Xerox Phaser 6128 MFP Service Manual

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Phaser® 6128MFP

Multi-Function Printer

Phaser® 6128MFP

Service Manual

Phaser® 6128MFP

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: March 2009

Prepared By:

Xerox Corporation XOG 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Unpublished rights reserved under the copyright laws of the United States.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.

XEROX®, CentreWare®, Phaser®, PrintingScout™, and Walk-Up® are trademarks of Xerox Corporation in the United States and/or other countries.

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As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.

PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTON E® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.

ii Phaser 6128MFP Service Manual

About this Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Service Safety Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx

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 and Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Internal View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

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

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

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

Scanning Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Copy Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Fax Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Memory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Print Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

First Print Output Time (FPOT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

First Copy Output Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Image Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

Mounting Surface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21

Media and Tray Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Controller Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Job Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Non-Genuine Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Maintenance Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26

Information Pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27

Contents

Phaser 6128MFP Service Manual iii

Contents

2 Theory of Operation

Phaser 6128MFP Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Print Process Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Printing Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Development. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Transfer (Drum ---> Paper). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Imaging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Excess Toner Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Media Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Media Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Media Path Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Manual Feed & Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Transfer Belt and Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Toner Cartridge & Dispenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Imaging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Printer Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Printer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Laser Unit Light Quantity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Drive Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Sub-Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

CCD Image Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Scanning on Document Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Automatic Document Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

ADF Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

ADF Media Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

ADF Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Fax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Fax Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Fax Scans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Protocol Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Fax Standards (ITU-T Recommendations). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

iv Phaser 6128MFP Service Manual

3 Error Messages and Codes

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

Accessing Error History Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Error History Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Error Messages Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Error Message and Code Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Jam Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Jam at Tray or Jam at Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Jam at Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Jam at Front Cover Open Front Cover and Remove Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Jam at Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Jam at Manual Feed Slot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

Jam at Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Jam at Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53

Consumable/Routine Maintenance Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Replace Fuser or Fuser Life Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55

Reseat Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

Toner Cartridge Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58

Low Density Yellow Cartridge Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59

Low Density Magenta Cartridge Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60

Low Density Cyan Cartridge Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62

Low Density Black Cartridge Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63

Non-Xerox Toner Cartridge Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Insert Cartridge Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Non-Xerox Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

IU CRUM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69

Imaging Unit Life, Replace Imaging Unit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

Check Imaging Unit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71

Insert Imaging Unit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

Tray and Media Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73

Load Tray or Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

Load Tray or Illegal Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Insert Output to Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Check Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78

Insert Output to Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Load or Remove Paper from Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

Reseat Paper at Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-83

Configuration, Memory, and Firmware Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Invalid User Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Disabled Func Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Limit Exceeded Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-87

Invalid Job Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88

MCU Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Download Mode Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90

PAGEC Timer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

RAM Disk Full Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92

Collate Full Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

Firmware Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94

MCU Communication Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-95

MCU NVRAM Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96

Contents

Phaser 6128MFP Service Manual v

Contents

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

Control Panel Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-98

K Mode Sol Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Main Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

Sub Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

Fan Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Front Cover Open Close Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Side Door Open Close Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

Scanner ADF Cover R Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

CTD Sensor Error (CMYK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

Check Unit CTD Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Transfer Life or DTB Life Over Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

Env Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

Memory Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Out of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

RAM Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116

Controller Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117

Email Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118

Email Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118

SMB Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

SMB Login Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

SMB or DNS Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

SMB Login Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122

SMB Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123

SMB or FTP Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124

Scanner and Copier Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126

PC Scan Time Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126

Scanner Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128

Scanner Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129

Scanner Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130

Copier Error Last Sheet not Copied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131

Controller Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132

Fax Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133

Memory Full / Fax Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133

Fax Codec Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

MFD Controller Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Fax Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137

Fax Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

Target Fax Connect Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139

Fax Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

Fax Codec Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141

Fax Data Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

Incorrect Password Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144

Fax Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145

Fax Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146

Target Fax No Answer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147

Fax Communications Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148

vi Phaser 6128MFP Service Manual

4 General Troubleshooting

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

System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Entering Service Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Exiting Service Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Service Diagnostics Menu Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Service Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

IIT Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

IIT I/O Diagnostic Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

IOT Diagnostic Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

IOT Sensor Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

IOT Motor, Solenoid Testing Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Feed Roller Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Printer Does Not Come to a “Ready” State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Control Panel LED is On, Control Panel Display is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Fax Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Transmission Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Reception Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Other Fax Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Fax Failure After Installation/Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Fax Failure After Continuous Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Color Fax Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

Engine Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Inoperable Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Engine Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Printer Continually Displays Warming Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

LVPS Overcurrent Protection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

LVPS Overvoltage Protection Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

+24 VDC Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66

Abnormal Noise and Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Abnormal Noise When Power is Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Abnormal Noise During Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Abnormal Noise During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

AC Supply Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-73

DC Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

Operating System and Application Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Windows 2000, Windows XP, Windows Server Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Verify Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Verify Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Macintosh Troubleshooting (Mac OS 10.2 and Higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76

Contents

Phaser 6128MFP Service Manual vii

Contents

5 Print-Quality Troubleshooting

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

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

Checklist Before Troubleshooting Print-Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Check Printer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Symptom Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

Print-Quality Defect Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Light or Undertone Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Black Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Vertical Blank Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Horizontal Band, Voids, or Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Vertical Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Horizontal Stripes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

Partial Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Random Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

Repeating Bands, Lines, Marks, or Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Residual Image or Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31

Skew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

Damaged Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Unfused Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Color Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Wavy Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Incorrect Magnification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

Lines or Streaks (from ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Spots from ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44

Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45

No Image IOT Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45

Pattern IOT Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Grid 2 ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Cyan 20% ESS Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Magenta 20% ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-47

Yellow 20% ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-47

Black 20% ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48

CMY 20% ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48

Gradation ESS Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

Toner Pallet Check Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

Contamination Check Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50

Pitch Chart Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-51

Imaging Unit Refresh Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

MQ Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-53

Alignment Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Ghost Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54

Print-Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Color Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-55

Skew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56

Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-56

Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-57

Perpendicularity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-58

Magnification Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-59

Guaranteed and Maximum Print Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-59

. . . . . . . . . . . . . . . . . . . . . .5-58

viii Phaser 6128MFP Service Manual

6 Adjustments and Calibrations

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Color Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Printing the Color Registration Correction Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Enabling/Disabling Automatic Color Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Adjusting Color Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Resetting the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Initializing Print Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Initializing NVM (NVRAM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Scanner Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Print Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Fax/Scanner Parameter Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

7 Cleaning and Maintenance

Service Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

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

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

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

Contents

8 Service Parts Disassembly

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

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

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

Notations in the Disassembly Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Separator Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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

Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

Toner Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15

Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

Outer Pole Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Inner Pole Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

ESS Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22

Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Right Side Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-24

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-25

Lower Scanner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Phaser 6128MFP Service Manual ix

Contents

Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-27

Manual Feed No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-27

Manual Feed Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-29

Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30

Registration Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-32

Tray No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Tray No Paper Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-33

Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Drive Clutch and Bearing Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Feed Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37

Gear P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43

Humidity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

ESS Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

FAX Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-47

LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-47

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-50

Right Side Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-51

Interlock Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-52

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54

Power Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54

GFI Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-56

MCU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-57

Main Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-58

Sub-Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62

Duct Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62

Breaker Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-64

LVPS Card Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-66

Upper Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75

IIT Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-77

ADF Feed Roll Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77

ADF Seperator Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-78

ADF Input Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-78

ADF Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-79

IIT Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-82

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-86

Erase LED Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-86

Right Imaging Unit Restraint Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87

Left Imaging Unit Restraint Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-88

Toner Cartridge Holders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-90

Dispense Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91

Toner Motor Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-94

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-98

Transfer Belt Pivot Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Transfer Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103

x Phaser 6128MFP Service Manual

9 Parts List

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

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

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34

Contents

Parts List 3.2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Parts List 4.1 Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Parts List 5.1 Dispenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Parts List 6.1 Transfer & Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

Parts List 7.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Parts List 10.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14

Parts List 10.2 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

Parts List 10.3 Media Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Parts List 10.4 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-20

Parts List 10.5 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

Parts List 10.6 Electrical (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24

Parts List 10.7 Electrical (2/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26

Parts List 10.8 Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-28

Parts List 10.9 Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30

Parts List 10.10 ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-32

Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-34

10 Wiring

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

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

Reference

Phaser 6128MFP Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Procedural Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

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

System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

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

Wiring Diagram Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Media Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

Toner Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

ADF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23

Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

Removal Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Replacement Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Boot Controller Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Firmware Controller Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Firmware MPC Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

Index

Phaser 6128MFP Service Manual xi

About this Service Manual

Warning

Caution

Replacement Note

Note

The Phaser 6128MFP 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 disassembly 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 6128MFP Service Manual xiii

Manual Organization

The Phaser 6128MFP 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 cover the operation of Power On Self Test (POST), Service Diagnostics, In addition, this section includes troubleshooting methods for situations where error indicator is not available.

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.

xiv Phaser 6128MFP 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 6128MFP Service Manual xv

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.

xvi Phaser 6128MFP 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 will reduce the occurrence of component damage caused by static electricity.

Be sure the power is Off to the chassis or circuit board, and observe all other safety precautions.

• Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.

• After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

• Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices.

• Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it.

• Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

• Minimize body motions when handling 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 6128MFP Service Manual xvii

Service Safety Summary

General Guidelines

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

Precautions” on page xvi.

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 6128MFP 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 and there will be no hazards from the laser.

xviii Phaser 6128MFP 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 6128MFP Service Manual xix

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 Federal Communications Commission (FCC) Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. 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 printer and the 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.

xx Phaser 6128MFP 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:

January 1, 1995: Low Voltage Directive 73/23/EEC as amended by 93/68/EEC

January 1, 1996: Electromagnetic Compatibility Directive 89/336/EEC

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 6128MFP Service Manual xxi

General Information

In this chapter...

• Printer Introduction and Overview

• Printer Configurations

• Parts of the Printer

• Maintenance Items

• Consumables

• Specifications

• Controller Functions

Chapter

General Information

Printer Introduction and Overview

The Xerox Phaser 6128MFP combines a color laser print engine, scanner, copier, and Fax. The Phaser 6128MFP has a single-pass color laser architecture, which offers color and mono print speed at 12/16-ppm, and resolutions up to 600 x 600 dots-per-inch (dpi). The printer supports USB 2.0 and 10/100 Base-TX Ethernet connectivity. The Scanner supports USB Scan to Desktop, Network Scan to FTP, Network Scan to Server Message Block (SMB), and Network Scan to E-Mail with resolution up to 1200 dpi and interpolated up to 9600 dpi.

The Phaser 6128MFP provides a 35-sheet Automatic Document Feeder (ADF), a 250-sheet Tray, a manual feed slot supporting single-sheet feed of specialty media, card stock, and envelopes. The Output Tray holds 150 sheets facedown.

Tec hn ic al Su ppo rt In for ma t ion

The Xerox Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.

To ensure complete understanding of this product, participation in Xerox 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/partnersl

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

1-2 Phaser 6128MFP Service Manual

Printer Configurations

The printer is available in these configurations

Printer Configuration

Printer

Fea tures

Configuration

Processor and Clock Speed 400 MHz

Memory Configuration

384 MB

Print Speed (Color/Mono) 12/16

Resolutions (dpi)

Standard 600 x 600 x 1 bit

Enhanced 600 x 600 x 4 bit

PCL6 Fonts Standard

USB 2.0 Support Standard

General Information

Ethernet Interface 10/100 Base-TX

Manual Feed Slot (Single sheet) Standard

Standard Tray (250 Sheets) Standard

Wireless LAN Optional

a. The Phaser 6128MFP has one memory slot with 256 MB DDR2

DIMM installed to provide the maximum of 384 MB.

Phaser 6128MFP Service Manual 1-3

General Information

s6128mfp-126

Parts of the Printer

Front and Side Views

1. Automatic Document Feeder (ADF)

2. Output Tray

3. Front Door Release

4. Power Switch

5. Right Side Door

6. Sheet Feeder

7. Paper Tray

8. Front Door

9. Control Panel

1-4 Phaser 6128MFP Service Manual

Rear View

s6128mfp-127

General Information

1. A D F Co v e r

2. E S S Co v e r

3. U S B Po r t

4. Ethernet Port

5. P h o n e Li ne o u t

6. P h o n e Li ne i n

7. P ow e r t es t

8. AC input

Phaser 6128MFP Service Manual 1-5

General Information

s6128mfp-128

Internal View

1. F u s e r

2. I m a gi n g U ni t

3. Toner Cartridges

4. T r a n sfe r B e l t

5. F ro n t C ov e r R e le as e

1-6 Phaser 6128MFP Service Manual

Control Panel

s6128mfp-129

1 4 7 82 356

11121314151617181921

Control Panel Button Descriptions

General Information

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.

Phaser 6128MFP Service Manual 1-7

General Information

1. Function Select

buttons

2. Display Indicates messages, menus, and toner levels.

3. Arrow buttons Scroll through the menus. The Back Arrow

4. Job Status button Press to check active job status.

5. System button Switches the display to the Setup menu. The

6. Alphanumeric key pad Use to enter letters and numbers for names and

7. Clear All button Clears all text or numbers or instructions.

8. Power Saver button This light is on in power saver mode. Push the

9. Stop button Cancels the current print job.

10. Start button Press to start a copy, scan, or fax job.

11. Error LED The red light indicates an error condition.

Press to use the Copy, Fax, Email, and Scan menus on the display screen.

button also displays the Walk-Up Features menu.

green light indicates that the printer is ready. If the light is blinking, the printer is receiving data.

phone numbers.

button to exit power saver mode.

12. Speed Dial button Press to access directories of group or individual

fax telephone numbers.

13. Clear button Deletes a single character each time the button

is pressed. For use when entering email addresses and telephone numbers.

14. Redial/Pause button Press the button to recall the last fax number

used or to insert pauses in fax numbers.

15. Manual Dial button When faxing, press this button to enter a fax

number with the alphanumeric key pad.

16. Address Book button Press to access the Fax and Email address books.

17. OK button Press to accept the setting selected.

18. Exit button Press to go up one level in the menu.

19. Arrow LEDs These LEDs indicate the flow of data either into or out of the printer.

20. Job in Memory LED When illuminated, it indicates that there is a job in the printer’s memory.

21. Color Mode button Press to switch between Color and Black and White modes for your copy, fax, and scan job.

22. One touch keypad Use to dial stored speed-dial numbers.

1-8 Phaser 6128MFP Service Manual

LED Indicators

Note

LED State Printer State

Green Ready to Print or in Power Saver mode

Flashing Green Processing print job

Red Error occurs, can be fixed by user

Flashing Red Error occurs, cannot be fixed by user

Control Panel Shortcuts

Mode Buttons Pressed at Power On

Service Diagnostics Up + Down arrow buttons

General Information

Maintenance Items

Reset Password to 0000 (used when the Control Panel menus are locked)

Boot Download for Controller Up + Down + System buttons

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

Imaging Unit Approximately 30,000 pages

Fuser Up to 50,000 pages

Tray Separator Pad Up to 50,000 pages

Tray Pick Roller Up to 50,000 pages

ADF Feed Roll Assy Up to 35,000 pages

System

ADF Seperator 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.

Phaser 6128MFP Service Manual 1-9

General Information

s6128mfp-130

PL10.10.3 ADF Feed Roller Assembly

PL10.10.4 ADF Separator Pad Assembly

PL6.1.1 Fuser Assembly

PL4.1.21 PHD Assembly

PL10.3.5 Separator Roller Assembly

PL3.2.4 Feed Roller Assembly

PL5.1.21 Toner Cartridge (K)

PL5.1.22 Toner Cartridge (C)

PL5.1.23 Toner Cartridge (M)

PL5.1.24 Toner Cartridge (Y)

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.

Toner Cartridge Print Life

C,M,Y Black

Standard Capacity 1,000 pages 1,000 pages

High Capacity 2,500 pages 3,100 pages

1-10 Phaser 6128MFP Service Manual

Specifications

Printer Specifications

General Information

Characteristic Specification

Printing Technology Recording System: Tandem electro-photographic system

using OPC Drum and direct transfer by the Transport Belt

Exposure System: 4 semiconductors laser beam scanning system

Transfer System: Four-color finished toner image is transferred onto the paper

Fusing System: Thermal fusing system by Free Belt Nip Fusing (FBNF)

Print Volume Average 450 PV/month

Maximum 40,000 PV/month

Median 300 PV/month

Color Medium Cyan, Magenta, Yellow, and Black Toner Cartridges

Resolution / Addressability (dpi)

Print-Quality Mode 600 x 600 x 1bit (Standard)

Average Image Coverage

Maximum Image Coverage

Printer Life 100,000 pages

Maximum Duty Cycle

Warm-Up Time Less than 30 seconds from Power On

Operating System Windows 2000/ 2003 Server/ XP Pro/ XP/

Standard 600 x 600 x 1

Enhanced 600 x 600 x 4

600 x 600 x 4bit (Enhanced)

Color 5% each CMYK

Mono 5%

240% for all C, M, Y, K combined

40,000 pages/month*

Vista

Macintosh OS 10.2 or higher

Linux Redhat, SuSe, and TurboLinux 10

Desktop

* Assumes a 30 day month of printing.

Phaser 6128MFP Service Manual 1-11

General Information

Scanning Specifications

Characteristic Specifications

Scanning Mode

■ Platen Mode: Scan document using the document glass

■ Constant Velocity Transport (CVT) Mode: Scan

document via the Automatic Document Feeder (ADF)

Maximum Scan Size

■ Platen Mode: 215.9 mm x 297 mm (8.5 in. x 11.7 in.)

■ CVT mode; 215.9 mm x 355.6 mm (8.5 in. x 14 in.)

Media Size

Minimum

Maximum

■ Fast Scan Direction: 148 mm (5.8 in.)

■ Slow Scan Direction; 210 mm (8.3 in.)

■ Fast Scan Direction: 215.9 mm (8.5 in.)

■ Slow Scan Direction: 355.6 mm (14.0 in.)

USB Scanning

Resolution Up to 9600 dpi

■ Scan Interface

■ File Formats

TWAIN/ WIA BMP, JPG, PDF, TIFF

Network Scanning

Resolution Up to 600 dpi

Color Mode Color, Black & White

Original Type Text, Photo, Mixed

File Format JPG, PDF, TIFF

Lighter/Darker 7 levels

Sharpness 3 levels

Contrast 3 levels

Auto Exposure Off, Normal, Higher (1, 2)

Scan to Desktop via

Up to 6 SMB servers

SMB

Scan to FTP Up to 6 FTP servers

Scan to E-mail Yes (no individual user log in)

Network Scan to Computer via SMB

Document Glass, 150 dpi, mixed,

9 sec.

letter size

1-12 Phaser 6128MFP Service Manual

General Information

Scan Performance

Function Document Black & White Color

Copy Specifications

USB Scan to Application (TWAIN)

USB Scan to Computer (via Express

Document Glass, 300 dpi, 24-bit color, letter size

Scan Manager)

Network Scan to Computer via SMB

Network Scan to Email

Document Glass, 150 dpi, mixed, letter size

Characteristic Specifications

Resolution

■ Black & White: 600 x 600 dpi

■ Color: 600 x 600 dpi

Copy Mode Color, Black & White

8 sec. 10 sec.

12 sec. 33 sec.

9 sec. 8 sec.

9 sec. 10 sec.

Output Type Standard, Enhanced (Best)

Or i g i n a l Type Text, Phot o , Te x t / P ho t o

Reduce/Enlarge 25%-400%

Lighter/Darker 7 levels

Color Saturation 3 levels

Sharpness 3 levels

Color Balance 4 colors, 3 densities, 5 levels

Auto Exposure Off, Normal, Higher (1, 2)

Number of Copies 1-99

Multiple Up (N to 1) Off, Auto, ID Copy, Manual

Duplex Copy On, Off

Poster 2x2, 3x3, 4x4

Auto Fit On, Off

Cloning On, Off

Collate

■ Color: 19

■ B/W: 50

Phaser 6128MFP Service Manual 1-13

General Information

Fax Specifications

Characteristic Specifications

Communication Mode

Resolution Lines:

Pixels

Supported Protocols

Compression Form at

Incoming Call Control

■ Priority 1: ITU-T Super G3

■ Priority 2: ITU-T G3 ECM

■ Priority 3: ITU-T G3

B&W (Fast Scan x Slow Scan)

■ 8 pixels x 3.85 line / mm

■ 8 pixels x 7.7 line / mm

■ 8 pixels x 15.4 line / mm

■ 16 pixels x 15.4 line /mm

■ 400 x 400 ppi / 25mm

■ 300 x 300 ppi / 25mm

■ 200 x 200 ppi / 25mm

■ 100 x 100 ppi / 25mm

■ V. 34 (Max.33.6 kbps)

■ V. 17 (14.4/12/9.6/7.2 kbps)

■ V. 29 (9.6/7.2 kbps)

■ V. 27ter (4.8/2.4 kbps)

MH, MR, MMR, JBIG (B&W 1-bit) JPEG (Color Fax)

Telephone Mode, Fax Mode, Telephone/ Fax Mode, Answering Machine Mode, Distinctive Ring Pattern Detection (DRPD)

Lighter/Darker 7 levels

DM Protection Reject junk Fax

Forwarding & Local

Supported

Color Fax Resolution is fixed by 200 x 200 dpi

Fax Address Book Up to 200 Speed Dial numbers and up to 6 Group Dial

numbers stored in device memory. The Group Dial Numbers may have up to 200 fax numbers associated with each group; however, the total number of allowable fax numbers for all groups is 200.

Lan Fax

Resolution Normal: 200 x 100 dpi

Fine: 200 x 200 dpi Super Fine: 400 x 400 dpi

Driver PCL driver - supported

PS driver - not support

Color Not support

Delayed Start Up to 24 hours

Broadcast Sending Up to 30 destinations

Zoom 25%-400% (same as printer driver)

1-14 Phaser 6128MFP Service Manual

Fax Specifications (continued)

Characteristic Specifications

General Information

Auto Reduction/ Enlarge (Auto Fit)

Rotation On/Off (same as printer driver)

N-Up 1/ 2/ 4/ 8/ 16/ 32 (same as printer driver)

Watermark Supported (same as printer driver)

Phone Book Up to 500 Speed Dial numbers and up to 500 Group Dial.

Memory Specifications

Characteristic Specifications

Memory Minimum 128 MB Onboard

Supported RAM Supports one 256 MB DDR2 DIMM in one

On/Off (same as printer driver)

Local phone book stored on PC not linked device.

memory

Maximum 384 MB

expansion slot with 128 MB mounted onboard.

Electrical Specifications

Characteristic Specification

Power Supply Voltage/Frequency

Line Voltages 110-127 VAC ± 10%

Frequency Range 50/60 Hz ± 3 Hz

Current Capacity 110 V Engine: < 9 A

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

Power Saver Mode 18.4W or less

Standby Mode (Fuser On) 60W or less

Color Continuous Printing 360W or less

B/W Continuous Printing 360W or less

Maximum Value 1100 W or less

220-240 VAC ± 10%

220 V Engine: < 5 A

Phaser 6128MFP Service Manual 1-15

General Information

Print Speed

Resolution

600 Standard 12/12 16/16

600 Enhanced 12/12 16/16

Environmental Specifications

Characteristic

Te mp e ra tu re

Operating 5 to 32° C (41 to 90° F)

Standby -20 to 40° C (-4 to 104° F)

Humidity (% RH)

Operating 15 to 85% RH

Standby 5 to 85% RH

Altitude

Color A/A4

Mono

A/A4

Specification

Operating 0 to 3,100 meters (10,171 feet)

Acoustic Noise LWA(B) Sound Power Level (B) Sound Pressure (dBA)

Printing 6.16 51.6

Standby 4.3 25.7

1-16 Phaser 6128MFP Service Manual

Operating Mode

General Information

Mode Condition Description

Running Mode The printer is under operating condition

such as running or recording.

Fusing Maintained at operating temperature.

Exposure The Laser Unit Motor runs at the

operating speed.

Recording The system is operating.

Cooling Fan The fan operates at high speed.

Control Panel Operation

Fax

LCD - Backlight: On LED - Ready LED is turned On.

Sending or receiving a Fax.

Communication

Ready Mode The printer is in standby status, ready to

run.

Fusing The system keeps the standby

temperature.

Exposure The system is at Pause.

Recording The system is at Pause.

Cooling Fan The fan operates at low speed.

Control Panel Operation

LCD - Backlight: On LED: If printer is online, Ready LED is turned On.

Power Saver Mode (Deep Sleep)

The printer enters into the Power Saver mode to reduce power consumption when it has not received print data for the specified time.

Fusing The system is Off.

Exposure The system is at Pause.

Recording The system is at Pause.

Cooling Fan The system is Off.

Control Panel Operation

NOTE

When the printer receives a print job or a button is pressed, the printer exits the Power

Saver mode and enters the Ready mode.

LCD: Off, LCD Backlight: Off LED: Power Saver LED is turned On.

Phaser 6128MFP Service Manual 1-17

General Information

First Print Output Time (FPOT)

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

Mode Tray FPOT (sec.)

Color Tray As fast as 17.0 sec.

Manual Feed As fast as 17.0 sec.

Mono Tray As fast as 14.0 sec.

Manual Feed As fast as 14.0 sec.

First Copy Output Time

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).

• Document is on the document glass (Document setting: Platen mode).

• Media: Media feed from the standard media tray.

Mode FCOT (sec.)

Color Less than 30.0 sec.

Mono Less than 21.0 sec.

1-18 Phaser 6128MFP Service Manual

Image Specifications

Note

Refer to “Print-Quality Troubleshooting” on page 5-1 for detailed specifications.

Characteristic Specification

Maximum Print Area 210.9 mm (8.2 inches) x 351.6 mm (13.8 inches)

Guaranteed Print Area 207.9 mm (8.2 inches) x 347.6 mm (13.7 inches)

Skew 190 mm ± 1.2 mm

Perpendicularity 114.5 mm ± 0.8 mm

Parallelism

Horizontal 180 mm ± 1.2 mm

Vertical 234 mm ± 1.2 mm

Linearity

General Information

The printed image has 4 mm margins on all sides.

Horizontal 190 mm ± 0.5 mm

Vertical 234 mm ± 0.5 mm

Slant 269 mm ± 1.2 mm

Magnification Error

Horizontal Simplex 234 mm ± 0.5 mm

Horizontal Duplex 234 mm ± 0.8 mm

Vertical Simplex 190 mm ± 0.5 mm

Vertical Duplex 190 mm ± 0.8 mm

Registration

Leading Edge 10.0 mm ± 2.0 mm

Side Edge 8.5 mm ± 2.5 mm

Phaser 6128MFP Service Manual 1-19

General Information

s6128mfp-131

250 mm/

9.84 inches

425 mm/16.73 inches

100 mm/3.94 inches

100 mm/

3.94 inches

585 mm/

23.03 inches

507 mm/

19.96 inches

600 mm/23.62 inches

320 mm/

12.60 inches

Physical Dimensions and Clearances

Dimensions

Height 585 mm (23”)

Width 420 mm (16.7 in.)

Depth 507 mm (20”)

Weight (base printer without consumables)

Minimum Clearances

25 kg (55 lb.)

1-20 Phaser 6128MFP Service Manual

Mounting Surface Specifications

s6128mfp-132

10°

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 10 degrees or 7 mm.

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.

Phaser 6128MFP Service Manual 21

General Information

Media and Tray Specifications

The following tables list the recommended Xerox paper for the printer.

Supported Paper Size

Paper Type Dimension

Manual Feed Tray

Letter 8.5 x 11 in. Yes Yes

Legal 8.5 x 14 in. Yes Yes

US Folio 8.5 x 13 in. Yes Yes

Executive 7.25 x 10.5 in. Yes Yes

A4 210 x 297 mm Yes Yes

A5 148 x 210 mm Yes Yes

B5 JIS 182 x 257 mm Yes Yes

Custom Size

a. Minimum 3"x5", maximum 8.66"x14".

Ye s Ye s

Supported Paper Types and Weights

Paper Type Dimension

Plain Paper

65-90 g/m

Letter Head 85-120 g/m

(22-32 lb.

Manual Feed Tray

Ye s Ye s

Bond)

Pre-Punched 65-90 g/m

(17-24 lb. Bond) Yes Yes

Color Thin Card Stock 100-163 g/m Special 100-163 g/m

Ye s Ye s

(30-60 lb. Cover)

Thick Card Stock 170-216 g/m Glossy Paper 100-163 g/m Thick Glossy Paper 164-216 g/m

Ye s No

Ye s Ye s

Label N/A Yes Yes

Supported Envelopes

Type Di mension

Manual Feed Tray

Envelope #10 4.12 x 9.5 in. Yes Yes

Monarch Envelope 3.87 x 7.5 in. Yes Yes

C5 Envelope 162 x 229 mm Yes Yes

DL Envelope 110 x 220 mm Yes Yes

NOTE

Do not use envelopes with hot melt glue, windows, or metal clasps.

22 Phaser 6128MFP Service Manual

Controller Functions

Job Control

Cancel Print

Forced Output

IP Filter

General Information

Cancel a print job while printing is in progress using the Stop button on the Control Panel. Job cancellation is not immediate. Depending on the job size, it may take several seconds to completely cancel.

This function forces the printer to print the received data when the printer is waiting for the remaining data during job processing.

Accept or reject print jobs from up to five specified IP addresses. IP filter is available only to LPD and Port9100.

Job Recovery

When a print job fails due to a jam, the printer automatically restarts the job after the jam is removed

Job Timeout

When job transmission is interrupted for a certain period of time, the print data is deleted as an error. The timeout setting can be changed using the menu on the printer’s Control Panel.

Print Volume Management

Print Volume (PV) Management manages print volume per user and can manage up to 50 users.

RAM Disk

RAM Disk functions when memory is expanded, enabling Collation, Secure Print, Proof Print, Form Overlay, and Font Download. 256 MB is needed to enable RAM Disk and all related functions.

Collation

Phaser 6128MFP Service Manual 23

General Information

The job is stored in the memory and multiple copies are printed. When the entire job does not fit in the memory, the printer prints one copy up to the stored pages, and the remaining are discarded.

An error message will appear on the Control Panel: “Error xxxx Press set key.”

Two options are available to ensure Job Collation will process effectively:

• Break large print job into multiple small print jobs

• Increase memory for the printer

Secure Print

When memory is expanded to 256 MB or more, the printer holds print data, including a User Password (11 digits), User Name, and Document Name in the memory.

• User ID – consists of a variable length from 1 to 24 byte characters (20HFFH). The driver requests the User ID from the user when the Secure Print option is selected. A user ID cannot be blanked with only space characters.

• User Password – consists of a variable length from 0 to 11 digits. The password is an optional input and hidden from the user interface by displaying “*” for each digit. If a password is not specified, the driver will accept it as a zero-length string so that a password will not be required when requesting job output from the printer.

• Document Name – consists of a variable length from 0 to 24 characters (20HFFH) that specifies the document name.

The data will not be printed until the same password, user name, and document name are provided via the printer menu on the Control Panel. User can remove or keep the data after printing the document. The data remains in the printer memory as long as it is not cleared and will be cleared when the printer is turned off. User can omit entering a password (this is called Store Print - not available for MAC OS 10.2.).

Proof Print

Proof Print can be selected only when multiple sets of prints are specified in the printer driver. Proof Print requires at least 256 MB of memory. The printer prints only the first set of the print data including a user name and document name specified in the printer driver. User can keep or remove the data using the printer menu on the Control Panel. The data remains in the printer memory as long as it is not cleared and erased when the printer is turned Off. This function is not available for MAC OS 10.2 and Linux operating systems.

Form Overlay

The function for writing PCL6 forms are downloaded into RAM Disk.

Font Download

PCL6 fonts can be downloaded into RAM Disk.

24 Phaser 6128MFP Service Manual

Billing Meters

The Billing Print counter provides the number of pages printed properly (simplex print is counted as 1 and duplex print is counted as 2 - including N up).

If an error has occurred after the one side printed properly during duplex printing, it is counted as 1.

Color Print Counter Counts the number of pages printed in color (7

Mono Print Counter Counts the number of pages printed in mono (7

Total Print Counter Count the total number of pages printed in color and

ID Print

General Information

Counter Description

digits).

mono (7 digits).

User can position and print the User Name on the upper right, upper left, lower right, and lower left (only for PCL6) of the page.

Non-Genuine Mode

When the Toner Cartridge life has ended, the printer stops accepting print request (life of the Toner Cartridge is counted by the counter in the CRUM). This mode can be changed so the printer will not stop at the end of the Toner Cartridge rated life; however, the printer will display an end of life message on the Control Panel.

Toner Cartridge Control Panel Display

To ne r Cartridge Control Panel Display Functionality

Life

Normal Status

Xerox Xerox (TM)

To n er Cartridge

Xerox (refill To n er Cartridge)

Xerox (TM) To n er Cartridge

Warning Error

Replace Soon

End of Life Error

Replace To n er Cartridge

Empty Prints with full

Prints with full functionality.

functionality up to 40% of the Toner Cartridge life.

Other OEM (non-Xerox printer manufacturer)

Phaser 6128MFP Service Manual 25

Non-Xerox To n er Cartridge

Printer displays error and will not print.

General Information

Note

Toner Cartridge Control Panel Display (continued)

To ne r Cartridge Control Panel Display Functionality

Life

Normal Status

Warning Error

End of Life Error

Non-Xerox To n er Cartridge Manufacturer

Maintenance Function

Firmware Update

The Image Processor Board can be updated by customers and service technicians using a Windows PC or Macintosh with dedicated utilities. Firmware updates are available at www.xerox.com/office/support.

Detailed procedures are available in “Firmware Update” on page A-10.

Boot Code can be updated via USB port only.

Image Processor Board Available Available

MCU Board

Non-Xerox To n er Cartridge

Updated Firmware Windows

No Life Track ing

Via USB/IEEE1284 Via Network (port 9100)

Available Available

Replace To n er Cartridge

Prints with full functionality.

a. MCU Board cannot be updated when ROM starts to be used for MCU Board.

Diagnostics

Two types of diagnostic functions are available:

1. Auto Diagnostics: The printer is checked when it is turned on. It is checked

whether hardware (ROM, RAM, ASIC, etc....) operates properly.

2. Manual Diagnostics: Only qualified service personnel can perform manual diagnostics using the Service Mode in the Control Panel.

26 Phaser 6128MFP Service Manual

Information Pages

s6128mfp-133

Configuration Page

General Information

Print the Configuration Page from the Control Panel > System > Information Pages > Configuration. The Configuration Page includes this information.

Configuration Page Information

General Description Detail Description

Title Prints Title of the document

Product Name (Logo) Prints organization’s logo

General Total Impressions, Total Color Impressions, Total

Black Impressions, Memory Capacity, Printer Language, Number of Fonts Available, PostScript Ver sion, PostScript Serial Number, Firmware Version, Boot Version, Engine Version, PostScript CRD Version, Default Paper, Default Language, Current Temperature, Current Humidity

Print Volume Print Volume for each paper size

Network Setup Firmware Version, MAC Address, Ethernet, TCP/IP,

Protocol, Host Access List, Adobe Protocol

Phaser 6128MFP Service Manual 27

General Information

Configuration Page Information

General Description Detail Description

USB Setup Adobe Protocol

System Setup PowerSaver Time, Audio Tones, Time-Out,

Language, Auto Log Print, Print ID, Print Text, Banner Sheet, RAM Disk, Tray Switching, mm/inch, Start Up Page

Maintenance Auto Reg Adj., Non-Xerox Toner

PCL Paper Tray, Paper Size, Orientation, 2-Sided, Font,

Symbol Set, Font Size, Font Pitch, Form Line, Quantity, Image Enhance, Hex Dump, Draft Mode, Line Termination, Default Color

Control Panel Panel Lock

Tray Settings Tray

PCL Fonts List

The PCL Font List contains No., Fonts, Escape Sequence, Font ID, Sample

PCL Macro List

Print the PCL Macro List on A paper size from default tray.

Job History Report

The printer retains up to 20 job logs. Job History can be manually or automatically printed when the number of the retained job logs reaches 20. Job History reports include:

• Job sent data and time

• Input Interface (USB, LPD,...etc.)

• Document Name (File Name)

•Output Color

• User Name/Host Name

• Number of Printed Pages (Color/Mono)

• Number of Printed Impressions (Color/Mono)

•Paper Size

• Result (successful, error,...etc.)

28 Phaser 6128MFP Service Manual

Error History Report

Phaser® 6128MFP-N

Color Multifunction Printer

Error History Report

System Fail History

Paper Jam History

Date 10/30/2008

Time 11:13

Paper Jam Type IOT Remain Registration Jam

Date & Time : 10/30/2008 11:14

Page:1(Last Page)

XEROX CORPORATION and Fui Xerox Co., Ltd. 2008

The printer retains up to 42 jam and up to 42 fatal errors.. The error logs include the following information:

• Jam Errors: Item No., Total Print Count, Paper Jam Type

• Fatal Errors: Item No., Total Print Count, Chain-Link Code

General Information

Print Meter (Print Volume Report)

The Print Meter page contains, Date of Initialization, Job Accounting User Name, Pages, Sheets, and Date/Time.

Phaser 6128MFP Service Manual 1-29

Theory of Operation

In this chapter...

• Phaser 6128MFP Operational Overview

•Printing Process

•Media Path

• Major Assemblies and Functions

• Printer Modes

• Printer Control

• Drive Transmission

Chapter

Theory of Operation

Phaser 6128MFP Operational Overview

The Phaser 6128MFP is a full-color multifunction printer that uses raster output scanner (ROS) lasers with an electrophotographic four-color CMYK process. The tandem system consists of four color drums (C, M, Y, and K) which creates the toner image.

The following block diagram provides the sequence of events for the xerographic process (dashed lines) and the paper flow (solid lines) into and out of the printer.

Print Process Block Diagram

Imaging Unit

(1) Charge

(2) Exposure

(3) Development

(5) Cleaning

Transfer Belt

(4) Transfer (Drum to Paper)

(7) Cleaning

Paper

(6) Fusing

s6128mfp-001

2-2 Phaser 6128MFP Service Manual

Printing Process

Theory of Operation

The print process consists of the following steps:

1. Charging – The Drum surfaces are charged with electricity.

2. Exposure – The Drums are exposed to laser beams.

3. Development – Image is developed with toner.

4. Transfer (Drum ---> Paper) – Four color finished toner image on the Drums is transferred onto the paper.

5. Imaging Unit – Excess toner is removed from the Drum and BCR.

6. Excess Toner Collection – Excess toner is moved to the collection box.

7. Fusing – The Fuser applies toner on to paper using heat and pressure.

Exit Pinch Roller (Fuser)

Exit Roller (Fuser)

Heat Roller (Fuser)

Fuser Belt (Fuser)

PHD

BCR (PHD)

BCR Cleaner Roller (PHD) Magnet Roller (PHD)

Drum (PHD)

Fuser

BTR (Printer)

Drive Roller (Printer)

s6128mfp-002

Phaser 6128MFP Service Manual 2-3

Theory of Operation

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Cleaning Roller

BCR

Photoreceptor

Conductor

Drum

HVPS

Charging

The drum surface is charged with negative electricity by discharging of the bias charge roller (BCR) while rotating at a constant speed. This process is performed in parallel for Cyan, Magenta, Yellow, and Black colors.

The BCR is kept in contact with the drum and rotates following the rotations of the drum. The BCR is a conductive roller, which receives negative voltage from the High-Voltage Power Supply (HVPS) and discharges a negative Direct Current (DC) voltage.

The drum surface is uniformly and negatively charged with DC bias voltage. The drum surface is a photoreceptor (which is an insulator in a dark area and a conductor when receiving light) and the drum inside is composed of conductor.

The cleaning roller is a sponge that contacts the BCR to catch the toner.

2-4 Phaser 6128MFP Service Manual

Exposure

: Laser beams (Y)

: Laser beams (M)

: Laser beams (C)

: Laser beams (K)

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Front

Drum (K)

Drum (C)

Drum (M)

Drum (Y)

Polygon Mirror

Mirror

Lens

Mirror

Lens

Mirror

Lens

Mirror

Lens

Mirror

Lens

Laser Diode Board

Polygon Mirror

Scanner

SOS Board

Lens

Mirror

Rear View

SOS Sensor

Theory of Operation

Four laser diodes (one for each color) in the Laser Unit emit laser beams. The beams are directed by mirrors to the rotating polygon mirror attached to the scanner motor. As the polygon mirror rotates, the beams are directed through a series of lenses and mirrors to each of the drums, which are scanned by the beams from end to end in the axial direction.

Phaser 6128MFP Service Manual 2-5

The negatively charged drum surface is scanned by the laser beams to form an invisible electrostatic latent image on the drum surface. The process is performed in parallel for Cyan, Magenta, Yellow, and Black colors.

The area on the surface where the laser beam strikes becomes conductive. The negative charge on the surface flows to the more positive drum, lowering the voltage potential. In this way the surface areas exposed to the laser beam become the electrostatic latent image.

Theory of Operation

Laser Unit

Laser Beams

Laser Beam

Negative Electric Charge Positive Electric Charge

Photoreceptor

Conductor

Drum

Electrostatic Latent Image

Potential on

Drum Surface

-V

Drum Surface

Concept of Drum

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2-6 Phaser 6128MFP Service Manual

Development

HVPS

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: Negative Electric Charge : Positive Electric Charge : Toner : Carrier

Trimmer Rod

Paddle

Toner Cartridge

Auger

Magnet Roller

Agitator

Drum

Theory of Operation

Toner is electrically attached to the invisible electrostatic latent image on the drum surface to form the visible toner image on the drum.

The toner in the Toner Cartridge is agitated by the built-in agitator and fed into the developer. The augers are driven by the Toner Motor and the developer motor in the Main Drive. The toner to be consumed according to the print count is calculated and fed into the developer. This process, called toner dispensation, is controlled by two processes: pixel count dispense control (PCDC) and automatic density control (ADC).

The toner fed into the developer and the carrier in the developer are agitated by the auger, and supplied to the magnet roller arranged in the drum surface area. The toner and carrier are charged by friction due to agitation (toner in negative, carrier in positive), and they are attracted electrically. A uniform layer is formed by the trimmer bar as the carrier magnetic substance is attracted to the magnetic roller.

Phaser 6128MFP Service Manual 2-7

The magnet roller is covered by a thin semi-conductive sleeve. The developer bias voltage is supplied to the sleeve by the HVPS. Developer bias is negative DC voltage combined with AC voltage. The magnet roller is kept at constant negative voltage against the photoreceptor layer of the drum by DC voltage. Therefore, at the area on the drum surface where the negative electric charge does not decrease, potential is lower than the magnet roller, while the potential is higher than the magnet roller at the area where the negative charge on the drum surface decreases. The AC voltage shakes the developer on the magnet roller surface, causing the toner to transfer to the drum.

Thus, the negatively charged toner is attracted only to the area on the drum surface (electrostatic latent image) where the negative charge is lower than the charge on the magnet roller, forming the toner image on the drum. Once the toner adheres to the drum, the negative charge of the toner-bearing location increases, which decreases the potential and the toner-attracting force.

Theory of Operation

Drum Surface

Toner Image

Electric Potential on Drum

Developing Bias

-V

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Drum Surface

(Black Toner Image)

Drum Surface

(Cyan Toner Image)

Drum Surface

(Magenta Toner Image)

Drum Surface

(Yellow Toner Image)

Paper

Black Toner Image

Cyan Toner Image

Magenta Toner Image

Yellow Toner Image

Transfer (Drum ---> Paper)

The toner image formed on the drum surface is transferred onto the surface of the paper. The toner is transferred onto the paper in the order of Y, M, C, and K.

2-8 Phaser 6128MFP Service Manual

Imaging Unit

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: Positive Electric Charge : Negative Electric Charge : Toner

Erase Lamp (LED Assembly)

Blade

Cleaning Roll

BCR

Drum

Conductor

Photoreceptor

Theory of Operation

• Bias Transfer Roller (BTR) – The BTR is a conductive roller that receives

positive voltage from the HVPS. The BTR contacts the rear side of the Belt and applies the positive voltage to the Belt.

• Transfer B elt – The Transfer Belt is a conductive unit that receives positive

voltage from the BTR. After the negative charged toner image on the Drum surface is drawn by the positive charge on the belt, it is transferred from the Drum to the paper. The Transfer Belt feeds the paper toward the direction of the Fuser.

Excess toner is removed from the Drum and the BCR surfaces, while excess charge is also eliminated from the drum surface.

• Drum Cleaning – The cleaning blade contacts the surface of the drum

collecting the excess toner by scraping off toner.

• Cleaning Roller – The Cleaning Roller contacts the surface of the BCR

collecting the excess toner by scraping off toner.

• Charge Cleaning – When the Drum is charged by the BCR, any excess charge

hinders the Drum surface from being uniformly charged, which may lead to print quality problems. The the latent charge pattern remaining on the photoconductive drum is neutralized by the Erase Lamp (LED) to prepare the drum for the next Exposure cycle.

Phaser 6128MFP Service Manual 2-9

Theory of Operation

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Toner Cartridge

Collection Box

Auger Cleaning Side

Auger

Cleaner Blade

Excess Toner Collection

The excess toner is collected by the cleaner blade contacting the drum and is moved to the Toner Cartridge collection box by two augers.

2-10 Phaser 6128MFP Service Manual

Fusing

Theory of Operation

The image is bonded to the media by the Fuser. The heat roller with the heat lamp melts the toner particles. Toner is fused onto the media by the combination of

heat and pressure.

Warm-Up Stand By Printing

Main Heater Lamp On On/Off On

Paper

Fixed Toner

Heat Roller

Heater Lamp

Nip Spring

Unfixed Toner

Nip Head

Felt

Belt

Belt Frame

Sheet

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Phaser 6128MFP Service Manual 2-11

Theory of Operation

Media Path

Media is supplied from the Tray or the manual feed slot, and is transported into the printer along the paper path as shown in the diagram.

Manual Feed Slot

Registration Assembly

Exit Roller in the Fuser

Transfer Belt

Fuser

Top Cover

Tray

Motor Drive/

Solenoid/Feed Roller

Motor Drive/Clutch/

Registration Roller

Motor Drive/Belt

Motor Drive/Heat Roller/

Pressure Belt

Multiple Sheet Feed Prevention

Leading Edge Registration (Except SSI)

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2-12 Phaser 6128MFP Service Manual

Media Path Components

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: Laser Beam : Paper Transfer : Paper Sensors

Exit Roller

Heat Roller

Pressure Belt

Belt

Rubber Registration Roller

Metal Registration Roller

Exit Sensor

Manual Feed No Paper Sensor

Registration Sensor

Separator Roller

Feed Roller

Tray No Paper Sensor

Media path components for the printer are shown in the following figure.

Theory of Operation

Phaser 6128MFP Service Manual 2-13

Theory of Operation

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Bottom Plate

Side Guide (L)

Side Guide (R)

End Guide

Separator Roller

Major Assemblies and Functions

Major functional components are classified into the following categories:

•Tray

•Feeder

• Manual Feed & Registration

• Transfer Belt and Fuser

•Laser Unit

• Toner Cartridge & Dispenser

•Imaging Unit

•Drive

•Electrical

Tray

• Separator Roller

The Separator Roller and Feed Roller pinch the media to prevent multiple sheets from feeding.

• Left/Right Side Guide

The side guides move at a right angle to the paper transfer direction to align the paper width.

•Tray End Guide

The end guide moves in toward the paper transfer direction to determine the paper size.

2-14 Phaser 6128MFP Service Manual

• Bottom Plate

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Feed Roller

Separator Roller

Friction Clutch

The bottom plate is locked to the Tray bottom when the Tray is pulled out of the paper feeder, and unlocked when the Tray is installed in the paper feeder. When unlocked, the bottom plate lifts the paper, pushing it against the feed roller using spring tension.

Seperator Roller

The sheets loaded into the Tray are occasionally stuck together along the edges, which can cause a multiple feed or a jam. The sheets are fed by the Feed Roller to a position between the Feed Roller and the Separator Roller. Normally, when only one sheet is fed, both the Feed Roller and Separator Roller rotate to allow the sheet to pass.

However, when two sheets are fed concurrently, only the Feed Roller rotates. The Separator Roller is locked, allowing the upper sheet to pass, separated from the lower sheet that is stopped by the friction with the Separator Roller at rest.

The Separator Roller is pushed toward the Feed Roller by spring pressure, and controlled by the Friction Clutch.

Theory of Operation

Phaser 6128MFP Service Manual 2-15

Theory of Operation

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Feed Roller

Feed Solenoid

Tray No Paper Sensor

Feeder

• Tray No Paper Sensor

Detects the presence/absence of paper in the Tray based on the position of No Paper Actuator.

2-16 Phaser 6128MFP Service Manual

Theory of Operation

Tray No Paper Sensor

Paper

Bottom Plate

No Paper Actuator

(No Paper Position)

• Feed Solenoid

The Feed Solenoid transmits drive energy from the Main Drive Assembly to the Feed Roller.

• Feed Roller

When the Feed Solenoid operates, it allows the Feed Roller to rotate and feed the paper.

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Main Drive

Feed Solenoid

Feed Roller Drive

Feed Roller

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Phaser 6128MFP Service Manual 2-17

Theory of Operation

Manual Feed & Registration

Manual Sheet Feed No Paper Sensor

Registration Rollers

Manual Sheet Feed Actuator (No Paper Position)

Manual Sheet Feed No Paper Sensor

Manual Sheet Feed Actuator

Paper

Registration Rollers

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• Manual Feed No Paper Sensor

Detects media in the manual feed slot by the change in actuator position.

Upon detecting the sheet, the Registration Roller rotates for a predetermined duration to feed the sheet. The rollers stop immediately when the Registration Sensor detects the media.

• Registration Sensor

The Registration Sensor detects paper when the paper leading edge reaches the registration chute. When paper is fed from the manual feed slot, the Registration Sensor measures the paper length. The On time of the Registration Sensor determines the media length.

2-18 Phaser 6128MFP Service Manual

Theory of Operation

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Registration Sensor

Rubber Registration Roller

Metal Registration Roller

Registration Clutch

Registration Output Spring

Registration Actuator Spring

Registration Output Actuator

Registration Input Actuator

Registration Roller Actuator

Registration Sensor

Rear View

Front

• Registration Clutch

The Registration Clutch transmits drive energy from the Main Drive to the rubber registration roller, and transports paper from the Tray and manual feed slot toward the Imaging Unit. The timing of sheets feeding from the Registration Assembly is adjusted by the duration of the Registration Clutch operation so that the toner image on the drum is transferred to the correct position on the sheet.

Phaser 6128MFP Service Manual 2-19

Theory of Operation

Registration Rollers

Lead Edge Registration

When a sheet is fed from the Tray to the toner transfer position, the registration of the sheet may not be correctly maintained due to misalignment of lead edges in the tray.

To avoid this problem, the lead edge position needs to be aligned at the Registration rollers before the sheet is fed in front of the Transfer Belt, or in front of the BTRs.

Before the registration rollers are energized, the paper is advanced from the tray to the rollers. This process aligns the leading edge as shown below.

By pushing the edge of the sheet against the registration roller that is not turning, the lead edge of the sheet is registered.

Registration Rollers

Skewed Paper

Paper Size Control

The printer doesn’t have switches for detecting paper size, and the length of paper is detected only by the Registration Sensor when feeding paper. If printing data and paper size don’t match, an error is sent to the Image Processor board.

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2-20 Phaser 6128MFP Service Manual

Paper Detection

Front

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Registration Output Spring

Registration Actuator Spring

Registration Output Actuator

Registration Input Actuator

Registration Roller Actuator

Normal Position

Paper Detection: Trailing Edge

From Paper Tray

From Manual Sheet Feed

Paper

Registration Sensor

Rear View

Registration Sensor

Registration Roller Actuator

Since the paper path from manual feed slot to the Registration Sensor is different than from the Tray to the Registration Sensor, the Registration Sensor is provided with the Registration In Actuator and the Registration Roller Actuator.

• The Registration Roller Actuator detects the sheet from the manual feed slot and detects the tail edge of the paper from the Tray.

• The Registration In Actuator detects the lead edge of the paper from the Tray.

The movement of the Registration In Actuator does not affect the Registration Roller Actuator.

Theory of Operation

Phaser 6128MFP Service Manual 2-21

Theory of Operation

Transfer Belt and Fuser

Rear View

Exit Sensor

Front

Heater Lamp

Pressure Belt

NCS Temperature Sensor

STS Temperature Sensor

Heat Roller

Thermostat

Exit Roller

Fuser

ADC Sensor

Blade Assembly

Transfer Belt

The Transfer Belt consists of the transfer belt and ADC Sensor.

• transfer belt

• ADC Sensor

Transfer Belt

Belt

The Belt feeds the paper toward the direction of the Fuser.

The ADC Sensor detects the toner patches on the Belt and converts them to voltage value. The voltage value is used to control the density of toner.

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2-22 Phaser 6128MFP Service Manual

Fuser

Laser Unit

Theory of Operation

The Fuser fixes transferred toner onto the paper using heat and pressure and feeds the paper before and after toner is fixed. The Fuser consists of the following components: Heat Roller, Heater Lamp, Thermostat, Temperature Sensor, Pressure Belt, Exit Roller, and Exit Sensor.

•Exit Sensor

The Exit Sensor detects passage of printed pages after fusing on the Actuator’s position changes.

Rear View

Mirror

Scanner

Lens

Mirror

Polygon Mirror

Front

Laser Diode Board

Lens

Mirror

SOS Board

SOS Sensor

Mirror

Laser Unit

Windows

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Phaser 6128MFP Service Manual 2-23

Theory of Operation

The Laser Unit is an exposure unit that generates laser beams to form an electrostatic latent image on the drum surface. The Laser Unit consists of the following components: laser diode (LD) board, scanner, start of scan (SOS) board, lenses, mirrors, and windows.

• Laser Diode Board

The laser diode board consists of four laser diodes (LDs) corresponding to C, M, Y, and K. Each LD converts the electric signals of incoming image data into laser waves. In order to stabilize the laser light quantity during formation of an electrostatic latent image, the laser diode board monitors the intensity of the laser beam to adjust it to the appropriate level. This process is called auto power control (APC).

• Scanner

The scanner consists of a scanner motor that rotates at a constant speed and a polygon mirror that is mounted on the motor shaft. The laser light output from the LD is directed onto the polygon mirror. The polygon mirror, provided with six reflecting mirror faces, changes the reflection angle of the laser light as it rotates, thereby allowing the laser light to scan the drum along its axial direction. Scanning is performed using one reflecting mirror face for each line.

• Start of Scan (SOS) Board

The SOS Sensor on the SOS Board converts incoming laser beam, upon detection, to an electric signal as reference for starting scanning, and transmits this signal to the MCU Board. The SOS sensor signals are used to synchronize the starting point of the laser beam scanning with the starting point of the image writing.

•Lenses

The laser light reflected from the polygon mirror reaches the drum surface via the lenses, mirror, and window. The Lenses correct aberration.

•Mirror

The mirror directs the laser beam to the Imaging Unit.

• Window

The window is the area where the laser beams exit the Laser Unit.

2-24 Phaser 6128MFP Service Manual

Toner Cartridge & Dispenser

Theory of Operation

Dispenser Motor (K)

Toner Cartridge (K)

Dispenser Motor (C)

CRUM Connector (K)

Toner Cartridge (C)

Dispenser Motor (M)

CRUM Connector (C)

Toner Cartridge (M)

Dispenser Motor (Y)

CRUM Connector (M)

Toner Cartridge (Y) CRUM Connector (Y)

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The Toner Cartridge is a customer replaceable item that includes the following components:

• Customer Replaceable Unit Memory (CRUM) Connector

The CRUM Connector reads and writes the CRUM data. Printer specific information is stored in the CRUM.

• Dispenser Motor (C/M/Y/K)

The Dispenser Motor provides the drive for the Agitator and Auger in the Toner Cartridge, and supplies toner to the Developer.

Phaser 6128MFP Service Manual 2-25

Theory of Operation

Print Cartridge

Drum (K)

LED Assembly

Drum (C)

Drum (M)

Drum (Y)

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Developer (K)

Developer (C)

Developer (M)

CRUM

Developer (Y)

Rear View

Front

Imaging Unit

The Imaging Unit is a customer replaceable item that carries out the charging, development, transfer, and cleaning steps in the print process (see “Printing Process” on page 2-3).

The Imaging Unit consists of the following items:

• Developers

Each of the four Developers includes the Augers that distribute the toner and the Magnet Roller that applies toner to the Drum to develop the latent image.

•Drums

Each drum is given a latent image to which toner is applied by the Developer. The resulting toner image is transferred to the paper.

•CRUM

Information specific to the Developer/Imaging unit is stored in the CRUM.

•Erase Lamp (LED)

2-26 Phaser 6128MFP Service Manual

Drive

Imaging Unit Erase LampErase Lens

LED AssemblyDrum

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s6128-029

Sub Drive

Main Drive

Feed Drive

Theory of Operation

The light of the LED passes through the lens of the Developer, illuminates the drum, and eliminates the charge on the drum.

The drive consists of three assemblies:

• Main Drive Assembly

Drives the Imaging Unit, Transfer Belt, Registration Rollers, and Feeder.

• Sub Drive Assembly

Supplies drive to the Fuser and Developers (C, M, Y, K).

Phaser 6128MFP Service Manual 2-27

Theory of Operation

s6128-030

Black And White Mode

Full Color Mode

Drive From Sub Motor

Gear D3 In

Color Mode Switching Sensor

Color Mode Switching Solenoid

Gear D3 Out

Cam C

Gear C

Color Mode Switching Sensor

Color Mode Switching Solenoid

Cam C

Gear C

Drive From Sub Motor

Drive To Developer (Y, M, C)

Gear D3 In

Gear D3 Out

Cam C

• Feed Drive Assembly

The Feed Drive Assy transmits the driving force from the Sub Drive Assembly to relevant parts.

The drive path is changed by the Color Mode Switching Solenoid in the Feed Drive Assy to allow drive from the Main Drive Assy to reach only the Black Developer. This is done to ensure that the Sub Drive Assembly cannot rotate the Yellow, Magenta, and Cyan Developers during B/W printing.

The Color Mode Switching Sensor detects whether the drive path is set for B/W or full color.

2-28 Phaser 6128MFP Service Manual

Electrical

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Power Switch

LVPS

IP Board

GFI Breaker

EEPROM

Humidity Sensor

Multi Protocol Network Card (MPC)

HVPS

MCU Board

Fan

Theory of Operation

Side Cover Switch

Control Panel

Interlock Switch

Fan

The Fan removes heat from the printer to prevent overheating.

Power Switch

The Power Switch turns the printer AC Power Supply On/Off.

Phaser 6128MFP Service Manual 2-29

Theory of Operation

Note

Low-Voltage Power Supply (LVPS)

Two types of LVPS are available: 100/120V and 230V. The LVPS supplies AC power from the power source to the Fuser Heater; the LVPS also generates and supplies stable low-voltage DC power used for the logic circuits. The LVPS contains a control circuit for the Fuser heater, in addition to the power circuit.

LVPS Over-Current Protection Circuit

This circuit stops all outputs if the power supply voltage 3.3 VDC, 5 VDC, or 24 VDC is shorted. After short is repaired, cycle main power to reset the circuit.

LVPS Over-Voltage Protection Circuit

This circuit stops all outputs, if the power supply voltage 3.3 VDC, 5 VDC, or 24 VDC exceeds the specified voltage of 32 VDC or less for 24 VDC, 7 VDC or less for 5 VDC, or 4.4 VDC or less for 3.3 VDC. The circuit resets when main power is cycled after certain period of time.

Deep Sleep Mode (Power Saver)

The output of the following power supply are stopped according to the signals.

Signal +3.3 VDC +5 VDC +24 VDC

Sleep Off Off On

Deep Sleep Off Off Off

Machine Control Unit Board

The Machine Control Unit (MCU) Board controls the printing process based on the communication with the printer Image Processor Board and information from the Sensors or Switches. Major functions include:

1. Communicates with the Image Processor Board.

2. Receives information from the Sensors or Switches.

3. Controls the Main and Sub-Drive Assemblies.

4. Distributes low-voltage DC power from the LVPS to each component.

5. Controls the Laser Unit.

When replacing an MCU Board, be sure to transfer the contents of NVM from the old MCU Board to the new MCU Board.

High-Voltage Power Supply (HVPS)

The HVPS provides high-voltage power to the components in the transfer belt and Imaging Unit to perform charging, development, and primary transfer of the print process to the BCR, BTR, and Developer.

2-30 Phaser 6128MFP Service Manual

Theory of Operation

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RAM DIMM

USB Connection

Ethernet Connection

ADF Data Cable

Fax Board Connection

Electrically Erasable Programmable Read-Only Memory (EEPROM) Board

The EEPROM Board stores the printer unique information.

Image Processor Board

The Image Processor (I/P) Board (CONT AIO) is connected to the MCU Board, which controls the printer, including diagnostic, interface, and image processing.

The primary function of the I/P Board is to receive host data through one of the available ports (USB, or Ethernet, the Scannner, or FAX). The received host data is buffered, stored, and sent to the print engine in a rasterized format.

When installing a new I/P Board in the printer, you must transfer the following parts from the old board to the new board:

•Memory DIMM

•FAX Board

Humidity /Temperature Sensor

The Humidity/Temperature Sensor reads the humidity and temperature within the printer.

Phaser 6128MFP Service Manual 2-31

Theory of Operation

Host (Electric Signal)

Electronic Sub-system Control Board (Electric Signal)

Machine Control Unit (Electric Signal)

Laser Unit (Laser Beams)

Electrostatic Latent On Drum (Invisible Image)

Toner Image On Drum

Toner Image On Paper

Print Image On Paper

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Computer

I/P Board

MCU Board

Laser Unit

Imaging Unit

Transfer Belt

Fuser

Interlock Switch

The Interlock Switch is a switch that interrupts the supply of +24 VDC power to the HVPS or Motor upon the opening of the Front Cover.

Toner Access Door Switch

A switch that detects when the Toner Access Door is open.

GFI Breaker

Opens to shut off the AC power if it detects any voltage or current or leakage current that exceeds the rating of the AC power supply.

Data Flow

The electrical signal flow for the print data from the printer I/P Board is shown in the following diagram.

2-32 Phaser 6128MFP Service Manual

Printer Modes

Operational Modes

Theory of Operation

The Phaser 6128 printer includes the following modes:

•Ready Mode

The printer is ready for printing.

• Printing Mode

Printing is in progress.

•Sleep Mode

The printer has entered a power saving state.

• Deep Sleep Mode

The printer has entered a power saving state.

Printer Control

Paper Size Detection

Laser Unit Light Quantity Control

The printer has no switches for detecting paper size; only the length of the paper is detected by the Regi Sensor as the paper is feeding. If the detected size does not match the size sent in the print data, an error is reported to the Image Processor.

Image data is sent to the Laser Unit as an electric signal (data are expressed with high and low voltage values), and the laser diodes convert the image data from electric signals to optical signals (data are expressed with blinking laser beams).

Variations in light quantity of laser beams or variations in the optical system (such as lenses) or drum sensitivity cannot attain a proper electrostatic image. Therefore, the laser beam light quantity is monitored and controlled by the laser diodes.

The Laser Unit has four laser diodes for Yellow, Magenta, Cyan, and Black respectively and the beam intensity is automatically adjusted for each color.

Phaser 6128MFP Service Manual 2-33

Theory of Operation

Process Control

For stable printing, the parameters related to the image development must be corrected as necessary. The process control is performed in two methods after every 25 cumulative prints, upon termination of a print run, or during a continuous run.

•Potential Control

• Toner Density Control

The following controls supplement the above controls:

• High Area Coverage Mode

• Admix Mode

Potential Control

To attain stable printing image density, the drum charging voltage, the developing DC voltage, and the Laser Unit beam intensity are adjusted according to the developing capability of each color carrier that varies momentarily. The adjusted drum charging voltage, the developing DC voltage, and the Laser Unit beam intensity are fed back to keep the printing image density constant.

The outline of controls is as follows:

1. The Humidity/Temperature Sensor detects humidity and temperature.

2. The patches of respective colors (Yellow, Magenta, Cyan, and Black) for the potential control are generated and transferred on the transfer belt.

3. The ADC Sensor (Density Sensor) detects the density of the patch on the Belt.

4. The drum charging voltage, developing DC voltage, and the Laser Unit beam intensity are adjusted for each color according to the detected patch density.

Toner Density Control

Toner density must be kept constant to attain stable printing. The control system for this purpose is called toner density control.

1. PCDC (Pixel Count Dispense Control)

The amount of toner to be consumed in the developing process is calculated by counting the video signals entered to the Laser Unit. The amount of the toner to be consumed is calculated by the toner dispensing time. The toner motor is driven for the calculated toner dispensing time when supplying the toner to the Developer.

2. ADC (Auto Density Control)

The patches of respective colors (Yellow, Magenta, Cyan, and Black) for the toner density control are generated under a specified potential condition, and transferred on the Belt. The ADC Sensor measures this density, and the measured value is compared with reference value. If the toner density is low, the toner dispense quantity is increased at the next printing, or if the toner density is higher, the toner dispense quantity is reduced at the next printing. The toner dispense quantity is calculated by the toner dispense time. This calculation is made for each color.

2-34 Phaser 6128MFP Service Manual

High Area Coverage Mode

A continuous printing of any image of area coverage exceeding the toner dispense capability causes the toner density in the Developer to be lowered.

The High Area Coverage Mode postpones the next page feed and dispenses extra toner during this time, if the toner dispense time reaches the specified value during a continuous printing.

Admix Mode

The Admix Mode dispenses toner immediately to prevent the reduction of toner density, whenever the value of the toner density control patch measured by the ADC Sensor falls far below the standard value, by dispensing extra toner. If the toner density level cannot be recovered after this operation, it is determined that toner has run out.

ADC Sensor Control Function

The ADC Sensor is a reflection type sensor that radiates light from its LED onto the target and detects the reflected light at its photoreceptor and outputs electric signals responsive to the amount of the detected light.

To ensure an accurate patch density measurement, the surface of the ADC sensor is cleaned to remove soil due to toner, etc., and the light amount adjustment is made so that the reflected light amount satisfies the prescribed value, when creating the patch for potential control and toner density control.

Theory of Operation

Color Registration Control

The printer uses a tandem electro-photographic system with Organic Photo Conductor (OPC) Drums and direct transfer by the transfer belt. Because the images are formed on the individual Drums of the respective colors and then overlapped to form one image, a color shift may occur. The color registration control calculates how much the registration is shifted, and adjusts the Laser Unit write timing.

The scan control adjusts all four colors in the process direction.

The color registration control is made from a change in inside temperature and the print count at the execution of the process control. This control is outlined as follows:

1. With no toner on the transfer belt, the output value of the ADC Sensor is measured to determine the threshold value.

2. The patches for color registration control are generated on the Belt. These patches are composed of 10 mm lines of K, C, K, M, K, and Y in this order by the amount of four dispense counts, led by a black trigger.

Phaser 6128MFP Service Manual 2-35

Theory of Operation

10 mm

About One Half Turn Of Belt

s6180-035

Fuser Control

1. The ADC Sensor reads the patch density.

2. The amount of registration shift is calculated from the threshold value determined in step 1 and the patch density measured in step 3.

3. The Laser Unit write timing is changed according to the amount of registration shift.

Fuser Temperature Control

After the target temperature is set, the Heat Roller surface temperature is controlled by turning the Heater Lamp On/Off.

Temperature of individual area of the Heat Roller is detected by the Fuser Non-

Cool Down

Contact Sensor (NCS) in the middle of the Heat Roller and the Temp Sensor at the edge of it.

The target temperature set up varies depending on the time of Warm-up, Printing, or Process Control. The target set temperature is changed based on the printer’s interior temperature detected by the Humidity Sensor.

As printing continues, the distribution of temperature in the Heat Roller becomes uneven in both the paper feed and non-paper feed areas. Cooling Down suspends paper feeling for a certain period of time so that the Heat Roller temperature distribution can be uniform.

When the temperature of the Heat Roller edge is high, cooling down is performed to lower the temperature to the target value.

2-36 Phaser 6128MFP Service Manual

Fuser NCS Sensor Warm-Up

Main Drive

[ Belt ]

Transfer Belt

[ Name Of Moving Parts ]

Gear P3

Paper Feed Drive

Registration Feeder Chute

Registration Clutch

Rubber Registration Gear

Metal Registration Gear

Gear P2Gear T4

Gear P4

Gear P5

[ Registration Roller ]

[ Metal Registration Roller ]

Feed GearFeed Solenoid

Drive Gear

[ Feed Roller ]

HSG Xerographics (K)

[ Drum (K) ]

HSG Xerographics (C)

[ Drum (C) ]

Imaging Unit Gear 2

HSG Xerographics (M)

[ Drum (M) ]

HSG Xerographics (Y)

[ Drum (Y) ]

Imaging Unit Gear 2

Imaging Unit Gear 1

Imaging Unit

s6128-036

Drive Transmission

Main Drive

Theory of Operation

The Fuser Non-Contact Sensor at the center of the Heat Roller loses its accuracy when the temperature of the sensor itself is below -5° C. Therefore, the sensor is warmed up when the temperature is below -5° C.

The Main Drive transmits power as shown in the following diagram.

Phaser 6128MFP Service Manual 2-37

Theory of Operation

s6128-037

Paper Feed Drive

Imaging Unit

Main Drive

Gear P2

Gear P3

Gear P5

Feed Gear

[ Feed Roller ]

Registration Feeder Chute

Registration Clutch

[ Registration Roller ]

Rubber Registration Gear

Metal Registration Gear

[ Metal Registration Roller ]

Feed Solenoid

Imaging Unit Gear 2

[ Drum (M) ] [ Drum (Y) ]

Imaging Unit Gear 1

Imaging Unit Gear 2

[ Drum (K) ] [ Drum (C) ]

Transfer Belt

Gear T4

Drive Gear

[ Belt ]

[ Name Of Moving Parts ]

: Indicates The Engagement Of Gears

Front

2-38 Phaser 6128MFP Service Manual

Sub-Drive Assembly

Sub Drive power is transmitted differently for Black and White or Color as shown in the following figures.

Black and White Mode

Theory of Operation

Black And White Mode

Sub Drive

Gear D1 Gear P2

Gear DK

Gear D5

Magnet Gear (K)

[ Magnet Roller (K) ]

Hsg Assy Deve (K)

Imaging Unit

Gear D1

Gear D2

Gear D3 In

Gear D3 Out

Imaging Unit Drive

Main DriveSub Motor

Gear P3

Gear P4

Gear P4-2

Gear C

Cam C

Flange D3

[ Name of Moving Parts ]

Color Mode

Switching

Solenoid

s6128-038

Phaser 6128MFP Service Manual 2-39

Theory of Operation

[ Black And White Mode ]

Gear D1

Sub Motor

Gear D1

Gear D2

Gear D3 In

Gear D3 Out

Gear D2

Gear D3 In

Gear D4

Gear D3 Out

Sub Drive

[ Name Of Moving Parts ]

: Indicates The Engagement Of Gears.

HSG Developer (K)

Magnet Gear (K)

Gear DK

[ Magnet Roll (K) ]

Gear D5

Imaging Unit

Cam C

Flange D3

Cam C

Print Cartridge

Drive

Color Mode Switching Solenoid

Flange D3

Gear C

Gear P2

Gear P4

Gear P4-2

Main Drive

Gear P3

s6128-039

2-40 Phaser 6128MFP Service Manual

Color Mode

Theory of Operation

Full Color Mode

Sub Motor

Gear D1

Gear DK

Gear D5

Magnet Gear (K)

[ Magnet Roll (K) ]

Developer

Housing (K)

[ Name Of Moving Parts ]

Sub Drive Imaging Unit Drive

Gear D1

Gear D2

Gear D3 In

Gear D3 Out

Gear D4

Gear D5 Gear D5 Gear D5

Magnet Gear (C)

[ Magnet Roll (C) ]

Developer

Housing (K)

Magnet Gear (M)

[ Magnet Roll (M) ]

Developer

Housing (M)

Magnet Gear (Y)

[ Magnet Roll (Y) ]

Developer

Housing (Y)

Imaging Unit

s6128-040

Phaser 6128MFP Service Manual 2-41

Theory of Operation

s6128-041

Gear DK

Gear D1

Sub Motor

Gear D1

Gear D2

Gear D5

Magnet Gear (K)

[ Magnet Roller (K) ]

Sub Drive

Imaging Unit Drive

Developer (K)

Gear D4

Magnet Gear (C)

[ Magnet Roller (C) ]

Developer (C)

Magnet Gear (M)

[ Magnet Roller (M) ]

Magnet Gear (Y)

[ Magnet Roller (Y) ]

Developer (Y)

Developer (M)

Gear D5

Gear D4

Gear D5

Imaging Unit

Gear D2

Gear D4

Gear D3 In

Gear D3 Out

[ Name Of Moving Parts ]Full Color Mode

: Indicates The Engagement Of Gears

Front

2-42 Phaser 6128MFP Service Manual

Development and Excess Toner Collection

Theory of Operation

Development And Excess Toner Collecting

Main Drive Sub Drive

Print Cartridge Gear 1

Print Cartridge Gear 2

[ Drum ]

Cleaning Auger Gear

Side Auger Idler Gear

Side Auger Gear

[ Auger ]

[ Side Cleaning Auger ] [ Developer Paddle ]

Xerographics Housing (Y, M, C, K)

Imaging Unit

[ Name Of Moving Parts ]

Magnet Gear (Y, M, C, K)

[ Magnet Roller ]

Magnet Idler Gear

Paddle Idler Gear

Paddle Gear

Auger Gear

[ Auger Front ]

Auger Gear

[ Auger Rear ]

Developer Housing (Y, M, C, K)

s6128-042

Phaser 6128MFP Service Manual 2-43

Theory of Operation

Development And Excess Toner Collecting

: Indicates The Engagement Of Gears

Xerographics Housing (Y, M, C, K)

Cleaning Auger Gear

[ Auger ]

Gear Idler Paddle

Developer Housing (Y, M, C, K)

Auger Gear

[ Rear Auger ]

Auger Gear

[ Front Auger ]

Paddle Gear

[ Developer Paddle ]

Magnet Gear

[ Magnet Roller ]

[ Name Of Moving Parts ]

Side Auger Gear

[ Side Cleaning Auger ]

Side Auger Idler Gear

[ Drum ]

Magnet Idler Gear

Imaging Unit Gear 2

[ Drum ]

Imaging Unit Gear 1

Sub Drive

Main Drive

Imaging Unit Gear 2

[ Drum ]

Front

Imaging Unit

s6128-043

2-44 Phaser 6128MFP Service Manual

Dispense Assembly

Rotation of the toner motors drives the agitator and auger in the Toner Cartridge.

Theory of Operation

Toner Dispenser

Dispenser

Motor (K)

Idler Gear (K)

Auger Idler

Gear (K)

Auger Gear (K)

[ Auger (K) ]

Auger Idler

Gear (K)

Agitator Gear (K)

[ Agitator (K) ]

Toner

Cartridge (K)

Dispenser

Motor (C)

Idler Gear (C)

Auger Idler

Gear (C)

Auger Gear (C)

[ Auger (C) ]

Auger Idler

Gear (C)

Agitator

Gear (C)

[ Agitator (C) ]

Toner

Cartridge (C)

Idler Gear (M)

Auger Idler

Gear (M)

Dispenser

Cartridge (M)

Dispenser Motor (M)

Auger Idler

Gear (M)

Auger Gear (M)

[ Auger (M) ]

Agitator

Gear (M)

[ Agitator (M) ]

Toner

[ Name Of Moving Parts ]

Dispenser

Motor (Y)

Idler Gear (Y)

Auger Idler

Gear (Y)

Auger Gear (Y)

[ Auger (Y) ]

Auger Idler

Gear (Y)

Agitator Gear (Y)

[ Agitator (Y) ]

Toner

Cartridge (Y)

s6128-044

Toner Dispenser

Toner Cartridge (K)

Agitator Gear (K)

[ Agitator (K) ]

Toner Cartridge (C)

Toner Cartridge (M)

Toner Cartridge (Y)

Right

[ Name Of Moving Parts ]

: Indicates The Engagement Of Gears

Dispenser

Agitator Idler Gear (K)

Idler Gear (K) Dispenser Motor (K)

Auger Idler Gear (K)

Auger Gear (K)

[ Auger (K) ]

Dispenser Motor (C)

Dispenser Motor (M)

Dispenser Motor (Y)

Left

s6128-045

Phaser 6128MFP Service Manual 2-45

Theory of Operation

Fuser Drive

[ Name Of Moving Parts ]

Sub Drive

Heat Roller Idler Gear

Heat Roller Gear Exit Idler Gear

[ Heat Roller ]

Exit Gear

[ Exit Roller ]

Fuser

s6128-046

2-46 Phaser 6128MFP Service Manual

Theory of Operation

Fuser Drive

Exit Gear

[ Exit Roller ]

Exit Idler Gear

[ Name Of Moving Parts ]

: Indicates The Engagement Of Gears

Fuser

Heat Roller Gear

[ Heat Roller ]

Heat Roller Idler Gear

Sub Drive

Front

s6128-047

Phaser 6128MFP Service Manual 2-47

Theory of Operation

s6128-048

Scanner Home Position Sensor

CCD Image Sensor

Scanner Assy

CVT Position (Home Position)

Platen Registration Point

Scanner

The Scanner consists of a lamp (fluorescent lamp, etc.) that illuminates the original document with uniform light and a Charged Coupled Device (CCD), which reads the light reflected from the image.

A CCD is a light-receiving element that produces an electrical signal in response to light. In the case of a Fax, a number of CCDs are arranged in a line.

The white areas of the original document reflect the light from the lamp. The black areas reflect no light. The CCDs read the light reflected from the original, outputting sequentially to the control circuit, which areas are white and which black as binary data (1/0 digital data: 1 bit).

To scan the original, the CCD device is shifted a distance of one line after each line is scanned. When the original is scanned directly on the document glass, the CCD is moved across the original. When the ADFis used, scanning is performed by moving the original with the CCD fixed at one position. This is called Constant Velocity Transport (CVT).

The scanning section consists of a Scanner Assembly that scans documents placed on the document glass.

The optical image reflected from the document reaches the Charged Coupled Device (CCD) image sensor via the light path.

2-48 Phaser 6128MFP Service Manual

Scanner Components

s6128-050

Scanner Assy

Scanner Home Position Sensor

Carriage Motor

Cold Cathode Fluorescent Lamp

CCD PWBA

Theory of Operation

•ADF Open Sensor

The ADF Open Sensor detects whether or not the ADF is open and determines the timing of document size detection.

• Carriage Motor

The Carriage Motor drives the Scanner Assembly.

• Scanner Home Position Sensor

The Scanner Home Position Sensor is a part of the rear section of the Scanner Assembly frame that functions as an Actuator which shields the Scanner Home Position Sensor, thus detecting the Registration position.

• Cold Cathode Fluorescent Lamp (Exposure Lamp)

The Cold Cathode Fluorescent Lamp exposes the document.

•Charged Coupled Device Board

The Charged Coupled Device (CCD) Board (Image Sensor) converts optical images into electrical signals.

Phaser 6128MFP Service Manual 2-49

Theory of Operation

Media

CCD Image Sensor (Scanner Assy)

Scanner Controller Board

Controller (Image Processor Board)

Laser Unit

Drum (CRU)

Scanner

Engine

s6128-049

Image Data Flow

The image data from the media set on the Scanner or ADF goes through the following components before it is printed at the Engine section.

Document Scanning Steps

A CCD Image Sensor is used to read image data from the media. The CCD Image Sensor output is adjusted to ensure the image reading is stabilized. Adjustment includes Automatic Gain Control (AGC) and Automatic Offset Control (AOC).

Reference data for adjustment is collected and used to perform compensation on the read image data. Compensation includes shading, white variation, and black variation compensations. These adjustment and compensation steps are described below:

1. AGC (Auto Gain Control): White Level Variation Adjustment

During AGC, the Scanner Assembly is moved to the position of the white reference plate, and the Exposure Lamp is illuminated. The light reflected from the white reference plate is read by the CCD Image Sensor as the white reference value, which is used to adjust the CCD Image Sensor output.

2. AOC (Auto Offset Control)

AOC is performed by turning Off the Exposure Lamp after AGC. This state is read by the CCD Image Sensor as the black reference value, which is used to adjust the CCD Image Sensor output. (The order of AGC and AOC adjustment depends on the model.)

3. Shading Compensation

Shading compensation compensates for pixel-by-pixel sensitivity variations and the non-uniformity of lamp light in the fast scanning direction. The AGC and AOC adjustment values are used to compensate for the image data read by the CCD Image Sensor.

2-50 Phaser 6128MFP Service Manual

Xerox Phaser 6128 MFP Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

About this Service Manual

Manual Organization

Symbols Marked on the Product

Power Safety Precautions

Electrostatic Discharge (ESD) Precautions

Service Safety Summary

Regulatory Specifications

General Information

Printer Introduction and Overview

Tec hn ic al Su ppo rt In for ma t ion

Printer Configurations

Parts of the Printer

Front and Side Views

Rear View

Internal View

Control Panel

Specifications

Printer Specifications

Scanning Specifications

Copy Specifications

Fax Specifications

Memory Specifications

Electrical Specifications

Print Speed

Environmental Specifications

Operating Mode

First Print Output Time (FPOT)

First Copy Output Time

Image Specifications

Physical Dimensions and Clearances

Mounting Surface Specifications

Media and Tray Specifications

Controller Functions

Job Control

Non-Genuine Mode

Maintenance Function

Diagnostics

Information Pages

Theory of Operation

Phaser 6128MFP Operational Overview

Print Process Block Diagram

Printing Process

Charging

Exposure

Development

Transfer (Drum ---> Paper)

Imaging Unit

Excess Toner Collection

Fusing

Media Path

Media Path

Media Path Components

Major Assemblies and Functions

Tray

Feeder

Manual Feed & Registration

Transfer Belt and Fuser

Laser Unit

Toner Cartridge & Dispenser

Imaging Unit

Drive

Electrical

Printer Modes

Operational Modes

Paper Size Detection

Laser Unit Light Quantity Control

Process Control

Color Registration Control

Fuser Control

Main Drive

Sub-Drive Assembly

Scanner