Xerox Phaser 6250 Service Manual
Phaser
Color Laser Printer
Service
Manual
®
6250
Phaser® 6250
Warning
Color Laser Printer
Service Manual
The following servicing instructions are for use by qualified service
personnel only. To avoid personal injury, do not perform any servicing other
than that contained in the operating instructions, unless you are qualified to
do so.
First Printing: July, 2003
071-0869-00
Service Terms
Note
Caution
Warning
Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used, and
always read NOTE, CAUTION, and WARNING statements.
Common Acronyms:
The following list defines the acronyms that may be fournd in this manual.
ADC: Automatic Density Control MCU: Engine Control Board
BTR: Bias Transfer Roller NCS: Non-Contact Sensor
CRUM: Customer Replaceable Unit
Monitor
CTD: Toner Density Control PL: Corresponds to the FRU Parts List.
DRV: Motor Driver Board RMI: Routine Maintenance Item
ESD: Electrostatic Discharge ROS: Laser Scanning Unit
IDT: Intermediate Transfer Unit RTC: Charge Roller
PHD: Imaging Unit
A note indicates an operating or maintenance procedure, practice or condition
that is neccessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or add a
comment on the results achieved through a previous action.
A caution indicates an operating or maintenance procedure, practice or condition
that, if not strictly observed, results in damage to, or destruction of, equipment.
A 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.
iv Phaser 6250 Color Printer
Symbols Marked on the Product
0
30 min.
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal
injury.
The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.
Avoid pinching fingers in the printer. Use caution to avoid
personal injury.
Use caution (or draws attention to a particular component).
Refer to the manual(s) for information.
Service Manual v
Power Safety Precautions
Power Source
For 110 VAC printers, do not apply more than 140 volts RMS between the supply
conductors or between either supply conductor and ground. Use only the specified
power cord and connector. For 220 VAC printers, do not apply more than 264 volts
RMS between the supply conductors or between either supply conductor and ground.
Use only the specified power cord. This manual assumes that the reader is a qualif ied
service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet
only. If necessary, contact a licensed electrician to install a properly grounded outlet.
If the product loses its ground connection, contact with conductive parts may cause an
electrical shock.
Disconnecting Power
Turning the power off using the On/Off switch does not completely de-engergize the
printer. You must also disconnect the printer power cord from the AC outlet. Position
the power cord so that it is easily accessible during servicing so that you may power
down the printer during an emergency . Disconnect the po wer plug by pulling the plug,
not the cord.
Disconnect the power cord in the following cases:
■ if the power cord or plug is frayed or otherwise damaged,
■ if any liquid or foreign material is spilled into the case,
■ if the printer is exposed to any excess moisture,
■ if the printer is dropped or damaged,
■ if you suspect that the product needs servicing or repair,
■ whenever you clean the product.
vi Phaser 6250 Color Printer
Electrostatic Discharge (ESD) Precautions
Some semiconductor components , and the respective sub-assemblies that contain
them, are vulnerable to damage by Electrostatic discharge (ESD). These components
include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect
transistors and other semiconductor chip components. The following techniques will
reduce the occurrence of component damage caused by static electricity.
Be sure the power is off to the chassis or circuit board, and observe all other safety
precautions.
■ Immediately before handling any semiconductor components assemblies, drain
the electrostatic charge from your body. This can be accomplished by touching an
earth ground source or by wearing a wrist strap device connected to an earth
ground source. Wearing a wrist strap will also prevent accumulation of additional
bodily static charges. Be sure to remove the wrist strap before applying power to
the unit under test to avoid potential shock.
■ After removing a static sensitive assembly from its anti-static bag, place it on a
grounded conductive surface. If the anti-static bag is conductive, you may ground
the bag and use it as a conductive surface.
■ Do not use freon-propelled chemicals. These can generate electrical charges
sufficient to damage some devices.
■ Do not remove a replacement component or electrical sub-assembly from its
protective package until you are ready to install it.
■ Immediately before removing the protective material from the leads of a
replacement device, touch the protective material to the chassis or circuit
assembly into which the device will be installed.
■ Minimize body motio ns when handling unpackaged replacement devices. Motion
such as your clothes brushing together, or lifting a foot from a carpeted floor can
generate enough static electricity to damage an electro-statically sensitive device
■ Handle IC’s and EPROM’s carefully to avoid bending pins.
■ Pay attention to the direction of parts when mounting or inserting them on
Printed Circuit Boards (PCB’s).
Service Manual vii
Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the preceding Po wer Safety
Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this
product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several
points in this product. To a v oid personal injury , do not touch exposed connections and
components while power is on. Disconnect power before removing the power supply
shield or replacing components.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and
other metallic objects could come into contact with dangerous voltages and currents.
Power source: This product is intended to operate from a power source that will
not apply more then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110
volt AC outlet between the supply conductors or between either supply conductor and
ground. A protective ground connection by way of the grounding conductor in the
power cord is essential for safe operation.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are
displayed on potentially dangerous components. As you service the printer, check to
make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers and the printer’s front panel are in place and all interlock
switches are functioning correctly after you have completed a printer service call. If
you bypass an interlock switch during a service call, use extreme caution when
working on or around the printer.
CLASS 1 LASER PRODUCT
The Phaser® 6250 Color Laser Printer is certified to comply with Laser Product
Performance Standards set by the U.S. Department of Health and Human Services as
a Class 1 Laser Product. This means that this is a class of laser product that does not
emit hazardous laser radiation; this is possible only because the laser beam is totally
enclosed during all modes of customer operation. When servicing the printer or laser
unit, follow the procedures specified in this manual and there will be no hazards from
the laser.
viii Phaser 6250 Color Printer
Servicing Electrical Components
Warning
Warning
Warning
Warning
2
3
Before starting any service procedure, switch off the printer power and unplug the
power cord from the wall outlet. If you must service the printer with power applied,
be aware of the potential for electrical shock.
Turning the power off by using the On/Off switch does not completely deenergize the printer. You must also disconnect the printer power cord from the
AC outlet. Position the power cord so that it is easily accessible during servicing.
Do not touch any electrical component unless you are instructed to do so by a
service procedure.
S7300-0
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate drive
assemblies, rollers, and gears.
Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
S7300-0
Servicing Fuser Components
This printer uses heat to fuse the toner image to media. The Fuser Assembly is
VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fuser
to cool before you attempt to service the Fuser Assembly or adjacent
components.
Service Manual ix
Regulatory Specifications
Federal Communications Compliance
The equipment described in this manual generates and uses radio frequency energy. If
it is not installed properly in strict accordance with Xerox instructions, it m ay cause
interference with radio and television reception or may not function properly due to
interference from another device. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one
or more of the following measures:
■ Reorient or relocate the receiver (device being interfered with).
■ Increase the separation between the printer and the receiver.
■ Connect the printer into an outlet on a circuit different from that which the
receiver is connected.
■ Route the interface cables on the printer away from the receiver
■ Consult the dealer, Xerox service, or an experienced radio/television
technician for help.
Changes or modifications not expressly approved by Xerox can affect the emission
and immunity compliance and could void the user's authority to operate this product.
To ensure compliance, use shielded interface cables. A shielded parallel cable can be
purchased directly from Xerox at www.xerox.com/office/6250supplies
Xerox has tested this product to internationally accepted electromagnetic emission
and immunity standards. These standards are designed to mitigate interference caused
or received by this product in a normal office environment. This product is also
suitable for use in a residential environment based on the levels tested.
In the United States this product complies with the requirements of an unintentional
radiator in part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference; (2) this device must
accept any interference received, including interference that may cause undesired
operation.
This digital apparatus does not exceed the Class B limits for radio noise emissions
from digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications, ICES-003.
Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les
limits applicables aux appareils numériques de la classe B prescrites dans le
Réglement sur le brouillage radioélectrique édicté par le ministere des
Communications du Canada, NMB-003.
.
x Phaser 6250 Color Printer
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to which
this declaration relates, is in conformity with the following standards and other
normative documents:
In the European Union
following the provisions of the Low Voltage Directive 73/23/EEC and its
amendments:
EN 60950
(IEC 950)
"Safety of Information Technology Equipment including Electrical
Business Equipment"
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC
and its amendments:
EN55022:1998
(CISPR 22)
EN61000-3-2:1995
+A1:1998+A2:1998
(IEC61000-3-2)
EN61000-3-3:1995
(IEC61000-3-3)
EN55024:1998
(CISPR 24)
CISPR 24 Immunity
Phenomena Basic Standard Test Specification
Electrostatic Discharge IEC61000-4-2:1995 6kV Contact, 10kV Air
Radio-Frequency
Electromagnetic Field
(radiated)
Fast Burst Transients IEC61000-4-4:1995 5/50 Tr/Th ns, 5kHz Rep. Freq
Line Surge IEC61000-4-5:1995 Combination wave
Radio-Frequency
Electromagnetic Field
(Conducted)
Line voltage dips IEC61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz
"Limits and Methods of measurement of radio interference
characteristics of Information Technology Equipment." Class B.
“Part 3: Limits - Section 2: Limits for harmonic current emissions
(equipment input current less than or equal to 16A per phase).”
“Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker
in low-voltage supply systems for equipment with rated current less
than or equal to 16A.”
"Information technology equipment - Immunity characteristics - Limits
and methods of measurement. "
IEC61000-4-3:1995 80-1000 MHz, 3V/m, 80% AM @ 1KHz
0.5kV on Signal Lines
1kV on AC Mains
2.0kV Common mode
2.0kV Differential mode
IEC61000-4-6:1996 0.15 - 80 MHz, 3V, 80% AM @ 1kHz
30% dip for 25 cycles @ 50 Hz
Service Manual xi
CISPR 24 Immunity
Phenomena Basic Standard Test Specification
Line voltage drop-out IEC61000-4-11:1994 >95% dropout for 250 cycles @ 50 Hz
This product, if used properly in accordance with the user's instructions is neither
dangerous for the consumer nor for the environment. A signed copy of the
Declaration of Conformity for this product can be obtained from Xerox.
xii Phaser 6250 Color Printer
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . vii
Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
1 General Information
Printer Introduction and Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Memory and RAM Capabilities . . . . . . . . . . . . . . . . . . . . . 1-4
Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Phaser 6250 Front Panel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Image Processor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Routine Maintenance Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Consumable Life Counter Behavior . . . . . . . . . . . . . . . . . . . . . . 1-10
Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Physical Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . 1-11
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
2 Theory of Operation
Overview of the Phaser 6250 Color Laser Printer Theory of Operation . . 2-2
Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Printer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Selective Control; Paper Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
LED Light Density CTD (ADC) Control of Sensor . . . . . . . . . . . . . 2-8
Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Transfer Roller Assembly Control. . . . . . . . . . . . . . . . . . . . . . . . 2-11
Toner Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Paper Path Route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Service Manual xiii
Major Assemblies and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Frame and Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Main Drive Assembly - Transmission Route . . . . . . . . . . . . . . . 2-17
Gear Layout - Print Engine and Tray 1. . . . . . . . . . . . . . . . . . . . 2-18
Paper Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Paper Feed - Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
HCF Drive and Gears - Transmission Route. . . . . . . . . . . . . . . . 2-25
500-Sheet Feeder Drive and Gears - Transmission Route . . . . . 2-26
Retard Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Chute Assembly In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Duplex Motor Drive and Gear - Transmission Route . . . . . . . . . 2-31
Chute Assembly Registration (REGI). . . . . . . . . . . . . . . . . . . . . 2-32
Transfer Roller and Fuser Assembly . . . . . . . . . . . . . . . . . . . . . 2-33
Fuser Drive Assembly - Transmission Route. . . . . . . . . . . . . . . 2-34
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Imaging Unit Charge Voltage Contacts . . . . . . . . . . . . . . . . . . . 2-36
Toner Cartridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Toner Cartridge Assembly - cont’d . . . . . . . . . . . . . . . . . . . . . . 2-39
Toner Motor Drive Assembly - Transmission Route . . . . . . . . . 2-40
Developer Assembly Transmission Route . . . . . . . . . . . . . . . . . 2-40
3 Error Messages and Codes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . 3-4
General Notes on Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 3-4
Voltage Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Service Diagnostic Front Panel Button Descriptions . . . . . . . . . . 3-7
Diagnostic Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Service Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Jam History Error Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Error Messages and Codes Summary Table . . . . . . . . . . . . . . . 3-17
Jam Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Jam at Fuser: Jam F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Jam at Duplex: Jam D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Jam at Registration Roller: Jam RR. . . . . . . . . . . . . . . . . . . . . . 3-23
Misfeed at Tray 1 (MPT): Jam T1. . . . . . . . . . . . . . . . . . . . . . . . 3-25
Misfeed at Tray 2: Jam T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Misfeed at Tray 3: Jam T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Misfeed at Tray 4: Jam T4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Door and Cover Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Close Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Consumable Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
xiv Phaser 6250 Color Printer
Install or Reseat Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Replace Imaging Unit or
Imaging Unit is Near End of Life. . . . . . . . . . . . . . . . . . . . . . 3-38
Install or Reseat Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Replace Transfer Roller or
Transfer Roller is at End of Life . . . . . . . . . . . . . . . . . . . . . . 3-40
Install or Reseat Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Replace Fuser or Fuser is Near End of Life. . . . . . . . . . . . . . . . . 3-42
Install or Lock [Y] [M] [C] [K] Toner Cartridge . . . . . . . . . . . . . 3-43
Replace [Y] [M] [C] [K]Toner Cartridge or
[Y] [M] [C] [K] Toner Is Low . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Dusty Density Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Output Tray is Full, Unload Paper. . . . . . . . . . . . . . . . . . . . . . . . 3-48
Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge. . . . . . . . 3-49
Tray and Media Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Insert Tray [2] or Tray [2] Missing. . . . . . . . . . . . . . . . . . . . . . . 3-50
Insert Tray [3] [4] or Tray [3] [4] Missing . . . . . . . . . . . . . . . . . 3-52
Tray 2 Paper is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Tray [3] [4] Paper is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Out of Paper; Load Tray 1 (MPT) with [size] [type] . . . . . . . . . . 3-56
Out of Paper; Load Tray [2] [3] [4] with [size] [type]. . . . . . . . . 3-57
Wrong Paper Size; Load Tray 2 with [size] [type] . . . . . . . . . . . 3-58
Wrong Paper Size; Load Tray [3] [4] with [size] [type] . . . . . . . 3-60
Wrong Paper Type; Load Tray [1 (MPT)] [2] [3] [4]
with [size] [type] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Laser Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Density Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Fuser Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Fuser Failure (cont’d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Fuser Failure (cont’d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Fuser Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Rear Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Generic Fan Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Engine Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Imaging Unit Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Fuser Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Controller to Engine Communications Failure . . . . . . . . . . . . . . 3-74
Engine NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Replace [Y] [M] [C] [K] Toner Cartridge . . . . . . . . . . . . . . . . . . 3-76
[Y] [M] [C] [K] Toner Cartridge Failure . . . . . . . . . . . . . . . . . . . 3-77
Non-Phaser 6250 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Non-Phaser 6250 Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Environmental Sensor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Service Manual xv
4 General Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Printer Status Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Power-Up Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
System Start-Up and POST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
System Boot Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
POST Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
LED Blink Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
POST Diagnostic Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . 4-7
Front Panel Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
No Front Panel Display after Power is Turned ON . . . . . . . . . . . . 4-8
Front Panel LED is on, Front Panel Display is Blank. . . . . . . . . . . 4-8
Front Panel Continually Displays “Warming Up...”. . . . . . . . . . . . 4-8
Front Panel Continually Displays "Install or Reseat Imaging Unit" 4-8
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Inoperable Printer Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine Power-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Printer Does Not Come to a "Ready" State . . . . . . . . . . . . . . . . . . 4-9
Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Media Jams and the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . 4-17
Macintosh printing problems. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Windows printing problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Network Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5 Print-Quality Troubleshooting
Print-Quality Problems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Defects Associated with Specific Printer Components. . . . . . . . . 5-3
Front Panel Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Test Print 1: CMYK Sample Page. . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Test Print 2: RGB Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Test Print 3: Test Pattern Sample . . . . . . . . . . . . . . . . . . . . . . . . 5-6
600 x 600 Service Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Print Engine Test Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Light Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Light Print in Only One Color. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Black Prints with White Margin Border . . . . . . . . . . . . . . . . . . . 5-14
Solid Dark or Dirty Prints, No Border. . . . . . . . . . . . . . . . . . . . . 5-15
xvi Phaser 6250 Color Printer
Missing Band, Voids Or Streaks In a Single Color
or All Colors Parallel to the Leading Edge. . . . . . . . . . . . . . . 5-16
Missing Band, Voids or Streaks in a Single Color
or All Colors in Direction of Paper Travel . . . . . . . . . . . . . . . 5-18
Repeating and/or Random Spots . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Residual Image, Ghosting or Hot Offset. . . . . . . . . . . . . . . . . . . 5-22
Incomplete Fusing or Cold Offset. . . . . . . . . . . . . . . . . . . . . . . . 5-23
Mis-Registration, Color Layer not Correctly Registered
in the Process Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Dirty Vertical Streaks on the Edges of the Page . . . . . . . . . . . . . 5-25
6 Adjustments and Calibrations
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Color Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Margin Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Horizontal and Vertical Color Registration . . . . . . . . . . . . . . . . . . 6-3
Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
PostScript NVRAM Resets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Service Diagnostics PostScript NVRAM Resets. . . . . . . . . . . . . . . . . . . . 6-8
7 Cleaning and Maintenance
Service Preventive Maintenance Procedure. . . . . . . . . . . . . . . . . . . . . . . 7-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8 Service Part Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Orientation of the Printer. . . . . . . . . . . . . . . . . . . . . . . . 8-2
General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Notations in the Disassembly Text. . . . . . . . . . . . . . . . . . . . . . . . 8-3
Removing Routine Maintenance Items and Consumables. . . . . . . . . . . . 8-4
Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Imaging Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Fuser Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Toner Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Print Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Front Cover (PL 1.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Front Panel (PL 1.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Fuser Fan (PL 1.1.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Top Main Cover (PL1.1.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Image Unit Top Cover (Door C) (PL1.1.10) . . . . . . . . . . . . . . . . 8-10
Right and Left Side Covers (PL1.1.24), (PL1.1.30) . . . . . . . . . . 8-11
Service Manual xvii
Rear Cover (PL 1.1.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Left and Right Links (PL 1.1.23) . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Tray 1 (MPT) (PL1.1.99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Front Right Cover (PL 1.1.25) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Front Left Cover Assembly (PL1.1.29). . . . . . . . . . . . . . . . . . . . 8-16
Paper Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Paper Feed Roller (PL 2.1.2) (Routine Maintenance Item). . . . . 8-18
Turn Chute Assembly (PL3.1.2). . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Printer Chassis/Feeder Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-20
Paper Pick Assembly (PL3.3.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Right and Left Housing (PL 3.2) . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Temperature/Humidity Harness (PL3.2.1) and Sensor (PL3.2.2) 8-24
High-Capacity Feeder Harness (PL3.2.3). . . . . . . . . . . . . . . . . . 8-25
Paper Size Switch Assembly (PL3.2.4) . . . . . . . . . . . . . . . . . . . 8-26
Low Paper Lever (PL3.2.7), Indicator (PL3.2.8) and
Indicator Guide (PL3.2.10). . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Paper Pick Rollers (PL3.3.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
No Paper Actuator (PL3.3.5), No/Low Paper Sensor (PL3.3.4) . 8-30
Link Actuator (PL3.3.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Feed Solenoid (PL3.3.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Turn Clutch Assembly (PL3.3.18) . . . . . . . . . . . . . . . . . . . . . . . 8-34
Roll Turn Assembly (PL3.3.20) . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
Paper Feed Roller (Routine Maintenance Item) . . . . . . . . . . . . . 8-36
Retard Roller Housing Assembly (PL4.1.1). . . . . . . . . . . . . . . . 8-37
Turn Roll (PL 4.1.2), Turn Clutch (PL 4.1.9),
and Friction Clutch Assembly (PL 4.1.4) . . . . . . . . . . . . . . . 8-38
Retard Roller Assembly (PL4.1.5) . . . . . . . . . . . . . . . . . . . . . . . 8-39
Chute Assembly In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Chute Assembly In (PL 5.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
CTD (ADC) Sensor (PL 5.1.11) . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Toner Full Sensor (PL 5.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Fuser Drive Assembly (PL 5.1.18) . . . . . . . . . . . . . . . . . . . . . . . 8-44
Right Latch (Door A) (PL 5.1.21). . . . . . . . . . . . . . . . . . . . . . . . 8-45
Left Latch (PL 5.1.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Chute Assembly Out (PL6.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Output Tray Full Actuator (PL 6.1.5) and
Full Stack Sensor (PL 6.1.4). . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Duplex Actuator (PL 6.1.13) and Duplex Sensor (PL 6.1.4). . . . 8-51
Tray 1 Actuator (PL 6.1.37) and Tray 1 Sensor (PL 6.1.4). . . . . 8-53
Static Eliminator Assembly (PL 6.1.9). . . . . . . . . . . . . . . . . . . . 8-55
Duplex Roller (PL 6.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Latch Plate (PL 6.1.17), Latch Out (PL 6.1.18),
Latch Holder (PL 6.1.19), and Latch Spring Out (PL 6.1.20) 8-57
Tray 1 Paper Pick Assembly (PL 6.1.27) (Roll Feed). . . . . . . . . 8-58
Tray 1 Feed Solenoid (PL 6.1.40). . . . . . . . . . . . . . . . . . . . . . . . 8-59
xviii Phaser 6250 Color Printer
Tray 1 Shaft (PL 6.1.28). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Tray 1 Bottom Plate (PL 6.1.42). . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Chute Assembly Exit (PL 7.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Exit Roller (PL 7.1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Mid Roller (PL 7.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
Duplex Motor Assembly (PL 7.1.8) . . . . . . . . . . . . . . . . . . . . . . 8-65
Exit Actuator (Fuser) (PL 8.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Strap (PL 8.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
Laser Unit (PL 9.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
Housing Assembly Bias (PL 9.1.4). . . . . . . . . . . . . . . . . . . . . . . 8-69
Chute Assembly Registration (PL 9.1.6) and
Housing Assembly Electric (PL 9.1.11) . . . . . . . . . . . . . . . . 8-71
Registration Sensor Actuator (PL 9.1.9) and
Registration Sensor (PL 9.1.8). . . . . . . . . . . . . . . . . . . . . . . 8-73
OHP Sensor and Harness (Kit) (PL 9.1.12) . . . . . . . . . . . . . . . . 8-75
Toner Cartridge Holder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Toner Cartridge Holder Unit Assembly (PL 10.1). . . . . . . . . . . . 8-77
Toner Cartridge Holder Assembly. . . . . . . . . . . . . . . . . . . . . . . . 8-80
Toner Present Switch Bracket and Actuator
(PL 10.1.6 and 10.1.22). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
Toner Low Sensor (PL 10.1.5). . . . . . . . . . . . . . . . . . . . . . . . . . 8-84
CRUM Reader Box Assembly (PL 10.1.21) . . . . . . . . . . . . . . . . 8-85
EEPROM Board (PL 10.1.14). . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
Sub-High Voltage Power Supply Board (PL 10.1.15). . . . . . . . . 8-87
Frame and Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
Left Lever Plate (PL 11.1.1), Lever Bracket (PL 11.1.2),
Lever Link (PL 11.1.3), Lever Drum (PL 11.1.4), and
Lever Spring (PL 11.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
Lever Plate Right (PL 11.1.7), Lever Bracket (PL 11.1.2),
Lever Link (PL 11.1.6), Lever Drum (PL 11.1.4), and
Lever Spring (PL 11.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Main Drive Assembly (PL 11.1.14). . . . . . . . . . . . . . . . . . . . . . . 8-94
Developer Drive Assembly (PL 11.1.13). . . . . . . . . . . . . . . . . . . 8-95
Actuator, I/L (PL 11.1.8) and Spring, I/L (PL 11.1.9). . . . . . . . . 8-96
Earth Ground Circuit Board (PL 11.1.16) . . . . . . . . . . . . . . . . . . 8-97
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
AC Switch Harness Assembly (PL 12.1.11) . . . . . . . . . . . . . . . . 8-98
Low-Voltage Power Supply (PL 12.1.10) . . . . . . . . . . . . . . . . . . 8-99
Motor Driver Board (PL 12.1.12) . . . . . . . . . . . . . . . . . . . . . . . 8-101
Rear Fan (PL 12.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102
Card Cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-103
Housing Assembly Contact (PL 12.1.14) . . . . . . . . . . . . . . . . . 8-106
Engine Control Circuit Board (PL12.1.1) . . . . . . . . . . . . . . . . . 8-107
Image Processor Board (PL12.1.4) . . . . . . . . . . . . . . . . . . . . . 8-110
Service Manual xix
Optional High Capacity Feeder Disassembly . . . . . . . . . . . . . . . . . . . . 8-111
Cover Front (PL14.2.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Cover, Right (PL14.2.1) and Cover, Left (PL14.2.3) . . . . . . . . 8-112
Turn Chute Assembly (PL14.3.7) . . . . . . . . . . . . . . . . . . . . . . . 8-113
Tray 3 Harness Assembly (PL14.5.3), Tray 4 Harness Assembly
(PL14.5.4), and HCF Plug Harness Assembly (PL14.5.2) . 8-114
Circuit Board, HCF (PL14.5.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-116
Drive Feeder Assembly (PL14.5.5). . . . . . . . . . . . . . . . . . . . . . 8-117
Indicator Assembly (PL14.5.9) . . . . . . . . . . . . . . . . . . . . . . . . 8-118
Right Tray Guide (PL14.3.5)and Low Paper Lever (PL 14.5.8) 8-119
Left Tray Guide (PL14.3.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-122
Link Actuator (PL 14.4.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-124
HCF Paper Pick Assembly (PL14.4.1) . . . . . . . . . . . . . . . . . . . 8-125
Idler Gear (PL14.5.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-126
No Paper, Low Paper Sensor (PL14.5.7). . . . . . . . . . . . . . . . . 8-127
Paper Size Switch Assembly (PL14.3.6) . . . . . . . . . . . . . . . . . 8-128
Casters, Locking (PL 14.2.5)/Non-Locking (PL 14.2.6) . . . . . . 8-129
Optional 500-sheet Feeder Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8-130
Cover Front (PL15.2.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-130
Cover, Right (PL15.2.2) and Cover, Left (PL15.2.1) . . . . . . . . 8-131
Turn Chute Assembly (PL15.3.9) . . . . . . . . . . . . . . . . . . . . . . . 8-132
Tray 3 Harness Assembly (PL15.5.3) and
STF Plug Harness Assembly (PL15.5.2). . . . . . . . . . . . . . . 8-133
Circuit Board, STF (PL15.5.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-135
Drive Feeder Assembly (PL15.5.5). . . . . . . . . . . . . . . . . . . . . . 8-136
Indicator Assembly (PL15.5.8) . . . . . . . . . . . . . . . . . . . . . . . . 8-137
Right Tray Guide (PL15.3.5)and Low Paper Lever (PL 15.5.7) 8-138
Left Tray Guide (PL15.3.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-141
Link Actuator (PL 15.4.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143
STF Paper Pick Assembly (PL15.4.1) . . . . . . . . . . . . . . . . . . . 8-144
No Paper, Low Paper Sensor (PL15.5.6). . . . . . . . . . . . . . . . . 8-145
Paper Size Switch Assembly (PL15.3.6) . . . . . . . . . . . . . . . . . 8-146
9 Parts List
Serial Number Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Using the Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
PL 1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
PL 2.1 Universal Paper Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
PL 3.1 Paper Feed I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
PL 3.2 Paper Feed II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
PL 3.3 Paper Feed III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
PL 4.1 Housing Assembly Retard . . . . . . . . . . . . . . . . . . . . . . . 9-14
PL 5.1 Chute Assembly In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
PL 6.1 Chute Assembly Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
xx Phaser 6250 Color Printer
PL 7.1 Chute Assembly Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
PL 8.1 Transfer Roller & Fuser Assembly (RMIs) . . . . . . . . . . . 9-24
PL 9.1 Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
PL 10.1 Holder Toner Cartridge Assembly . . . . . . . . . . . . . . . . . 9-28
PL 11.1 Frame and Drive Assemblies. . . . . . . . . . . . . . . . . . . . . 9-30
PL 12.1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
PL 13.1 Harness Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Optional High-Capacity Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
PL 14.1 Paper Trays 3 & 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
PL 14.2 High-Capacity Feeder Covers . . . . . . . . . . . . . . . . . . . . 9-37
PL 14.3 High-Capacity Feeder Guides and
Turn Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
PL 14.4 Paper Pick Assembly Trays 3 & 4. . . . . . . . . . . . . . . . . 9-40
PL 14.5 High-Capacity Feeder Harness, Board and Motor . . . . . 9-42
Optional 500-sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
PL 15.1 Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
PL 15.2 500-sheet Feeder Covers. . . . . . . . . . . . . . . . . . . . . . . . 9-45
PL 15.3 500-sheet Feeder Guides and Turn Chute Assembly. . . 9-46
PL 15.4 Paper Pick Assembly Tray 3 . . . . . . . . . . . . . . . . . . . . . 9-48
PL 15.5 500-sheet Feeder Harness, Board and Motor . . . . . . . . 9-50
Xerox Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
10 Wiring Diagrams
Plug/Jack Locator Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Map 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Map 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Map 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Map 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
High-Capacity Feeder Plug/Jack Locator Table . . . . . . . . . . . . . . . . . . 10-10
Map 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
500-sheet Feeder Plug/Jack Locator Table . . . . . . . . . . . . . . . . . . . . . 10-12
Map 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Notations used in Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 10-14
Main Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Paper Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Developer Section 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Developer Section 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Laser Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Xerographics 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Xerographics 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Service Manual xxi
Printer Options Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
High Capacity Feeder Main Wiring Diagram. . . . . . . . . . . . . . . 10-27
Drive Section (HCF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Paper Tray 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
500-sheet Feeder Main Wiring Diagram. . . . . . . . . . . . . . . . . . 10-31
Drive Section (STF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
A Appendix
Printer Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Index
xxii Phaser 6250 Color Printer
General
Information
In this chapter...
■ Printer Introduction and Overview
■ Printer Configurations
■ Parts of the Printer
■ Phaser 6250 Front Panel Configuration
■ Image Processor Board
■ Routine Maintenance Items
■ Printer Specifications
Chapter
1
Printer Introduction and Overview
0
The Xerox Phaser® 6250 Color Laser Printer Service Manual is the primary
document used for repairing, maintaining, and troubleshooting the printer.
T o ensure complete understanding of this product, participation in Xerox Phaser 6250
Service Training is strongly recommended.
Phaser 6250 Color Laser Printer shown with the Optional HighCapacity Feeder
1
[
MPT
]
2
3
4
6250-01
Printer Configurations
The Phaser 6250 Printer combines a single-pass, tandem color laser design, with an
image processor supporting PostScript 3 and PCL5c page description languages. The
printer is a high performance, A4, 26 page per minute (ppm) desktop color laser
printer supporting resolutions up to 2400 x 600 dots-per-inch (dpi).
The Phaser 6250 comes in five configurations. The main differences are optional
networking, standard memory, optional high-capacity feeder, duplexing (2-sided
printing) capabilities, and optional internal hard drive.
1-2 Phaser 6250 Color Laser Printer Service Manual
A replaceable “Configuration Chip” holds configuration information that enables or
disables built-in features as described below.
Printer Configuration
Features
6250B 6250N 6250DP 6250DT 6250DX
Max Print Speed 26 26 26 26 26
Memory (Mbytes) 128 256 256 512 512
PostScript Fonts 137 137 137 137 137
PCL Fonts 81 81 81 81 81
Embedded PCL Yes Yes Yes Yes Yes
Job Pipelining No Yes Yes Yes Yes
Secure, Proof, and Saved
Print Jobs
PDF 1.4 support No Opt* Opt* Opt* Yes
Banner-Size printing No Opt* Opt* Yes Yes
Default Resolutions (dpi) 2400x600 2400x600 2400x600 2400x600 2400x600
Photo Mode No Yes Yes Yes Yes
Job Collation No Opt* Opt* Opt* Yes
Auto-Duplex No No Yes Yes Ye s
Single Tray, 500-Sheet
Feeder
Tray 3
1000-Sheet High-Capacity
Feeder
Trays 3 & 4
Ethernet capabilities Opt Yes Yes Ye s Yes
USB, Parallel Yes Yes Yes Yes Yes
Hard Drive Opt** Opt Opt Opt Yes
* Requires optional hard drive
** Hard drive will work but does require N upgrade to support storage features
*** 500-Sheet Feeder is not stackable
No Opt* Opt* Opt* Yes
Opt Opt Opt Yes*** No
Opt Opt Opt Opt Yes
General Information 1-3
Printer Memory and RAM Capabilities
The printer features two slots that accept 64, 128, and 256 Mbytes of SDRAM. All
combinations are allowed for 64, 128, 256, 320, 384, and 512 Mbytes. Memory
modules must have the following characteristics:
■ PC133 DRAM Standard
■ 144 Pin SODIMM
■ Serial Presence Detect
■ 3.3 Volt
The startup Page and the Configuration Page list the amount of RAM installed in the
Printer.
If the memory does not meet the above specifications, it will be ignored by the printer.
1-4 Phaser 6250 Color Laser Printer Service Manual
Parts of the Printer
Exterior
1
2
3
4
5
6
6250-021
1. Top Cover (Output Tray) 6. High-Capacity Feeder with Tray 3 and Tray 4
2. Control Panel (Front Panel) 7. Door Latch B
3. Front Cover 8. Door Latch A
4. Tray 1 (Multi-Purpose Tray) 9. Power On/Off Switch
7
8
9
5. Tray 2 (Universal Paper Tray)
General Information 1-5
Phaser 6250 Front Panel Configuration
22
The Front Panel contains one tricolor LED, a display window and six function
buttons. These buttons navigate the menu system shown in the display window,
perform various functions, and select modes of operation for the printer.
LED Indicators:
■ Green = Ready to Print or
Printing
■ Flashing Yellow = Warning ■ Flashing Red = Error
■ Flashing Green = Receiving, Processing Data,
Printing or Power Saver Mode
Front Panel Button Descriptions
35
Phaser 6250
12 4678
LED (Power/Status)
1
Graphic front panel display
2
Cancel Button
3
Back Button
4
Up Arrow Button - scrolls up the menu system
5
Down Arrow Button - scrolls down the menu
6
system
OK (select) Button
7
Information Button - for additional explanation
8
or help
OK
6250-0
Front Panel Shortcuts
Mode Press this selection at Power On
Skip execution of POST diagnostics OK
Print Service Diagnostics Map INFO
Reset PostScript NVRAM BACK+OK
Password Bypass UP+DOWN
Enter Service Diagnostics BACK+INFO
1-6 Phaser 6250 Color Laser Printer Service Manual
Rear View
9
4
5
1
2
3
6250-01
6
7
8
1. Top Cover 5. Paper Tray Rear Cover
2. Toner Cartidges 6. USB Connector
3. AC Power Connector 7. Ethernet 10BaseT and 100Tx
Connector
4. Image Processor Board 8. IEEE 1284 Parallel Connector
Rear Panel Configuration Interfaces
■ IEEE 1284 Parallel
■ Ethernet 10BaseT and 100Tx
■ USB
General Information 1-7
Image Processor Board
3
The components identified in the following figure need to be transferred from the old
board to the new board when installing a new Image Processor Board in the printer.
Data stored in the NVRAM can be transferred to the new board using the MCU
NVRAM Store/Restore functions instead of by moving the component. Detailed
information on the Store/Restore functions is available in "Service Diagnostic Tests"
on page 3-9.
pin 1
1234
1. Hard Drive (available option) 3. NVRAM
2. Configuration Chip 4. Memory (RAM) DIMM 1 and DIMM 2
(available option)
6250-02
1-8 Phaser 6250 Color Laser Printer Service Manual
Routine Maintenance Items
20
95
A printer part or assembly that has a limited life, and requires periodic replacement.
2
1
3
1. Transfer Roller 3. Fuser Assembly
2. Imaging Unit
6250-0
Consumables
Consumables consist of the four toner cartridges used in the printer.
6250-4
General Information 1-9
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