by the cleaning blade is transferred by two gear driven augers into the Imaging Unit waste toner reservoir.

Theory of Operation

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Theory of Operation

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Waste Toner Collection Drive

Waste toner collection augers are driven by the Main Motor.

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Waste Toner Full Sensor

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Waste toner near full and full conditions are detected by the waste toner near full sensor, toner agitating screw, and an internal counter. An agitating auger is used in the reservoir to provide the maximum waste toner storage capacity. A waste toner near full condition occurs when light emitted from the sensor LED is obstructed during its travel through the light guide.

Theory of Operation

Rotation of the toner agitating screw causes the actuator to move up and down via the float plate, so that the waste toner near full sensor detects “H” and “L” signals alternately. When the amount of waste toner in the waste toner reservoir exceeds a predetermined level, the toner agitating screw no longer rotates. This stops the signal transitions from the waste toner near full sensor indicating a near full condition.

A waste toner full condition exists when 200 images are reached after a waste toner near full condition is detected. When the LED light is unblocked following Imaging Unit replacement, the waste toner full condition is reset.

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Theory of Operation

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Media Handling

Tray 1 Feeder

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Tray 1 Drive

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Pick Roller

Main Motor (M1)

Tray 1 Pick Solenoid (SD1)

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When the Tray1 Pick Solenoid is energized, drive from the Main Motor is transmitted to the Pick Roller via the Tray 1 Pick Clutch. At the same time, the Lift Cam is rotated, which raises the Lift Plate. The media is taken up and fed in by the Pick Roller.

Theory of Operation

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Theory of Operation

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Separation Pad

Retard Rollers

Pick-Up Roller

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Registration Sensor

The fixed Separation Pad system plus the Retard Rollers are used for paper separation. This ensures that only one sheet of paper is fed.

Tray 1 Media Detection

Tray media empty/misfeed conditions are detected by the registration sensor.

To reduce the number of detected paper misfeeds, another feed sequence is carried out if a registration sensor signal transition fails to occur within a predetermined period of time. If after the second feed attempt media is not detected, a media empty/misfeed condition is reported.

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Media Size Detection

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Output Tray

Theory of Operation

Media size is detected using the Registration Sensor. The length of the media is determined by the length of time the Registration Sensor remains High indicating media in the registration section.

If the media size specified by the controller does not match the media size detected by the Registration Sensor, the system displays an error message on the Control Panel. The sheet causing the size error continues through the print process and is output to the tray. Operations for subsequent sheets are specified from the controller.

Media is transported from the Fuser to the output tray using the Exit Roller. The Exit Sensor monitors the media output.

For printers without an installed Duplex Unit, the exit roller is driven by the Main Motor. During 1-sided printing, the exit roller rotates in the forward direction and feeds the media onto the output tray. If an optional Duplex Unit is attached, the exit roller is driven by the Duplex Unit.

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Theory of Operation

Paper Feed Roller

Pick-Up Roller

Document Feeder Transport Motor

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Output Tray Full Sensor

The Output Tray Full Sensor monitors output tray status.

Paper Full Sensor

Automatic Document Feeder (ADF)

The ADF feeds documents to the Scanner platen for scanning. The functional components within the ADF are illustrated below.

Paper Exit Roller

Paper Exit Rollers

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ADF Pick Operation

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Paper Feed Roller

Separator Pad

1. The media feed sensor detects media loaded in the document feeder.

2. The document stopper establishes the leading edge position of the document. The stopper is lowered in the standby state and raised when the document is taken up and fed in.

3. The document stopper is raised and lowered in synchronism with the raising and lowering motion of the pick-up roller.

4. The pick-up roller and media feed roller turn to take up and feed the original properly.

5. The pick-up roller transports the original up to the media feed roller.

6. The ADF Transport Motor drives the pick-up roller and media feed roller through a gear train.

Theory of Operation

Double feeding of paper is prevented using coefficient of friction between the feed roller and separator pad.

Single sheet feeding The coefficient of friction on the front side of the paper fed between the media feed roller and separator pad is equal to that on the backside of the paper. This allows the media feed roller to transport the paper.

Multiple sheet feeding The coefficient of friction between the paper and separator pad is greater than that between sheets of paper. This ensures that only the first sheet of paper is transported by the media feed roller.

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Theory of Operation

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Registration Roller 1

Registration Roller 2

Registration Roller

Registration Sensor

Document Feeder Transport Motor (M100)

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Document Feeder Transport Motor (M100)

Exit Roller

ADF Transport Operation

ADF Exit Operation

1. The registration roller is rotated by the drive from the ADF Transport Motor and move the original to the document scanning position.

2. The ADF Transport Motor drives the transport roller through a gear train.

3. Activation of the registration sensor establishes the document scan start timing.

4. Deactivation of the registration sensor establishes the document scan end timing and timing to de-energize the ADF Transport Motor.

The exit roller, driven by the ADF Transport Motor, turns to feed the original out of the ADF. The original is fed onto the output tray.

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Duplex Unit

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Switchback Motor

Door Sensor

Transport Motor (M6)

Loop Sensor (PS13)

Registration Solenoid (SD7)

Registration Roller

AD Drive Board

Transport Sensor

Transport Roller

Cooling Fan Motor (FM3)

Theory of Operation

The Duplex Unit adds 2-sided print capability to the system. The following illustrations show the location of components within the Duplex Unit.

Phaser 6121MFP Service Manual 2-57

Registration Roller

Transport Roller

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Theory of Operation

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Duplex Unit Drive

The print engine’s Exit Roller, driven by the Fuser gear assembly during one-sided operations, feeds media into the Duplex Unit. For duplex operation, the duplex option lever disconnects drive to the Exit Roller, and engages the Duplex Switchback Motor.

This reverses the Exit Roller feeding the media into the Duplex Unit.

After entering the Duplex Unit, two Transport Rollers, driven by the Duplex Unit Transport Motor, move media through the system.

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Xerox Phaser 6121 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

General Information

Printer Introduction and Overview

Technical Support Information

Printer Configurations

Parts of the Printer

Front Views

Options

Consumables

Specifications

Printer Specifications

Performance Specifications

Environmental Specifications

Media and Tray Specifications

First Print Output Time (FPOT)

Physical Dimensions and Clearances

Mounting Surface Specifications

Information Pages

Theory of Operation

Operational Overview

System Control

Paper Path of the Printer

Print Engine Paper Path

Automatic Document Feeder (ADF) Print Path

Sensors

Major Assemblies and Functions

Main Engine Component Overview

Scanner

Toner Cartridge Rack

Transfer Belt

Process Control

Media Handling

Tray 1 Feeder

Output Tray

Automatic Document Feeder (ADF)

Duplex Unit