Xerox Phaser 6180 Service Manual

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Phaser® 6180

Color Laser Printer

Service Manual

701P45793

Phaser®6180

Color Laser Printer

Service Manual

701P45793

First Printing: January 2007

arning

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.

Service Terms

Not

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 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.

Caution

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

arning

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

Product Terms

Caution: A personal injury hazard exists that may not be apparent. For

example, a panel may cover the hazardous area.

Danger: A personal injury hazard exists in the area where you see the sign.

Phaser 6180 Color Laser Printer Service Manual iii

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 manual(s) for information.

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

Do not touch the item.

Do not expose the item to sunlight.

Do not expose the item to light.

iv Phaser 6180 Color Laser Printer Service Manual

Power Safety Precautions

Power Source

Disconnecting Power

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.

arning

Turning the power Off using the power switch does not completely deenergize 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.

Phaser 6180 Color Laser Printer Service Manual v

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 electro-statically sensitive device.

■ Handle IC’s 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).

vi Phaser 6180 Color Laser Printer Service Manual

Service Safety Summary

General Guidelines

Warning Labels

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

Precautions” on page 1-v.

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.

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 6180 Color Laser Printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this 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.

Phaser 6180 Color Laser Printer Service Manual vii

Servicing Electrical Components

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.

arning

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

s6180-256

Servicing Mechanical Components

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

arning

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

Servicing Fuser Components

arning

This printer uses heat to fuse the toner image to paper. 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.

s6180-257

viii Phaser 6180 Color Laser Printer Service Manual

Regulatory Specifications

United States (FCC Regulations)

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.

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.

Phaser 6180 Color Laser Printer Service Manual ix

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.

x Phaser 6180 Color Laser Printer Service Manual

Manual Organization

The Phaser 6180 Color Laser Printer 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 print engine and attached options. Also included are detailed replacement procedures, parts lists, and wiring diagrams.

The Phaser 6180 Color Laser Printer Service Manual contains these sections:

Introductory, Safety, and Regulatory Information: This section contains important

safety information and regulatory requirements.

Section 1 - General Information: This section contains an overview of the

printer’s operation, configuration, specifications, and consumables.

Section 2 - Theory of Operation: This section contains detailed functional

information on the print engine components.

Section 3 - Error Codes and Messages: This section provides detailed

troubleshooting procedures for error messages and codes generated by resident diagnostics.

Section 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.

Section 5 - Print-Quality Troubleshooting: This section focuses on techniques to

correct image quality problems associated with the printer output.

Section 6 - Adjustments and Calibrations: This section provides procedures for

the adjustment of print engine components.

Section 7 - Cleaning and Maintenance: This section provides periodic cleaning

procedures for the printer.

Section 8 - Service Parts Disassembly: This section contains removal

procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary.

Section 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.

Section 10 - Plug/Jack and Wiring Diagrams: This section contains the plug/jack

locations and the wiring diagrams for the printer.

Appendix A - Reference: This section provides an illustration of the printer’s

menu structure, printer firmware update instructions, a list of printer error chain link codes, and a list of acronyms and abbreviations.

Phaser 6180 Color Laser Printer Service Manual xi

Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

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

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Multi-Protocol Network Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Optional 550-Sheet Feeder (Tray 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Memory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

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

Print Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

First Print Output Time (FPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Image Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Mounting Surface Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

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

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

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

ID Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Toner Remaining Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

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

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

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

Contents

Phaser 6180 Color Laser Printer Service Manual xiii

Contents

2 Theory of Operation

Phaser 6180 Printer 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Cleaning (Print Cartridge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Neutralization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Paper Path Route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Tray 1 (MPT) & Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Tray 3 - Optional 550-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Printer Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Printer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Paper Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Selective Control on Paper Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Laser Unit Light Quantity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Process Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Color Registration Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Fuser Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Drive Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Dispenser (C) (M) (Y) (K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Duplex Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Optional 550-Sheet Feeder Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

xiv Phaser 6180 Color Laser Printer 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, Chain Link Codes, and Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

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

Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Jam at Tray 2 (Feeder 1 Jam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Jam at Tray 3 (Feeder 2 Jam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Jam at Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Jam at Tray 2 (Feed Jam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Jam at Exit/Jam at Registration Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Jam at Duplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Consumable/Routine Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Insert Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Replace Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Fuser CRUM ID Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Ready Fuser Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Print Cartridge Near Life (Yellow/Magenta/Cyan/Black). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Check Cartridge (Yellow/Magenta/Cyan/Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Replace Print Cartridge (Yellow/Magenta/Cyan/Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Empty Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Print Cartridge CRUM Error (Yellow/Magenta/Cyan/Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Print Cartridge CRUM ID Error (Yellow/Magenta/Cyan/Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Insert Print Cartridge (Yellow/Cyan/Magenta/Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Insert Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Replace Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Transfer Unit CRUM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Ready Transfer Unit Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Tray and Paper Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Load Tray 1 (MPT) (Paper Mismatch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Load Tray 2 (Paper Mismatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Load Tray 3 (Paper Mismatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Insert Tray 2 (Tray Missing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Insert Tray 3 (Tray 3 Missing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Load Tray 1 (MPT) (No Suitable Paper). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Load Tray 2 (No Suitable Paper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Load Tray 3 (No Suitable Paper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Multiple Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Contents

Phaser 6180 Color Laser Printer Service Manual xv

Contents

Configuration, Memory, and Firmware Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Control Panel Language Set Unsupported. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Engine Model Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Out of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

PDL Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Invalid Job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

MPC Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

Network Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

MCU Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

MCU Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

MCU NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Fan Motor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

Main Motor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Sub Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Deve Motor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Tray 2 Motor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Optional Feeder Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Optional 550-Sheet Feeder Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

Duplex Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Door A Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

ADC Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Environmental (Humidity/Temperature) Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-101

Controller System Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

RAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Parallel Port Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

MACPHY Chip Test Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

MACPHY Internal Loop Test Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

MACPHY External Loop Test Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

4 General Troubleshooting

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

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

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

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Entering Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Using Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Service Diagnostics Control Panel Button Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Menu Map - Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Menu Map - Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Printer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Motors, Clutches, Solenoids, Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Duplex Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Clutch, Fan, Motor, Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Service Diagnostics Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Service Diagnostic Tests and Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Printer Does Not Come to a “Ready” State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Control Panel LED is On, Control Panel Display is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Engine Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

xvi Phaser 6180 Color Laser Printer Service Manual

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Inoperable Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Engine Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Printer Continually Displays Warming Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Printer Continually Displays Insert Print Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

LVPS Overcurrent Protection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

LVPS Overvoltage Protection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

+24 VDC Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

Abnormal and Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Abnormal Noise when Power is Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Abnormal Noise During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

AC Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Operating System and Application Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Windows 2000, Windows XP, Windows Server Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Verify Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Verify Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Macintosh Troubleshooting (Mac OS 10.2 and Higher). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

UNIX / Linux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

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

Checking the Printer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

No Image IOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

TestPat600 IOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Grid 2 ESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Cyan 20% ESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Magenta 20% ESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Yellow 20% ESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Black 20% ESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

CYM 20% ESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Gradation ESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Print-Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Environmental Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Quality Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Paper Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Printer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Phaser 6180 Color Laser Printer Service Manual xvii

Contents

Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Print-Quality Defect Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Repeating Defect Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Light or Undertone Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Blank Print (No Print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Vertical Blank Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Horizontal Band, Voids, or Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Vertical Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Horizontal Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Partial Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Random Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Repeating Bands, Lines, Marks, or Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Residual Image or Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Damaged Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Color Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

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

Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

7 Cleaning and Maintenance

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

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

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

Cleaning the Print Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

RIP (Repair, Inspect, and Prevent) Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

8 Service Parts Disassembly

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

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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

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

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

Transfer Unit (PL4.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Print Cartridge (C/M/Y/K) (PL5.1.18-21). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Fuser (PL6.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

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Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Rear Cover (PL1.1.4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Right Side Cover (PL1.1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Left Side Cover (PL1.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Top Cover (PL1.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Front Cover (PL1.2.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Tray 2 Cover (PL1.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Extender Cover (PL1.1.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Control Panel (PL1.2.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Tray 1 (MPT) Base (PL1.2.26). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Tray 1 (MPT) Cover (PL1.2.24). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Tray 1 (MPT) Retard Holder (PL2.1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Bottom Plate (PL2.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Tray 1 (MPT) Front Cover (PL2.1.22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Tray 2 Handle (PL2.1.23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

No Paper Actuator (PL2.1.26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Bottom Plate - Tray 2/Tray 3 (PL2.2.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Tray 2 Side Guide (Left/Right) (PL2.2.9 & PL2.2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Tray 2 Retard Roll (PL2.2.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Tray 2 End Guide (PL2.2.22). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Tray 1 (MPT) Feed Solenoid (PL3.1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Tray 1 (MPT) Roll (PL3.1.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Tray 1 (MPT) Feed Roll (PL3.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Tray 1 (MPT) No Paper Sensor (PL3.1.15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Registration Clutch (PL3.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Feed Clutch (PL3.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Feeder Unit (PL3.2.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

Turn Clutch (PL3.2.25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

No Paper Sensor (PL3.2.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Tray 2 Feed Roll (PL3.2.53). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Laser Unit (PL5.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

CRUM Connector (PL5.1.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

Print Cartridge Sensor Assembly (Black) (PL5.1.4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Print Cartridge Sensor Assembly (Cyan/Magenta/Yellow) (PL5.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Print Cartridge Sensor (PL5.1.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Dispenser (C/M/Y/K) (PL5.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

BIAS (PL5.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

LED (PL5.1.15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

HVPS (PL5.1.17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

Exit Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

Exit Out Chute (PL6.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

Duplex Gate Chute (PL6.1.13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64

Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65

Star Wheel (PL7.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65

Left Link (PL7.1.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66

Right Link (PL7.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68

Right Tray Guide (PL7.1.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70

Left Tray Guide (PL7.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71

Tray 2 Size Switch (PL7.1.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73

Main Drive (PL8.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73

Drive Assembly (PL8.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76

. . . . . . . . . . 8-72

Phaser 6180 Color Laser Printer Service Manual xix

Contents

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79

EEPROM Board (PL9.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79

Interlock Harness (PL9.1.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80

LVPS (PL9.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81

Main Fan (PL9.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84

Power Switch (PL9.1.13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85

Humidity/Temperature Sensor (PL9.1.19). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86

MCU Board (PL9.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87

Image Processor Board (PL9.1.27). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89

Controller Shield (PL9.1.25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92

Multi-Protocol Network Card (PL9.1.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94

Duplex Unit (PL11.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94

Duplex Fan (PL11.1.25). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95

Optional 550-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96

Optional 550-Sheet Feeder (PL12.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96

Tray 3 Left Cover (PL12.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-97

Tray 3 Right Cover (PL12.1.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98

Tray 3 Cover (PL12.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-99

Tray 3 Turn Clutch (PL12.1.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100

Tray 3 Feed Clutch (PL12.1.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101

Tray 3 Feeder (PL12.1.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102

Tray 3 Feed Roll (PL12.1.9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104

Tray 3 Size Switch (PL12.2.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105

Tray 3 Feeder Drive (PL12.2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106

Tray 3 Right Guide (PL12.2.11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107

Tray 3 Left Guide (PL12.2.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108

Tray 3 Retard Roll (PL12.3.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-109

9 Parts List

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

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

Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38

Parts List 1.1 Covers (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Parts List 1.2 Covers (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Parts List 2.1 Tray 2 (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Parts List 2.2 Tray 2 (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Parts List 3.1 Paper Feeder (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Parts List 3.2 Paper Feeder (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Parts List 4.1 Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Parts List 5.1 Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

Parts List 6.1 Fuser & Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

Parts List 7.1 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

Parts List 8.1 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

Parts List 9.1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

Parts List 10.1 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

Parts List 11.1 Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

Parts List 12.1 Optional-550 Sheet Feeder - Tray 3 (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

Parts List 12.2 Optional 550-Sheet Feeder - Tray 3 (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

Parts List 12.3 Optional 550-Sheet Feeder - Tray 3 (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36

Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

xx Phaser 6180 Color Laser Printer Service Manual

10 Plug/Jack and Wiring Diagrams

Plug/Jack Diagrams and Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

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

Optional Feeder Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Duplex Plug/Jack Designators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Plug/Jack Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

General Diagram - Plug/Jack Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Map 1 - Electrical and Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Map 2 - Laser Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Map 3 - Image Processor Board and Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Map 4 - LVPS and MCU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Map 5 - Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

Map 6 - Optional 550-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Notations Used in the Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

Wiring Diagrams Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

General Wiring Diagram - Electrical (refer to page 10-22 for details) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

Detailed Electrical Wiring Diagram (1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

Detailed Electrical Wiring Diagram (2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23

Detailed Electrical Wiring Diagram (3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

Detailed Electrical Wiring Diagram (4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

Detailed Electrical Wiring Diagram (5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

Detailed Electrical Wiring Diagram (6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27

Electrical Wiring Diagram (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

Electrical Wiring Diagram (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

Tray 1 (MPT) and Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38

Xerographic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42

Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48

Optional 550-Sheet Feeder Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50

Duplex Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52

Contents

A Reference

Phaser 6180 Menu Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Boot Controller Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Firmware Controller Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Firmware MPC Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Printer Chain Link Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

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

Index

Phaser 6180 Color Laser Printer Service Manual xxi

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Parts of the Printer

■ Printer Options

■ Maintenance Items

■ Consumables

■ Printer Specifications

■ Controller Functions

Chapter

General Information

Printer Introduction and Overview

The Xerox Phaser 6180 Color Laser Printer has a single-pass color laserdesign architecture, which offers color and mono print speed at 20/26-ppm, and resolutions up to 600 x 600 dots-per-inch (dpi). The printer supports Adobe PostScript 3 and PCL6, USB 2.0, Parallel port, and 10/100 Base-TX Ethernet.

The Phaser 6180 printer provides a standard 150-Sheet Tray 1 (MPT) and a standard 250-Sheet Tray 2. Tray 1 (MPT) supports specialty media, card stock, and envelopes. The Output Tray holds 300 sheets facedown.

The printer options add memory, paper capacity, and functionality. Memory upgrades are available to increase the standard RAM from 128 up to 1152 MB maximum. A 550-Sheet Feeder is available as an option. Auto-duplexing is available and no tools are required to install the Duplex Unit. The MultiProtocol Network Card expands the supported network protocols.

Technical Support Information

The Xerox Phaser 6180 Color Laser Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.

To ensure complete understanding of this product, participation in Xerox Phaser 6180 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.pl

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

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

1-2 Phaser 6180 Color Laser Printer Service Manual

Printer Configurations

General Information

The Phaser 6180 printer is available in two configurations.

Phaser 6180 Configurations

Printer Configuration

Features

6180N 6180DN

Processor and Clock Speed 400 MHz 400 MHz

Memory Configuration* 128 MB 128 MB

Print Speed (Color/Mono) 20/26 20/26

Resolutions (dpi)

Standard 600 x 600 x 1 bit 600 x 600 x 1 bit

Enhanced 600 x 600 x 4 bit 600 x 600 x 4 bit

Adobe PostScript 3 Fonts Standard Standard

PCL6 Fonts Standard Standard

Job Pipelining Standard Standard

USB 2.0 Hi-Speed Support Standard Standard

Parallel Port Standard Standard

Ethernet Interface 10/100 Base-TX 10/100 Base-TX

Tray 1 (MPT) (150 Sheet) Standard Standard

Tray 2 (250 Sheet) Standard Standard

550-Sheet Feeder Optional Optional

Duplex Unit Optional Standard

Wireless LAN Optional Optional

Print Speed - Maximum Duplex (Letter/ A4) (Color/Monochrome)

Warranty 1 year onsite 1 year onsite

* All configurations have one memory slot supporting 256 MB/ 512 MB/ 1 GB DDR2 DIMMs, to a

maximum of 1152 MB. Standard memories are soldered on board.

14/18 14/18

Phaser 6180 Color Laser Printer Service Manual 1-3

General Information

Parts of the Printer

Front and Side Views

1. Tray 2

2. Tray 3

3. Tray 1 (MPT)

4. Front Cover (Door A)

s6180-346

5. Control Panel

6. Output Tray

7. Extender Cover

8. Top Cover

9. Front Cover Release Button

10. Power Switch

1-4 Phaser 6180 Color Laser Printer Service Manual

Rear View

General Information

s6180-259

1. Ethernet Port

2. Parallel Port

3. USB Port

4. Power Cord Connector

Phaser 6180 Color Laser Printer Service Manual 1-5

General Information

Control Panel

The Control Panel consists of 2 LEDs, 1 display window, and 8 functional buttons. These buttons are used to navigate the menu system, perform functions, and select modes of operation for the printer.

Control Panel Button Descriptions

Ready

CMYK

1 2

4 5 7 8

s6180-333

1. Ready LED (Power/Status) LED On - Ready to print or processing print job. LED blinking - The printer is receiving data. LED Off - An error has occurred and the printer is offline.

2. Error LED Light On - Error with print job. (blinking = not user fixable) (On solid = user fixable)

3. Graphic Control Panel Display Displays printer settings, status, and messages.

4. Menu Button Changes display between Menu mode and Print mode.

5. 4 Way Cursor Buttons Moves between the Menu levels.

Up and Down arrows Switches between Menus or Items on the

same level.

Right and Left arrows Switches between the Menu levels.

6. Cancel Button Cancels the current print job.

7. OK Button Move to the next level, confirm setting, and print report.

8. Wake Up LED/Button LED comes On when the printer is in Power Saver Mode. Press this button to exit the Power Saver Mode.

1-6 Phaser 6180 Color Laser Printer Service Manual

LED Indicators

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

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

Boot Download for Controller Up + Down + Menu buttons

Phaser 6180 Color Laser Printer Service Manual 1-7

General Information

Printer Options

Additional Memory

Phaser 6180 printer options include:

■ Additional Memory (256 MB/ 512 MB/ 1024 MB)

■ Optional 550-Sheet Feeder (Tray 3)

■ Duplex Unit

■ Multi-Protocol Network Card

The printer features one slot that accepts 256, 512, or 1024 MB of DDR2 DIMMs. Memory modules must meet the following characteristics:

■ 200 Pin DDR2 DIMM (8 chip type)

■ Unbuffered, Non-parity

The printer Configuration page lists the amount of RAM installed in the printer.

Duplex Unit

s6180-447

User can install the Duplex Unit without using any tools and by simply removing the Transfer Unit.

Duplex Unit

s6180-452

1-8 Phaser 6180 Color Laser Printer Service Manual

Multi-Protocol Network Card

Not

The Multi-Protocol Network Card provides additional protocols and security features including IPP, SMB, SSL/HTTPs, WINS, DDNS, and Netware.

General Information

s6180-449

Optional 550-Sheet Feeder (Tray 3)

The Optional 550-Sheet Feeder increases the input capacity of the printer and can be attached to the printer underneath Tray 2 with 2 screws.

Only one Optional 550-Sheet Feeder is supported.

s6180-448

Phaser 6180 Color Laser Printer Service Manual 1-9

General Information

Not

Maintenance Items

An item is a printer part or assembly that has a limited life, and requires periodic replacement. Routine maintenance items are typically customer replaceable.

The listed items have limited life and require periodic replacement.

Phaser 6180 Maintenance Items

Item Print Life

Transfer Unit Up to 100,000 pages

Fuser Up to 100,000 pages

Feed/Retard Roller Up to 100,000 pages

Print life is based on “typical” office printing and 5% coverage per color on 24 lb. paper. The 100,000 life is not guaranteed and varied depending on usage habits.

Transfer Unit

Fuser

Feed Rollers

Tray 2

Retard Roller

1-10 Phaser 6180 Color Laser Printer Service Manual

s6180-451

Tray 3

Optional 550-Sheet Feeder Retard Roller

General Information

Optional 550-Sheet Feeder Feed Roller

s6180-351

Phaser 6180 Color Laser Printer Service Manual 1-11

General Information

Consumables

Consumables consist of 4 Print Cartridges used in the printer.

CMY Toner will not be consumed when printing in Mono mode or when printing a Grayscale job only. Internal counters track Consumables and Maintenance Items life usage.

Each Print Cartridge has a CRUM (Customer Replaceable Unit Meter) to record the information. CRUM counts the amount of remaining toner. When toner empty is detected, Life End status will be sent to indicate toner empty.

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

Print Cartridge Print Life

Color Mono

Standard Capacity 2,000 pages 3,000 pages

High Capacity 6,000 pages 8,000 pages

s6180-352

1-12 Phaser 6180 Color Laser Printer Service Manual

Printer Specifications

Functional 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 2,000 PV/month

Maximum 60,000 PV/month

For Duplex prints, prints on the front and back sides of paper are counted as 2 PV. Maximum PV is 2,000 PV/day

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

Resolution / Addressability (dpi)

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

Average Image Coverage

Maximum Image Coverage

Printer Life 300,000 pages

Maximum Duty Cycle 60,000 pages/month*

Warm-Up Time Less than 30 seconds from Power On

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

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

Macintosh OS 10.2 or higher

Linux Redhat, SuSe, and TurboLinux 10

Desktop

* Assumes a 30 day month of printing.

Phaser 6180 Color Laser Printer Service Manual 1-13

General Information

Memory Specifications

Electrical Specifications

Characteristic Specifications

Memory Minimum 128 MB On-Board

memory

Maximum 1152 MB

Supported RAM Supports up to 1152 MB of DDR2 DIMM with one

slot for 256 MB/ 512 MB/1 GB

Characteristic Specification

Power Supply Voltage/Frequency

Line Voltages 110-127 VAC ± 10%

220-240 VAC ± 10%

Frequency Range 50/60 Hz ± 3 Hz

Current Capacity 110 V Engine: < 8 A

220 V Engine: < 4 A

Power Consumption

Power Saver Mode 110 V Engine: 5.4 W

220 V Engine: 6.3 W

Standby Mode (Fuser On) 110 V: 70 W

220 V: 68.9 W

During Color Continuous Printing

During B/W Continuous Printing

Maximum Value 900 W

In-rush Current

Maximum at 1st 2.5 msec 50 Amp (Cold start)

Within 10 msec 80 Amp (110 V/ 220 V/ 240 V)

110 V Engine: 450 W 220 V Engine: 410 W

110 V Engine: 410 W 220 V Engine: 375 W

135 Amp (Hot start

85 Amp (100 V)

Leakage Current Power Current

110 V M/C < 3.5 (UL) mA

120 V < 3.5 (UL) mA

220-240 V < 3.5 mA (IEC)

NERGY STAR Sleep Mode < 45 W

1-14 Phaser 6180 Color Laser Printer Service Manual

Print Speed

General Information

Simplex (ppm) Duplex (ipm)

Resolution

600 Standard 20/20 26/25 14/14 18/18

600 Enhanced 20/20 26/25 14/14 18/18

Paper Type (65 - 220 gsm)

Letter 18 26 12 21

A4 17 25 12 25

A5 18 26 12 21

Legal 15 26 11 18

Transparency 6 6 N/A N/A

Environmental Specifications

Characteristic Specification

Temperature

Operating 5 to 32° C (41 to 90° F)

Color

A/A4

Mono

A/A4

Color

A/A4

Mono

A/A4

Standby -20 to 40° C (-4 to 104° F)

Humidity (% RH)

Operating 15 to 85% RH

Standby 5 to 85% RH

Altitude

Operating 0 to 3,500 meters (11,482 feet)

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

Printing 6.6 49.1

Standby 4.0 28.6

Phaser 6180 Color Laser Printer Service Manual 1-15

General Information

Operating Mode

Mode Condition Description

Running Mode The printer is under operating condition

such as running or recording.

Fusing The system keeps the operating

temperature.

Exposure The Laser Unit Motor runs at the running

speed.

Recording The system is under operating condition.

Cooling Fan The fan operates at high speed.

Control Panel Operation

Standby Mode The printer is under standby condition.

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

Power Saver Mode

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

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

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

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

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

Note: When the printer receives a print job or the Wake Up button is pressed, the

printer exits the Power Saver mode and enters the Ready mode.

1-16 Phaser 6180 Color Laser Printer Service Manual

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 Standby mode (Laser Unit Motor Off, Fuser Ready)

■ Paper is A size Short Edge Feed (SEF)

■ Process control time is not included

Mode FPOT (sec.)

Color As fast as 10.0

Mono As fast as 10.0

General Information

Phaser 6180 Color Laser Printer Service Manual 1-17

General Information

Not

Image Specifications

The printer has 4 mm margins on all sides.

■ 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

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

1-18 Phaser 6180 Color Laser Printer Service Manual

Physical Dimensions and Clearances

Printer Dimensions

Print Engine 6180N 6180DN

Height 470 mm (18.5 in.) 470 mm (18.5 in.)

Width 400 mm (15.7 in.) 400 mm (15.7 in.)

Depth 493 mm (19.4 in.) 493 mm (19.4 in.)

General Information

Weight (base printer with standard fill print cartridges)

Optional 550-Sheet Feeder Value

Height 138 mm (5.4 in.)

Width 400 mm (15.7 in.)

Depth 493 mm (19.4 in.)

Weight 7.7 kg (16.9 lb.)

Minimum Clearances

121.5 cm (47.8 in.)

10 cm (4 in.)

27.2 kg (59.8 lb.) 28.3 kg (62.3 lb.)

60 cm

(23.6 in.)

35 cm

(14 in.)

13 cm (5 in.)

10 cm (4 in.)

60 cm

(23.6 in.)

s6180-261

Phaser 6180 Color Laser Printer Service Manual 1-19

General Information

Mounting Surface Specifications

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

1. In order to function properly, the printer must be placed on a surface with

the following minimum dimensions.

121.5 cm

10 cm

60 cm60 cm

13 cm

10 cm

s6180-264

2. Mounting surface flatness must be within the specified range.

Right Hand Side

5mm Max

s6180-263

1-20 Phaser 6180 Color Laser Printer Service Manual

3. The printer must not be tipped or tilted more than 7 mm.

10° or 7 mm

General Information

10° or 7 mm

s6180-262

Failure to adhere to the specified mounting specifications will void all guarantees of print-quality and/or performance. Known problems that can 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 training edge of

the print.

Phaser 6180 Color Laser Printer Service Manual 1-21

General Information

Media and Tray Specifications

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

Supported Paper Size

Paper Type Dimension Tray 1 (MPT) Tray 2, 3

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* Yes Yes

* All trays support Custom sizes. Tray 1 supports a wider range of Custom size dimensions than trays 2 and 3.

Supported Paper Types and Weights

Paper Type Paper Weight Tray 1 (MPT) Tray 2, 3

Plain Paper 65-90 g/m

Letter Head 85-120 g/m

Glossy Paper 100-163 g/m

Thick Glossy Paper 164-216 g/m

Pre-Punched 65-90 g/m

Thin Card Stock 100-163 g/m

Thick Card Stock 170-216 g/m

(22-32 lb. Bond) Yes Yes

(17-24 lb. Bond) Yes Yes

Yes Yes

Yes No

Label N/A Yes Yes

Transparency N/A Yes No

Special 100-163 g/m

Yes No

(30-60 lb. Cover)

Supported Envelopes

Type Dimension Tray 1 (MPT) Tray 2, 3

Envelope #10 4.12 x 9.5 in. Yes No

Monarch Envelope 3.87 x 7.5 in. Yes No

C5 Envelope 162 x 229 mm Yes No

DL Envelope 110 x 220 mm Yes No

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

1-22 Phaser 6180 Color Laser Printer Service Manual

Controller Functions

Job Control

Cancel Print

Forced Output

IP Filter

General Information

User can cancel a print job while printing is in progress using the Cancel button on the Control Panel. Job cancellation is not immediate. Depending on the job size, it may take a while 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.

User can accept or reject print jobs 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 paper jam, the printer automatically restarts the job after the jammed paper is removed. User does not have to reprint the entire job.

Job Timeout

When job transmission is interrupted for a certain period of time, the print data is deleted as an error. 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.

Phaser 6180 Color Laser Printer Service Manual 1-23

General Information

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

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 (20H-

FFH). 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

(20H-FFH) 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 will be cleared when the printer is turned Off. This function is not available for MAC OS 10.2 and Linux operating systems.

1-24 Phaser 6180 Color Laser Printer Service Manual

Form Overlay

Not

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

Font Download

PCL6 fonts can be downloaded into RAM Disk.

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.

General Information

Same data is stored in two or more addresses in one IC. When the Controller is replaced, IC can be transferred.

ID Print

Counter Description

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

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

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

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 Print Cartridge life has ended, the printer stops accepting print request (life of the Print 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 print cartridge rated life; however, the printer will display an end of life message on the Control Panel.

Print Cartridge Control Panel Display

Print Cartridge Control Panel Display Functionality

Life Warning

Normal Status

Xerox Xerox (TM)

Print Cartridge

Phaser 6180 Color Laser Printer Service Manual 1-25

Error

Replace Soon

End of Life Error

Replace Print Cartridge

Prints with full functionality.

General Information

Not

Print Cartridge Control Panel Display (continued)

Print Cartridge Control Panel Display Functionality

Life

Normal Status

Warning Error

End of Life Error

Xerox (refill Print Cartridge)

Other OEM (non-Xerox printer manufacturer)

Non-Xerox Print Cartridge Manufacturer

Toner Remaining Amount

The CentreWare Internet Services (IS) and PrintingScout (SimpleMonitor) allow the printer to display toner remaining amount.

Maintenance Function

Firmware Update

Xerox (TM) Print Cartridge

Non-Xerox Print Cartridge

Replace Soon

No Life Tracking

Empty Prints with full

functionality up to 40% of the Print Cartridge life.

Printer displays error and will not print.

Replace Print Cartridge

Prints with full functionality.

The Image Processor Board and Multi-Protocol Network Card firmware can be updated by customers and service technicians using Windows PC or Macintosh with dedicated utilities. Firmware updates are available at www.xerox.com/office/6180support.

Detailed procedures are available in the “” on page A-2.

Boot Code can be updated via USB or Parallel port only.

Updated Firmware Windows

Via USB/IEEE1284 Via Network (port 9100)

Image Processor Board Available Available

Multi Protocol Network Card Available Available

MCU Board Available Available

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

1-26 Phaser 6180 Color Laser Printer Service Manual

Diagnostics

Information Pages

Demo Page

Configuration Page

General Information

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.

Demo Page provides sample of print for the Phaser 6180 Color Laser Printer. The Demo Page is printed in color from selected paper tray.

s6180-504

Phaser 6180 Color Laser Printer Service Manual 1-27

General Information

User can print the Configuration Page from the Control Panel > Menu >

Information Pages > Configuration. The Configuration Page is printed in

from the default tray and includes the following 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 Version, PostScript Serial Number, Firmware Version, Boot Version, Engine Version, PostScript CRD Version, Default Paper, Default Language, Current Temperature, Current Humidity

Printer Options Multi-Protocol Card (when installed)

Duplex Unit: (00.00.00) Paper Tray: Tray 1 (MPT), Tray 2-3

Print Volume Print Volume for each paper size

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

Parallel Setup ECP, Adobe Protocol

USB Setup Adobe Protocol

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

Maintenance Auto Reg Adj, Non-Xerox Toner

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

PostScript PS Error Report, PS Job Time-Out, Paper Select

Control Panel Panel Lock

Tray Settings MPT Mode, Tray 2

PCL Fonts List

Protocol, Host Access List, Adobe Protocol

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

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

Mode

User can print the PCL Fonts List default in color on A size paper from default tray. The PCL Font List contains:

■ No., Fonts, Escape Sequence, Font ID, Sample

PCL Macro List

User can print the PCL Macro List default on A paper size from default tray.

1-28 Phaser 6180 Color Laser Printer Service Manual

PostScript Fonts List

User can print the PostScript Fonts List default on A size paper from default tray. The PostScript Fonts List contains:

■ Print Fonts, Fonts Sample

Job History Report

The printer can retain up to 20 job logs. Job History can be manually or automatically printed when the number of the retained job logs has reached

20. User can print the Job History Report default on A paper size from default tray. The Job History Report contains:

■ Job sent data and time

■ Input Interface (USB, LPD,...etc.)

■ Document Name (File Name)

■ Output Color

■ User Name/Host Name

General Information

■ Number of Printed Pages (Color/Mono)

■ Number of Printed Impressions (Color/Mono)

■ Paper Size

■ Result (successful, error,...etc.)

Phaser 6180 Color Laser Printer Service Manual 1-29

General Information

Error History Report

The printer can retain up to 42 jam errors and up to 42 fatal errors. User can print the Error History Report default on A paper size from default tray using the printer menu in the Control Panel.

Jam Error log includes the following information:

■ Item No., Total Print Count, Paper Jam Type

Fatal Error log includes the following information:

■ Item No., Total Print Count, Chain-Link Code

Print Meter (Print Volume Report)

User can print the Print Meter page default on A paper size from default tray. The Print Meter page contains:

■ Date of Initialization, Job Accounting User Name, Pages, Sheets, Date/

Time

s6180 506

1-30 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

In this chapter...

■ Phaser 6180 Printer Operational Overview

■ Printing Process

■ Paper Path of the Printer

■ Major Assemblies and Functions

■ Printer Modes

■ Printer Control

■ Drive Transmission

Chapter

Theory of Operation

Phaser 6180 Printer Operational Overview

The Phaser 6180 Color Laser Printer is a full-color laser printer that uses Raster Output Scanner (ROS) lasers with an electrophotographic four-color CMYK process. The tandem system consists of four color print cartridges (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 Phaser 6180 Printer.

Print Process Block Diagram

Print Cartridge

(C, M, Y, K)

(1) Charge

(2) Exposure

(3) Development

(5) Cleaning

Transfer Unit

(4) Transfer (Drum to Paper)

(6) Neutralization

Paper

(7) Fusing

s6180-133

2-2 Phaser 6180 Color Laser Printer Service Manual

Printing Process

Theory of Operation

The Phaser 6180 Printer 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. Cleaning (Print Cartridge) – Remaining toner on the drums is collected.

6. Neutralization – The Detack Saw neutralizes the charge on the paper via

the Belt.

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

8. Cleaning – Remaining toner on the Transfer Unit is collected.

Print Cartridge (C, M, Y, K) (1) Charging (3) Development (4) Transfer (5) Cleaning

Laser Unit (2) Exposure

Fuser (7) Fusing

Laser Beam Paper Transfer

Transfer Unit (4) Transfer (6) Neutralization (8) Cleaning

s6180-134

Phaser 6180 Color Laser Printer Service Manual 2-3

Theory of Operation

Charging

The Drum surface is charged with negative electricity by discharging of the Bias Charge Roll (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 roll, 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 BCR Cleaner contacts with the BCR to catch the toner.

Photoreceptor

HVPS

Cleaning Roll

BCR

Conductor

Drum

s6180-135

2-4 Phaser 6180 Color Laser Printer Service Manual

Exposure

Theory of Operation

Laser beams are emitted from the laser diodes in the Laser Unit. The Drum for each color is scanned from end to end in the axial direction as the polygon mirror rotates, which attaches the fixed mirror and lenses to the Scanner Motor of the Laser Unit.

Rear View

Laser Diodes

Laser Diode Board

Lens

Scanner

Mirror

Polygon Mirror

Mirror

Front

SOS Board

SOS Sensor

Window

Mirror

Laser Beam (K) Laser Beam (C) Laser Beam (M) Laser Beam (Y)

Mirror

Drum (K)

Mirror

Drum (C)

Mirror

Lens

Polygon Mirror

Mirror

Drum (M)

Drum (Y)

s6180-136

Phaser 6180 Color Laser Printer Service Manual 2-5

Theory of Operation

The negative 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 voltage potential drops due to exposure to the laser beam becomes the electrostatic latent image.

Laser Unit

Laser Beams

Concept of Drum

Photoreceptor

Conductor

Laser Beam

Negative Electric Charge Positive Electric Charge

Photoreceptor

Conductor

Drum

Electrostatic Latent Image

Drum Surface

Potential on

Drum Surface

Laser Beam

-V

Laser Beam

Electrostatic Latent Image

s6180-137

2-6 Phaser 6180 Color Laser Printer Service Manual

Development

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 Print Cartridge is agitated by the built-in Agitator and fed into the Developer part. 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 is called Toner Dispensation, which 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 Roll 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 absorbed electrically. A uniform layer is formed by the Trimmer Bar as the carrier magnetic substance is attracted to the Magnetic Roll.

Negative Electric Charge Positive Electric Charge Toner Carrier

Print Cartridge

Agitator

Trimmer Bar

Auger

Developer

Waste Toner Collecting Area

Drum

Magnet Roll

HVPS

s6180-138

Phaser 6180 Color Laser Printer Service Manual 2-7

Theory of Operation

The Magnet Roll is covered by a thin semi-conductive sleeve over the surface. The Developer Bias voltage is supplied to this semiconductor sleeve from the High-Voltage Power Supply (HVPS). Developer Bias is negative Direct Current (DC) voltage combined with Alternating Current (AC) voltage. The Magnet Roll 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 roll, while the potential is higher than the magnet roll at the area where the negative charge on the drum surface decreases. The AC voltage shakes the Developer on the Magnet Roll surface, causing the toner to transfer to the drum.

Thus, the negatively charged toner is attracted only by the area where the negative charge has decreased on the drum surface from the Magnet Roll (electrostatic latent image) and the toner image is formed on the drum. When the toner is attached, the negative charge at the portion of the drum increases where the toner is located increases, the potential decreases, and the force to attract the toner decreases.

Drum Surface

Toner Image

Electric Potential on Drum

-V

Developing Bias

s6180-446

2-8 Phaser 6180 Color Laser Printer Service Manual

Transfer (Drum ---> Paper)

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.

(Black Toner Image)

(Cyan Toner Image)

(Magenta Toner Image)

Drum Surface

Theory of Operation

Paper

Black Toner Image

Cyan Toner Image

Magenta Toner Image

Yellow Toner Image

Drum Surface

(Yellow Toner Image)

s6180-140

Phaser 6180 Color Laser Printer Service Manual 2-9

Theory of Operation

■ Bias Transfer Roll (BTR) – The BTR is a conductive roll, which receives

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

■ Transfer Unit (Belt) – The Transfer Unit is a conductive unit, which

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 Unit feeds the paper toward the direction of the Fuser.

■ Electric Static Attachment (ESA) Roll – The ESA Roll is a conductive

roll, which receives positive voltage from the HVPS and discharges to the paper to improve the toner transfer efficiency.

Drum Surface

Paper

Drum (K)

Drum (C)

Drum (M)

Negative Electric Charge Postive Electric Charge Ton er

BTR

Drum (Y)

HVPS HVPS

ESA Roll

Transfer Unit

s6180-139

2-10 Phaser 6180 Color Laser Printer Service Manual

Cleaning (Print Cartridge)

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 Roll – The Cleaning Roll 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 excess charge on the surface of the Drum is eliminated by irradiating the light of the Erase Lamp (LED).

Theory of Operation

Positive Electric Charge

Negative Electric Charge

Toner

Cleaning Roll

Erase Lamp (LED)

Blade

Conductor

Drum

Photoreceptor

BCR

s6180-141

Phaser 6180 Color Laser Printer Service Manual 2-11

Theory of Operation

Neutralization

The Detack Saw neutralizes the charge on the paper via the Belt.

The Detack Saw, a metal sheet secured at the ground level, is installed at several millimeters away from the back side of the belt.

Drum

Paper

BTR

Negative Electric Charge Positive Electric Charge

Detack Saw

Drum

BTR

Transfer Unit

HVPS

s6180-142

2-12 Phaser 6180 Color Laser Printer Service Manual

Fusing

Theory of Operation

Toner is applied by the BTR and the Developers. The toner image is applied on the paper with the Fuser (Fusing Unit) by the Free Belt Nip Fusing (FBNF) thermal fusing system. The Heat Roll with the Heater Lamp melts the toner particles. Toner is fused onto the paper by the combination of heat and

pressure.

Warm-Up Stand By Printing

Main Heater Lamp On On/Off On

Paper

Nip Spring

Nip Head

Cleaning

Fixed Toner

Heat Roll

Heater Lamp

Unfixed Toner

Sheet

Pad

Belt

Belt Frame

s6180-143

A cleaning blade in the Print Cartridge scrapes off toner remaining on the drum surface after transfer has occurred. Then, the latent charge pattern remaining on the photoconductive drum is neutralized by the Erase Lamp to prepare the drum for the next Exposure cycle.

Phaser 6180 Color Laser Printer Service Manual 2-13

Theory of Operation

Paper Path of the Printer

Paper Path Route

The paper is supplied from Tray 1, 2, or optional Tray 3, and is transported into the printer along the paper path as shown in the diagram.

Tray 1 (MPT)

Multiple Sheet Feed Prevention

Motor Drive/Solenoid/

MPT Roll

Turn Roll

Registration

Transfer Unit

Fuser

550-Sheet Feeder

(Tray 3)

Motor Drive/Clutch/

Feed Roll/Turn Roll

250-Sheet Standard

Tray (Tray 2)

Motor Drive/

Clutch/Regi Roll

Motor Drive/Belt

Multiple Sheet Feed Prevention

Motor Drive/

Clutch/Feed Roll

Lead Edge Registration

Motor Drive/Heat Roll/

Pressure Belt

Exit Roll in the Fuser

Motor Drive/Clutch/

Exit Roll

Duplex Module

Motor Drive/Clutch/

Dup Roll

Output Tray

s6180-144

2-14 Phaser 6180 Color Laser Printer Service Manual

Paper Path Components

Paper path components for the printer and the Optional 550-Sheet Feeder are shown in the following figure.

Heat Roller (Fuser)

Regi Roller (Metal) (Registration)

No Paper Sensor (250-Sheet Feeder)

No Paper Sensor (550-Sheet Feeder)

Exit Roller (Fuser)

Duplex Gate (Fuser)

Theory of Operation

Laser Beam Paper Transfer Paper Sensors

Exit Sensor (Fuser)

Pressure Belt (Fuser)

Duplex Gate

Duplex Roller (Duplex Module)

Duplex Jam Sensor (Duplex Module)

Belt (Transfer Unit)

Duplex Roller (Duplex Module)

Regi Roller (Rubber) (Registration)

Regi Sensor (Registration)

Tray 1 (MPT) No Paper Sensor

Tray 1 (MPT) Roller

Tray 1 (MPT) Turn Roller

Feed Roller (250-Sheet Feeder)

Tray 2 Retard Roller (250-Sheet Feeder)

Turn Roller (550-Sheet Feeder)

Tray 3 Retard Roller (550-Sheet Feeder)

Feed Roller (550-Sheet Feeder)

s6180-145

Phaser 6180 Color Laser Printer Service Manual 2-15

Theory of Operation

Major Assemblies and Functions

Major functional components for the printer are classified into the following categories based on the printer configuration.

■ Tray 2

■ Paper Feeder

■ Tray 1 (MPT) & Registration

■ Fuser

■ Transfer Unit

■ Laser Unit

■ Print Cartridge

■ Main Drive

■ Refer to “Mechanical Components” on page 2-56 for detailed diagrams.

■ Duplex Unit

Tray 2

■ Tray 3 - Optional 550-Sheet Feeder

Bottom Plate

Left Side Guide

Retard Roll

Tray 2 End Guide

Right Side Guide

s6180-146

■ Tray 2 Left/Right Side Guide

The Side Guide moves at a right angle toward the paper transfer direction to align the paper width.

2-16 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

■ Tray 2 Retard Roll

The Retard Roll and Feed Roll pinch the paper to prevent multiple sheets of paper from feeding.

■ Tray 2 End Guide

The End Guide moves in toward the paper transfer direction to determine the paper size. The On/Off of the Size Switch adjusts according to the Tray End Guide position to detect the paper size.

■ Tray 2 Bottom Plate

a. When the tray is inserted into the Sheet Feeder, the Actuator is

pushed toward the front by the Left Guide, which pushes the Stopper.

b. The Stopper unlocks the Bottom Lock Oneway Gear. c. When the tray is pushed until it stops, the Bottom Lock Lever is

pressed down by the Support Nudger in the Sheet Feeder.

d. The Bottom Lock Lever actuates the Bottom Lock Lever Gear, which

pushes the Bottom Rack Lock toward the rear.

e. The gear on the Bottom Rack Lock is disengaged from the Bottom

Lock Oneway Gear, which allows the Bottom Plate to raise up by the Bottom Up Springs.

Bottom Rack Lock

Bottom Lock Lever

Bottom Rack Lock

Left Guide

Actuator

Support Nudger

Bottom Lock Lever Gear

Bottom Plate

Bottom Up Spring

Bottom Lock Oneway Gear

Front of TrayRear of Tray

Bottom Lock Oneway Gear

Stopper

Lock Part (Tray Housing)

Stopper

s6180-367

Phaser 6180 Color Laser Printer Service Manual 2-17

Theory of Operation

Tray 2 Multiple Sheet Feed Prevention

The sheets loaded into Tray 2 are occasionally stuck together along the edges, which can cause a multiple feed or a jam. The Nudger Roller feeds the sheets to a position between the Feed Roller and the Retard Roller. Normally, when only one sheet is fed, both the Feed Roller and Retard Roller rotate to allow the sheet to pass.

Feed Roller (Takeaway Roller)

Friction Clutch

Feed Roller (Nudger Roller)

Retard Roller (Separator)

Single Feed

s6180-489

2-18 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

However, when two sheets are fed concurrently, only the Feed Roller rotates. The Retard Roller is coupled to a friction clutch that prevents the roller from rotating due to extra force from feeding two sheets; this process allows the upper sheet to pass by as the lower sheet is stopped by the friction with the Retard Roller at rest.

The Retard Roller is pushed toward the Feed Roller by spring pressure, and controlled by the Friction Clutch with which it is coupled.

Friction Clutch

Feed Roller (Takeaway Roller)

Retard Roller (Separator)

Multiple Feed

Feed Roller (Nudger Roller)

s6180-147

Phaser 6180 Color Laser Printer Service Manual 2-19

Theory of Operation

Paper Feeder

No Paper Sensor

Feed Roller (Nudger Roller)

Paper Size Switch

Tray 2 Feed Clutch

Feed Roller (Takeaway Roller)

■ Tray 2 Feed Roller

The Feed Roller (Takeaway Roller) feeds the paper when the Feed Clutch operates.

■ Tray 2 Feed Clutch

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

■ Tray 2 Size Switch

The Size Switch detects the presence and size of the paper in the tray.

s6180-265

Size Switch

Size Switch Actuator

Tray End Guide

s6180-150

2-20 Phaser 6180 Color Laser Printer Service Manual

■ Tray 2 End Guide

Not

The paper size is detected at the End Guide position.

Tray 2 End Guide

A5 (SEF)

B5 (SEF)

Executive (SEF)

Letter (SEF)

Legal 14" (SEF)

A4 (SEF)

Legal 13" (SEF)

Theory of Operation

All paper should be loaded SEF.

s6180-149

Refer to “Paper Size Detection” on page 2-50 for detailed information on paper size switches and paper size.

■ Tray 2 No Paper Sensor

The No Paper Sensor detects the presence of the paper in the tray based on the Tray 2 No Paper Actuator position.

No Paper Sensor

No Paper Actuator

Actuator (No Paper Position)

s6180-151

Phaser 6180 Color Laser Printer Service Manual 2-21

Theory of Operation

Not

Tray 1 (MPT) & Registration

Rubber Registration Roller

Turn Roll

Metal Registration Roller

Registration Sensor

Registration Clutch

Turn Clutch

Tray 1 (MPT) Feed Roller

Tray 1 (MPT) No Paper Sensor

■ Tray 1 (M P T) Turn C l utch

Tray 1 (MPT) Feed Solenoid

Tray 1 (MPT) Gear

s6180-268

The Turn Clutch transmits drive energy from the Drive Assembly to the Tur n R o l l e r.

■ Tray 1 (MP T ) Turn Roll e r

The Turn Roller is rotated by the drive from the Drive Assembly through the Turn Clutch to feed paper from the Tray 1 (MPT) or duplex paper path to the Registration Chute.

■ Tray 1 (MPT) Registration Sensor

The Registration Sensor detects paper when the paper leading edge reaches the Registration Chute. When paper is fed from Tray 1 (MPT), the Registration Sensor measures the paper length. The On time of the Registration Sensor is converted into the paper length.

On: The paper activates the Actuator.

■ Tray 1 (MPT) Registration Clutch

The Registration Clutch transmits drive energy from the Main Drive to the Registration Rubber Roller, and transports paper from Tray 1 (MPT) and the duplex path to the Print Cartridge direction. The timing of sheets feeding from the Registration is adjusted by the duration of the Registration Clutch operation so that the toner image on the drum can be transferred to the appropriate position on the sheet.

2-22 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

■ Tray 1 (MPT) Feed Solenoid

The Feed Solenoid controls drive energy from the Drive Assembly to the Tray 1 (MPT) Feed Roller.

Tray 1 (MPT) Feed Roller

Tray 1 (MPT) Feed Solenoid

Retard Roller

Drive Assembly

■ Tray 1 (MPT) No Paper Sensor

s6180-266

The No Paper Sensor detects the presence of paper in Tray 1 (MPT) based on the Actuator’s position.

Tray 1 (MPT) No Paper Sensor

Paper

No Paper Actuator

s6180-267

Phaser 6180 Color Laser Printer Service Manual 2-23

Theory of Operation

Multiple Sheet Feed Prevention

The sheets loaded in Tray 1 (MPT) are occasionally stuck together at the edges, which can cause a multiple sheet feed or a jam. Normally, when only one sheet is fed, both the Feed Roller and Retard Roller rotate to allow the sheet to pass.

Tray 1 (MPT) Feed Roller

Torque Limiter

Retard Roller

Single Feed

s6180-499

2-24 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

However, when two sheets are fed concurrently, only the Feed Roller rotates. The Retard Roller is coupled to a friction clutch that prevents the roller from rotating due to the extra force from feeding two sheets; this process allows the upper sheet to pass by as the lower sheet is stopped by the friction with the Retard Roller at rest.

The Retard Roller is pushed toward the Feed Roller by spring pressure, and controlled by the Torque Limiter (Friction Clutch Retard) with which it is coupled.

Tray 1 (MPT) Feed Roller

Torque Limiter

Retard Roller

Multiple Feed

s6180-269

Phaser 6180 Color Laser Printer Service Manual 2-25

Theory of Operation

Lead Edge Registration

When a sheet is fed from Tray 1 (MPT) 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 Unit Belt, or in front of the BTR’s.

Registration Rollers

s6180-270

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 coming out of Tray 1 (MPT) against the Registration Roller that is not turning, the lead edge of the sheet is registered.

Registration Rollers

Skewed Paper

s6180-271

2-26 Phaser 6180 Color Laser Printer Service Manual

Paper Detection

Since the paper path from Tray 1/Duplex to the Registration Sensor and from the paper tray to the Registration Sensor are different, the Registration Sensor is provided with Actuators A and B.

■ Actuator A detects the sheet fed from Tray 1/Duplex.

■ Actuator B detects the sheet fed from the paper tray.

The movement of Actuator A does not affect Actuator B.

Theory of Operation

Registration Sensor

Actuator B

Registration Sensor Spring (B)

Actuator A

Registration Sensor Spring (A)

Normal Position

Actuator B

Registration Sensor

Actuator A

From Tray 1 (MPT) or Duplex

Registration Sensor

Paper

Actuator A

From Paper Tray

Registration Sensor

Paper

Actuator A

Actuator B

s6180-272

Phaser 6180 Color Laser Printer Service Manual 2-27

Theory of Operation

Fuser

Exit Sensor

Rear View

Temperature Sensor (STS)

Exit Roller

Pressure Belt

Temperature Sensor (NCS)

Heat Roller

Thermostat

Fuser

Front

Heater Lamp

Transfer Unit

ADC Sensor

ESA Roller

s6180-276

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.

■ Heat Roller

The Heat Roller is a metal tube with coated surface and a Heater inside. As the paper passes between the Heat Roller and Pressure Belt, heat that is applied to the paper, melts the toner, and fuses it to the paper.

2-28 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

■ Heater Lamp

The Heater Rods are glass tubes containing heater coils. The Main Heater Lamp heats the entire length of the Heat Roller, and the Dual SubHeater Rods heat the center.

■ Thermostat

The Thermostat provides a second-level of protection. If the Heat Roller temperature exceeds the current temperature, the Thermostat cuts off the AC power to the Heater Lamps.

■ Temperature Sensors

The temperature sensors are thermistors having a known value of resistance that varies with temperature. There are two Temperature Sensors. The Soft Touch Sensor (STS) is located at the edge of the Heater Lamp, and the Non-Contact Sensor (NCS) is located at the center of the Fuser. The sensors monitor temperature of each location to control lighting of the Heater Lamp. The Sensors are mounted in contact with the surface of the Heat Roller. Power to the Heater Lamp is turned On and Off using the signals from these sensors, so that the surface temperature of the Heat Roller can be maintained within a specified range. This signal is also used to provide a first stage of overheat protection.

■ Pressure Belt

The Pressure Belt maintains pressure on the paper passing between it and the Heat Roller. The pressure bonds the melted toner to the paper.

■ Exit Roller

The Exit Roller transports paper from the Fuser to the output tray.

■ Exit Sensor

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

Phaser 6180 Color Laser Printer Service Manual 2-29

Theory of Operation

Transfer Unit

The Transfer Unit consists of the Belt, ADC Sensor, ADC Solenoid, ADC Pad, and ESA Roller.

Normal Position

ADC Solenoid

ADC Solenoid On

Position of ADC Sensor

Position of ADC Sensor (Window = Open)

Spring

Shutter

ADC Pad

ADC Sensor

s6180-273

■ Belt

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

■ ADC Sensor

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.

■ ADC Solenoid

To activate the ADC Pad, turn On the ADC Solenoid for a fixed time before the ADC Sensor starts reading the toner patches. When turned On, the ADC Solenoid activates the ADC Pad, which cleans contamination on the ADC Sensor surface.

■ ESA Roller

The ESA Roller discharges a positive voltage to the paper. Toner transfer efficiency is raised by applying a positive charge to the paper.

2-30 Phaser 6180 Color Laser Printer Service Manual

Laser Unit

Theory of Operation

Rear View

Laser Diodes

Laser Diode Board

Lens

Scanner

Mirror

Polygon Mirror

Front

SOS Board

SOS Sensor

Window

Mirror

Laser Unit

s6180-277

The Laser Unit is an exposure unit that generates laser beams to form electrostatic latent image on the drum surface. The Laser Unit consists of the following components: Laser Diode (LD), Scanner, Start of Scan (SOS) Board, Lenses, Mirror, and Window.

Phaser 6180 Color Laser Printer Service Manual 2-31

Theory of Operation

■ Laser Diode Board

There are four Laser Diodes which produce laser beams that are turned On and Off according to the print data signal.

The Laser Diode Board is comprised of four 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 electrostastic latent image, the LD 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 is comprised 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 irradiated onto the Polygon Mirror via the Mirror. The Polygon Mirror, provided with six reflecting mirror faces, changes the reflection angle of the laser light as it rotates by the Scanner Motor, 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 and secure an optical path.

■ Window

The window prevents debris from entering the Laser Unit.

2-32 Phaser 6180 Color Laser Printer Service Manual

Print Cartridge

Theory of Operation

Print Cartridge (K)

Print Cartridge (C)

Dispenser (K)

Dispenser (C)

LED

Dispenser (M)

Dispenser (Y)

Print Cartridge (M)

Print Cartridge (Y)

CRUM Connector (K)

CRU Sensor (K)

CRUM Connector (C)

CRU Sensor (C)

CRUM Connector (M) CRU Sensor (M)

CRUM Connector (Y)

CRU Sensor (Y)

s6180-280

The Print Cartridge is a customer replaceable item consists of 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 (C/M/Y/K)

The Dispenser provides drive energy to the Agitator and Auger in the Print Cartridge, and provides toner to the Developer part of the Print Cartridge.

Phaser 6180 Color Laser Printer Service Manual 2-33

Theory of Operation

■ CRU Sensor (C/M/Y/K)

The CRU Sensor detects the presence of the Print Cartridge.

CRU Sensor Actuator (No Cartridge Position)

CRU Sensor Actuator (Cartridge in Position)

Print Cartridge Sensor (C, M, Y, K)Print Cartridge Sensor (C, M, Y, K)

Print Cartridge

■ Erase Lamp (LED)

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

Erase Lamp

LED Drum Print Cartridge

Erase Lens

CRU Sensor

s6180-278

s6180-279

2-34 Phaser 6180 Color Laser Printer Service Manual

Main Drive

Not

Theory of Operation

Main Drive

Exit Clutch

Main Motor

Sub Motor

Developer Motor

Tray 2 Motor

Drive Assembly

s6180-281

The Main Drive provides drive energy to the following components:

■ Main Motor

The Main Motor provides drive energy for the Black Drum, Transfer Unit, and Fuser.

■ Sub Motor

The Sub Motor provides drive energy for the Black Developer, Cyan, Magenta, and Yellow Drums.

■ Developer Motor

The Developer Motor provides drive energy for the Cyan, Magenta, and Yellow Developers.

■ Exit Clutch

The Exit Clutch transmits drive energy from the Main Motor to the Exit Roll in the Fuser. When Duplex mode is in use, the Exit Clutch stops. The Exit Roll is driven by the Duplex Motor.

■ Drive Assembly

The Drive Assembly provides drive energy for Tray 1 (MPT), Tray 2, and Registration. The Tray 2 Motor is part of the Drive Assembly.

Refer to “Mechanical Components” on page 2-56 for detailed diagrams.

Phaser 6180 Color Laser Printer Service Manual 2-35

Theory of Operation

Electrical

Interlock Switch

Humidity/Temperature Sensor

Control Panel

HVPS

Humidity/Temperature Sensor

Interlock Switch

Main Fan

LVP S

Power Switch

EEPROM Board

Image Processor Board

MCU Board

s6180-282

Control Panel

The Control Panel displays the printer status and operates the printer.

Ready

CMYK

s6180-458

Power Switch

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

2-36 Phaser 6180 Color Laser Printer Service Manual

Theory of Operation

Main Fan

The Main Fan removes heat from the printer to prevent overheating.

Electrically Erasable Programmable Read-Only Memory (EEPROM) Board

The EEPROM Board stores the printer unique information. Information on the EEPROM Board is also stored on the Machine Control Unit (MCU) Board.

Humidity /Temperature Sensor

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

Interlock Switch

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

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 circuit. The LVPS contains a control circuit for the heater of the Fuser, in addition to the power circuit.

s6180-459

Phaser 6180 Color Laser Printer Service Manual 2-37

Theory of Operation

High-Voltage Power Supply (HVPS)

The HVPS provides high-voltage power to the components in the Transfer Unit and Print Cartridge to perform charging, development, and primary transfer of the print process to the BCR, BTR, Developer, and ESA Roller.

s6180-461

2-38 Phaser 6180 Color Laser Printer Service Manual

Image Processor Board

The Image Processor (I/P) Board is connected to the MCU Board, which controls the printer, including Diagnostic, Interface, and Image Processing. The I/P Board is one of the major elements of the Phaser 6180 Printer.

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

1. Standard Memory (128 MB on-board RAM)

2. Optional Memory DIMM (should be swapped)

3. Multi-Protocol Network Card Connection

4. NVRAM

5. Ethernet Connection

6. PC Interface Connection (Parallel)

7. USB Connection

Theory of Operation

s6180-450

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 (if installed)

■ NVRAM

■ Multi-Protocol Network Card (if installed)

Phaser 6180 Color Laser Printer Service Manual 2-39

Theory of Operation

Not

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 Motors in the Main Drive and Drive Assembly.

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

component.

5. Controls the Laser Unit.

NVRAM

s6180-460

When replacing an MCU Board, ensure to transfer the NVRAM from the old MCU Board to the new MCU Board.

2-40 Phaser 6180 Color Laser Printer Service Manual

Data Flow

Theory of Operation

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

Computer

I/P Board

MCU Board

Laser Unit

Print Cartridges (4x)

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

Transfer Unit

Fuser

Toner Image On Paper

Print Image On Paper

s6180-283

Phaser 6180 Color Laser Printer Service Manual 2-41

Theory of Operation

Duplex Unit

Duplex Fan

Upper Duplex Roller

Duplex Board

Duplex Jam Sensor

Duplex Clutch

Duplex Motor

Lower Duplex Roller

■ Duplex Jam Sensor

s6180-284

The Duplex Jam Sensor detects paper that is carried to the Duplex Unit.

■ Duplex Clutch

The Duplex Clutch transmits drive energy from the Duplex Motor to the Exit Roller in the Fuser. When the Clutch operates, the Exit Roller rotates in the reverse direction.

■ Duplex Motor

The Duplex Motor provides drive energy to the Lower Roller (Duplex 2 Roller), Upper Roller (Duplex 1 Roller), and Exit Roll on the Fuser.

■ Duplex Board

The Duplex Board controls the Motor, Sensor, and Clutch.

■ Duplex Fan

The Duplex Fan removes heat from inside of the printer to prevent overheating.

2-42 Phaser 6180 Color Laser Printer Service Manual

Tray 3 - Optional 550-Sheet Feeder

Tray 3 Function

Left Side Guide

Theory of Operation

Bottom Plate

Tray 3 End Guide

Right Side Guide

Retard Roller

■ Tray 3 Side Guide (Left/Right)

The Left/Right Guide moves at a right angle to the paper transfer direction to align the paper width.

■ Tray 3 End Guide

The End Guide moves toward the paper direction to determine the paper size. The Size Switch On/Off switch varies according to the Tray 3 End Guide position to detect the paper size.

■ Tray 3 Retard Roller

The Retard Roller and the Feed Roller (Pick Up Unit) pinch the paper to feed.

s6180-260

Phaser 6180 Color Laser Printer Service Manual 2-43

Theory of Operation

■ Tray 3 Bottom Plate

a. When the tray is inserted into the Sheet Feeder, the Actuator is

pushed toward the front by the Left Guide, which pushes the Stopper.

b. The Stopper unlocks the Bottom Lock Oneway Gear. c. When the tray is pushed until it stops, the Bottom Lock Lever is

pressed down by the Support Nudger in the Feeder.

d. The Bottom Lock Lever actuates the Bottom Lock Lever Gear, which

pushes the Bottom Rack Lock toward the rear.

e. The gear on the Bottom Rack Lock is disengaged from the Bottom

Lock Oneway Gear, which allows the Bottom Plate to raise up by the Bottom Up Springs.

Bottom Plate

Bottom Up Spring

Bottom Rack Lock

Bottom Lock Oneway Gear

Bottom Lock Lever

Bottom Rack Lock

Left Guide

Actuator

Support Nudger

Bottom Lock Lever Gear

Lock Part (Tray Housing)

Front of TrayRear of Tray

Bottom Lock Oneway Gear

Stopper

s6180-285

2-44 Phaser 6180 Color Laser Printer Service Manual

Optional 550-Sheet Feeder

Theory of Operation

Turn Roller

Feed Roller

Tray 3 No Paper Sensor

■ Tray 3 No Paper Sensor

Turn Clutch

Feed Clutch

Size Switch

Optional Feeder Board

Optional Feeder Drive

The No Paper Sensor detects the presence of the paper in the paper tray based on the No Paper Actuator position.

■ Tray 3 Feed Clutch

The Feed Clutch transmits drive energy from the Feeder Drive to the Feed Roller.

s6180-286

■ Tray 3 Feed Roller

When the Feed Clutch operates, the Feed Roller rotates and feeds the paper.

Phaser 6180 Color Laser Printer Service Manual 2-45

Theory of Operation

Not

■ Tray 3 Turn Clutch

The Turn Clutch transmits drive energy from the Optional 550-Sheet Feeder Drive through the Turn Clutch to feed the paper from the paper tray to the printer.

■ Optional 550-Sheet Feeder Drive

The Optional 550-Sheet Feeder Drive drives the rollers of the Optional Feeder.

■ Optional 550-Sheet Feeder Board

The Optional 550-Sheet Feeder Board controls the Motor, Sensor, and Clutch.

■ Tray 3 Size Switch

The Size Switch detects the paper size and the presence of the paper tray.

Size Switch

Size Switch Actuator

Tray End Guide

■ Tray 3 End Gu i de

Paper is detected at the Tray 3 End Guide.

Tray 3 End Guide

Executive (SEF)

Legal 14" (SEF)

All paper should be loaded SEF.

A4 (SEF)

Legal 13" (SEF)

Letter (SEF)

s6180-150

A5 (SEF)

B5 (SEF)

s6180-453

Refer to “Paper Size Detection” on page 2-50 for detailed information on paper size switches and paper size.

2-46 Phaser 6180 Color Laser Printer Service Manual

Tray 3 Multiple Sheet Feed Prevention

The sheets loaded in Tray 3 are occasionally stuck together along the edges, which can cause a multiple sheet feed or a jam. The Nudger Roller feeds the sheets to a position between the Feed Roller and the Retard Roller. Normally, when only one sheet is fed, both the Feed Roller and Retard Roller rotate to allow the sheet to pass.

Theory of Operation

Feed Roller (Takeaway Roller)

Friction Clutch

Feed Roller (Nudger Roller)

Retard Roller (Separator)

Single Feed

s6180-489

Phaser 6180 Color Laser Printer Service Manual 2-47

Theory of Operation

The Retard Roller is pushed toward Feed Roller by spring pressure, and controlled by the Friction Clutch with which it is coupled.

Friction Clutch

Feed Roller (Takeaway Roller)

Retard Roller (Separator)

Multiple Feed

Feed Roller (Nudger Roller)

s6180-147

2-48 Phaser 6180 Color Laser Printer Service Manual

Printer Modes

Operational Modes

Theory of Operation

Power On

Initializing

Init CRU

Checking

Unit

Door Close

CRU Check

Wait

Cleaning

Motor Stop

Process Control Cleaning

Exit Paper

Ready

Printing

Wait

Process Control

PFC

Process Control Registration Control Fuser Warming Up Laser Warming Up Fuser Cooling Down

Start Feeding

Error Occurred

Error

Motor Stop

Printing

& Wait

& Error

Exit Paper

Printing

Feed Jam Occurred

Life Over

Error

The Phaser 6180 Printer includes the following modes:

■ Diagnostics Mode

The printer is ready to receive diagnostic commands, or the printer diagnostic function is operating.

Door Open

s6180-287

■ Wait Mode

The printer is preforming Print Quality adjustment.

■ Ready Mode

The printer is ready for printing.

■ Printing Mode

Printing is in progress.

■ Error Mode

An error is detected in the printer.

■ Initializing Mode

The printer is initializing with a new Developer Unit (new parts have been installed into the printer).

■ Checking Unit Mode

The printer is checking consumable units.

Phaser 6180 Color Laser Printer Service Manual 2-49

Theory of Operation

Not

Printer Control

Paper Size Detection

The paper size detection for Trays 2 and 3 is determined by three paper size switches in each paper tray slot. The switch condition is set by moving the paper guide in the tray. This in turn sets the plastic “fingers” on the side of the paper tray to a specific position that activates the correct switch combination for the selected paper size.

Paper Size Switches Indicated as SW1, SW2, and SW3

Paper Size

Letter (SEF) Off Off On

A4 (SEF) Off On On

A5 Off On Off

B5 (SEF) On Off Off

Legal 13” (SEF) On On On

Legal 14” (SEF) On On On

Executive (SEF) On Off On

No Tray Off Off Off

On: The Actuator is pushing the Size Switch.

Paper Size Switch

SW1 SW2 SW3

Switch 1

Switch 2

Switch 3

Size Switch

2-50 Phaser 6180 Color Laser Printer Service Manual

s6180-288

Xerox Phaser 6180 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Printer Introduction and Overview

Technical Support Information

Printer Configurations

Parts of the Printer

Front and Side Views

Rear View

Control Panel

Printer Options

Additional Memory

Duplex Unit

Multi-Protocol Network Card

Optional 550-Sheet Feeder (Tray 3)

Maintenance Items

Consumables

Printer Specifications

Memory Specifications

Electrical Specifications

Print Speed

Environmental Specifications

Operating Mode

First Print Output Time (FPOT)

Image Specifications

Physical Dimensions and Clearances

Mounting Surface Specifications

Media and Tray Specifications

Controller Functions

Job Control

Cancel Print

Forced Output

IP Filter

Job Recovery

Job Timeout

Print Volume Management

RAM Disk

Billing Meters

ID Print

Toner Remaining Amount

Maintenance Function

Firmware Update

Diagnostics

Information Pages

Demo Page

Configuration Page

PCL Fonts List

PCL Macro List

PostScript Fonts List

Job History Report

Error History Report

Print Meter (Print Volume Report)

Phaser 6180 Printer Operational Overview

Print Process Block Diagram

Printing Process

Charging

Exposure

Development

Transfer (Drum ---> Paper)

Cleaning (Print Cartridge)

Neutralization

Fusing

Cleaning

Paper Path of the Printer

Paper Path Route

Paper Path Components

Major Assemblies and Functions

Tray 2

Paper Feeder

Tray 1 (MPT) & Registration

Fuser

Transfer Unit

Laser Unit

Print Cartridge

Main Drive

Electrical

Duplex Unit

Tray 3 - Optional 550-Sheet Feeder

Printer Modes