Xerox Phaser 6250DT, Phaser 6250N Service Manual

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Service
Manual
Phaser
®
Color Laser Printer
6250
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Phaser
®
6250
Color Laser Printer
Service Manual
Warning
The following servicing instructions are for use by qualified service personnel only . To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.
First Printing: July, 2003
071-0869-00
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As an Energ y Star® partner, Xerox Corporation has determined that this product meets the Energy Star guidelines for energy efficiency. The Energy Star name and logo are registered U.S. marks.
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Note
Caution
Warning
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Service Manual v
Symbols Marked on the Product
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal injury .
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.
0
30 min.
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Service Manual vii
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. W earing 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 conducti ve, you may ground the bag and use it as a conductive surface.
Do not use freon-propelled chemicals. These can generate electrical charges
sufficient to damage some devices.
Do not remove a replacement component or electrical sub-assembly from its
protective package until you are ready to install it.
Immediately before removing the protective material from the leads of a
replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.
Minimize body motions when handling unpackaged replacement de vices. 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).
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Service Manual ix
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock.
Warning
Turning the power off by using the On/Off switch does not completely de­energize the printer. You must also disconnect the printer power cord from the AC outlet. Position the po wer cord s o that it is easily accessible during servicing.
Warning
Do not touch any electrical component unless you are instructed to do so by a service procedure.
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears.
Warning
Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
Servicing Fuser Components
Warning
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.
S7300-02
S7300-03
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Service Manual xi
Declaration of Conformity
Xerox Corporation, declares, under our sole responsibility that the printer to w hich 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:
following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:
EN 60950 (IEC 950)
"Safety of Information Technology Equipment including Electrical Business Equipment"
EN55022:1998 (CISPR 22)
"Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment." Class B.
EN61000-3-2:1995 +A1:1998+A2:1998 (IEC61000-3-2)
“Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase).”
EN61000-3-3:1995 (IEC61000-3-3)
“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.”
EN55024:1998 (CISPR 24)
"Information technology equipment - Immunity characteristics - Limits and methods of measurement. "
CISPR 24 Immunity Phenomena Basic Standard Test Specification
Electrostatic Discharge IEC61000-4-2:1995 6kV Contact, 10kV Air
Radio-Frequency Electromagnetic Field (radiated)
IEC61000-4-3:1995 80-1000 MHz, 3V/m, 80% AM @ 1KHz
Fast Burst Transients IEC61000-4-4:1995 5/50 Tr/Th ns, 5kHz Rep. Freq
0.5kV on Signal Lines 1kV on AC Mains
Line Surge IEC61000-4-5:1995 Combination wave
2.0kV Common mode
2.0kV Differential mode
Radio-Frequency Electromagnetic Field (Conducted)
IEC61000-4-6:1996 0.15 - 80 MHz, 3V, 80% AM @ 1kHz
Line voltage dips IEC61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz
30% dip for 25 cycles @ 50 Hz
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Service Manual xiii
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
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Service Manual xv
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
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Service Manual xvii
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
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Service Manual xix
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 12.1.1 2) . . . . . . . . . . . . . . . . . . . . . . . 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
Page 21
Page 22
Service Manual xxi
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
Page 23
Page 24
1
Chapter
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
Page 25
0
Page 26
General Information 1-3
A replaceable “Configuration Chip” holds configuration information that enables or disables built-in features as described below.
Features
Printer Configuration
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
No Opt* Opt* Opt* Yes
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 Yes
Single Tray, 500-Sheet Feeder Tray 3
Opt Opt Opt Yes*** No
1000-Sheet High-Capacity Feeder Trays 3 & 4
Opt Opt Opt Opt Yes
Ethernet capabilities Opt Yes Yes Yes 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
Page 27
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General Information 1-5
Parts of the Printer
Exterior
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
5. Tray 2 (Universal Paper Tray)
6250-021
1
7
8
9
2
3
4
5
6
Page 29
22
Page 30
General Information 1-7
Rear View
Rear Panel Configuration Interfaces
IEEE 1284 Parallel
Ethernet 10BaseT and 100Tx
USB
1. To p C o v e r 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
6250-019
1
2
3
4
5
6
7
8
Page 31
3
Page 32
General Information 1-9
Routine Maintenance Items
A printer part or assembly that has a limited life, and requires periodic replacement.
Consumables
Consumables consist of the four toner cartridges used in the printer.
1. Transfer Roller 3. Fuser Assembly
2. Imaging Unit
6250-020
1
2
3
6250-495
Page 33
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General Information 1-11
Printer Specifications
Physical Dimensions and Clearances
Print Engine Dimensions Value
Height: 445 mm (17.52 in.)
Width: 439 cm (17.28 in.)
Depth: 638 mm (25.12 in.)
Weight: Approximately 36.5 kg (80.5 lb.) Print engine
Approximately 56.5 kg (124.5 lb.) with Paper Tray(s) installed
Optional High-Capacity Feeder Dimensions Value
Height: 336 mm (13.23 in.) Optional Paper Tray Assembly
Width: 439 cm (17.28 in.)
Depth: 563 cm (22.17 in.)
Weight: Approximately 15 kg (33 lb.) no Paper Tray(s) installed
Approximately 20 kg (44 lb.) with Paper Tray(s) installed
Optional 500-sheet Feeder Dimensions Value
Height: 172 mm (6.77 in.) Optional Paper Tray Assembly
Width: 439 cm (17.28 in.)
Depth: 563 cm (22.17 in.)
Weight: Approximately 7 kg (15.4 lb.) no Paper Tray installed
Approximately 12 kg (26.4 lb.) with Paper Tray installed
Clearance Value
Top: 350 mm (13.78 in.)
Left: 100 mm (3.94 in.)
Right: 150 mm (5.91 in.)
Front: 600 mm (23.62 in.)
Rear: 200 mm (7.87 in.)
Mounting surface level tolerance:
Within 3 degrees of horizontal with all four feet in contact with the surface.
Page 35
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General Information 1-13
Electrical Specifications
Environmental Specifications
First Print-Out (in seconds) (Letter/A4) (printer in Ready state)
Mode Tray 1 Tray 2 Tray 3 Tray 4
Simplex, 600 dpi 14.5 15 16.5 18 Duplex, 600 dpi 23 23.5 25 26.5 Simplex, half-speed 23.5 24.5 27.5 30.5 Duplex, half-speed 38.5 39.5 42.5 45.5
Warm-up time 30 seconds from cold start (power off condition)
Characteristic Specification
Primary line voltages 110-127 V Printer - (90 - 140 V) 13 amp circuit
220-240 V Printer - (198 - 264 V) 7-8 amp circuit
Primary line voltage frequency range
100-120 V Printer - 50/60 Hz +
3Hz
220-240 V Printer - 50/60 Hz +
3Hz
Power consumption at rated voltage input
Mode Condition 100/120 VAC 220/240 VAC Print Mode Max.. 1000 W or less 1000 W or less Ready Mode Fuser On 180 W or less 180 W or less Sleep Mode Fuser Off 45 W or less 45 W or less
Characteristic Specification
Temperature:
Operating
Transportation
Storage
24 month maximum
1 month maximum
Optimal print-quality range: 17o to 26o C (62o to 80o F)
10
o
C to 32o C (50o F to 90o F)
-30
o
C to +50o C (-22o F to 122o F)
Normal: 0
o
C to 35o C (32o F to 95o F)
Severe: -20
o
C to 40o C (-4o F to 104o F)
Humidity
Operating Transportation Storage
Optimal print-quality range: 35% to 70% 10% - 85% 30% - 85% 5% - 95%
Altitude
Operating Transportation
0 - 2,500 meters (8,000 ft.) 0 - 6,092 meters (20,000 ft.)
Acoustic Noise
Idle Printing
Printer Only With Feeder Option
35.0db or less 35.0db or less
55.0db or less (Full Speed) 55.0db or less (Full Speed)
52.0db or less (Half Speed) 53.0db or less (Half Speed)
Functional Specifications (Continued)
Characteristic Specification
Page 37
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General Information 1-15
Note
For duplex configured printers, auto duplex operation is available through T ray 1 (MPT) and Trays 2, 3, and 4. Refer to the Paper Tips page for information on which paper types can be used for duplex printing.
Speciality Media
Phaser 25-Series Premium Transparencies
Letter 216 x 279 mm 8.5 x 11 in.
A4 210 x 297 mm 8.27 x 11.69 in. Other sizes will be handled through Tray 1 with use of the custom size option. Phaser Premium Postcards
Letter 216 x 279 mm 8.5 x 11 in.
A4 210 x 297 mm 8.27 x 11.69 in. Phaser Glossy Trifold Brochures
Letter 216 x 279 mm 8.5 x 11 in.
A4 210 x 297 mm 8.27 x 11.69 in. Weather Proof Paper
Letter 216 x 279 mm 8.5 x 11 in.
A4 210 x 297 mm 8.27 x 11.69 in.
Trays 1& 2 Only
Tray 1 O n l y Tray 1 O n l y
Tray 1 O n l y Tray 1 O n l y
Trays 1& 2 Only
Tray Capacity Universal Tray Tray 1/MPT
Standard Paper 500 Sheets 100 Sheets Transparency 100 Sheets*** 50 Sheets Envelopes N/A 10 each
* A5 paper is supported fr om all trays in Japan es e mo dels only ** Glossy paper can be used in all trays on the 6250 *** Tray 2 only
Specification Trays
Page 39
Page 40
2
Chapter
Theory of Operation
In this chapter...
Overview
Printer Controls
Paper Path of the Printer
Major Assemblies and Functions
Page 41
Page 42
Theory of Operation 2-3
surface is attracted by the high positive potential and transfers to IDT1. During this transfer, the remaining negativ e charge on the drum is neutralized by the high positive charge on IDT1.
5. Secondary Transfer (IDT1 --> IDT2): The toner images formed on both
IDT1 surfaces are then transferred onto the surface of IDT 2 to create a complete, 4-color toner image. IDT2 is also conductive and recei v es a positi ve v oltage from the HVPS. The received voltage puts IDT2 at a higher potential than IDT1 thus attracting the toner image and facilitating the transfer.
6. Cleaning: The IDT1 cleaner consists of a conductive roller brush rotating in
contact with IDT1 after the point where the toner is transferred to IDT2. The cleaner receives a high positive voltage from the HVPS allowing it to electrically attract any toner particles remaining on IDT1. Toner remaining on both IDT1’s after the image transfer to IDT2 is temporarily stored in the IDT1 cleaners.
7. Tertiary Transfer: The finished toner image on IDT2 is transferred onto the
print media using the voltage supplied by the transfer roller. The conductive transfer roller receives a high positive voltage from the HVPS that puts it at a higher potential than IDT2. Since the transfer roller is located behind the print media, the 4-color toner image is attracted to the high potential and deposits on the surface of the print media.
8. Cleaning: The IDT2 cleaner consists of a conductive roller brush rotating in
contact with IDT2 after the point where the toner is transferred to the print media. The cleaner receives a high positive voltage from the HVPS allowing it to electrically attract any toner particles remaining on IDT2. Toner remaining on IDT 2 after the image transfer to the print media is temporarily stored in the IDT2 cleaner.
9. Static Elimination: The positive charge on the print media can cause image
quality problems by scattering toner. To prevent this, negative DC voltage from the HVPS is applied to the back side of the print media by the Detack Saw, located on the Transfer Roller Assembly. This negative charge neutralizes and eliminates the charge on the print media resulting from the tertiary transfer.
10. Fixing: The finished toner image is unstable and easily smeared. To fix the
image, the print media goes through the Fuser Assembly where it passes between a pressure belt and the heat roller. The toner is fused onto the print media by the combination of heat and pressure.
11. Cleaning: During the general cleaning process, the voltage applied to the IDT
rollers and drums go through a cycle of changes to move the negative and positive charged toner particles from the cleaners and IDTs and then the transfer roller. The toner stored in the IDT1 cleaner, the IDT 2 cleaner and on the transfer roller is removed and deposited into the transfer roller waste recovery bin. Tone r from the charge roller and refresher is also removed and deposited into the transfer roller waste recovery bin. In each case the voltage at the point of attraction is set high and the voltage at the point of disposal is set to 0V with the result that the toner is moved to the high potentia l un til at last it is deposited on the transfer roller. Toner is removed from the transfer roller by the attached cleaning blade and deposited in the attached recovery bin.
Page 43
4
6
[
r]
P
Page 44
Theory of Operation 2-5
Print Modes
There are three print modes: Draft mode, Enhanced mode, and Photo mode. These are based on the resolution (600 dpi or 2400 dpi) and, depending on the media type, can also be affected by process speed (full speed/half speed/one-third speed).
Draft mode: 600 X 600 dpi resolution. Used to check layout. Provides
reduced toner usage.
Enhanced mode: 2400 X 600 dpi resolution. General purpose mode for crisp
bright color prints. Recommended for most office use. It is the default mode
Photo mode: 2400 X 600 dpi resolution. Highest quality color print with
very smooth color shades. When using photo paper or OHP, gloss is raised by setting the process speed to one-third.
Printer Controls
Paper Size Control
The paper size selection is controlled by three paper size switches located 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 postion that activ ates the correct switch combination for the selected paper size.
Paper Size Switches are indicated as SW1, SW2, and SW3
Paper Size
Paper Size Switch
SW1 SW2 SW3
LEGAL14" ON ON ON
US FOLIO (LEGAL 13)" ON ON OFF
EXECUTIVE ON OFF ON
B5 ON OFF OFF
A4 OFF ON ON
A5 (for reference only, supported in Tray 1 [MPT] only)
OFF ON OFF
LETTER OFF OFF ON
No Tray OFF OFF OFF
Page 45
Page 46
Theory of Operation 2-7
Bias control operates as follows:
1. The Temperature/Humidity Sensor sets the target values of the drum charging
voltage and biasing DC voltage.
2. Bias control test patches (see the adjacent figure for
patch configuration) of each of the four toner colors (yellow, magenta, cyan, and black) are generated and transferred to the Transfer Roller.
3. The CTD (ADC) Sensor compares an area on the
Transfer Roller where no toner is present with the test patches to determine toner density for each of the four colors.
4. The density measured in Step 3 is compared with the
target value set in Step 1 and the resulting difference is used to adjust the drum charging voltage and the biasing DC voltage for each toner color.
Toner Density Control
Toner density must be kept constant to attain a stable print image. To achieve this goal, the rate at which toner is dispensed must be adjusted to exactly match the rate at which it is consumed. There are two systems that work in conjuncti on to contr ol toner density: the Pixel Count Dispense Control (PCDC) and the Toner Density Control (CTD). (The CTD uses data from the ADC sensor, measured as described in the preceding paragraphs covering bias control.)
PCDC: The amount of toner consumed in the developing process is calculated by
counting the digital pulses applied to the Laser Unit. The toner motor is then driven for a period determined by the calculated result to supply toner to the developer, equivalent to the amount dispensed.
CTD (ADC): The toner test patches of each color (yellow , magenta, cyan, and black),
are generated and transferred to the transfer roller as specified in the Bias Control section. The CTD (ADC) sensor measuers the density of each patch. The printer adjusts the toner dispense time, which changes the quantity of toner to be dispensed. This calculation is made separately for each color. The CTD adjustment is made following completion of printing if either of the following conditions is satisfied:
Cumulative print count since power on exceeds 16 pages.
When a cleaning cycle is executed during continuous printing.
If either of the preceding control calculations results in an adjustment to the toner quantity to be dispensed, the result is calculated in terms of number of revolutions of the Toner Motor. For this description, this value is called the dispense count.
The dispense count calculated as specified above, is implemented over the next 8 prints. If 16 dispense counts are required as a result of low toner density during the CTD calculation, 2 dispense counts are added during each of the next 8 prints. This is in addition to any counts added or subtracted during each print as a result of PCDC.
Y
M
C
K
About 11mm
About 57mm
About 12mm
About 3mm
6250-069
Page 47
67
T
C
D
C
T
Page 48
Theory of Operation 2-9
depending on the Transfer Roller surface condition or dirty condition of CTD (ADC) sensor surface. The light density emitted from the LED is controlled so that the reflected light density meets the specified value.
This control is implemented in two ways:
Sets the light density so that the light reflected satisfies a specific value.
Adjusts the subsequent light density to be within a specific tolerance value.
1. Light Density Setting
The reflected light density can vary greatly if the transfer roller has been replaced or the CTD (ADC) sensor has been cleaned. To deal with this variance the light density is reset when the power is turned on or the front cover is opened and closed.
The intensity of the LED increases gradually and the set value is adjusted when the output of the CTD (ADC) sensor does not meet the specified value. If the output of the CTD (ADC) sensor does not reach the specified value, even though the light density is increased to the maximum limit, the controller signals the sensor is dirty. If the sensor output is extremely high, the controller will signal that the sensor is faulty.
2. Light Density Adjustment
At the execution of automatic density control, the light density adjustment is made just before the patches for toner density control are generated .
Light is emitted from the LED using the current light density setting, to check if the output value of the CTD (ADC) sensor is within the specified range. If the output value is low, light density is increased. If the output value is high, the light density is decreased.
If the output value is less than the first lower limit, the controller signals the sensor as dirty and generates a warning. If the output value is less than the second lower limit, the controler signals that the sensor is faulty and stops the printing.
Color Registration Control
The printer uses a quad system where drums and developers are used exclusively for each of the four colors (yellow, magenta, cyan, and black). Images are formed on the drums, in the respective colors, and then layered to form one image. To avoid a positional shift between the different color images, the color registration control calculates how much the registration has shifted b y comparing each of the other color patches in the registration string to the black bar that precedes it. Shift is corrected by adjusting the laser write timing to compensate.
Color registration control is made depending on the internal temperature and print count at the execution of process control.
Page 49
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Theory of Operation 2-11
Transfer Roller Assembly Control
Detecting the Installation of the Transfer Roller Assembly
Although there is no seperate sensor for this, the outpu t of th e CTD Sensor is used to detect installation or absence of the Transfer Roller when power to the printer is turned on, or the front cover is opened and closed.
Light emits from the LED of the CTD sensor with the specified intensity and if the output of the CTD Sensor is greater than the specified value the controller signals that the Transfer Roller is present (installed).
If printing is stopped by a jam, the toner image will be placed on the Transfer Roller. In this case the sensor output result is lo w, causing the controller to report the Transfer Roller as missing. To pre vent this, the Transfer Roller is rotated a half turn if output is lower than the specified value. If the output of the CTD sensor is than greater than the specified value, the controller reports installation of the Transfer Roller. If the output remains less than the specified value, the controller reports that the Transfer Roller is not installed.
Detecting the Life of the Transfer Roller Assembly
The Transfer Roller Assembly consists of a bias transfer roller and a waste toner recovery space. End of life of the Transfer Roller is detected when the waste toner recovery space becomes full.
The full waste toner recovery space is detected by the Toner Full Sensor.
1. Status of the waste toner recovery space is checked:
When the power is turned on.
When the front cover is opened and closed.
When paper exits the print engine.
2. “Transfer Roller is at End of Life” error message is generated when the toner full
sensor detects the waste toner recovery space is full.
3. “Replace Transfer Roller ” warning message is generated if the print count and
the toner dispense time are counted and the total count exceeds 15,000 prints.
4. “Transfer Roller is at End of Life” error/ “Replace Transfer Roller ” warning
messages are reset if the toner full sensor does not detect a full waste toner recovery space when power is turned on, or the front cover is opened and closed.
Page 51
Page 52
Theory of Operation 2-13
Fuser Control
Fuser Temperature Control
During fuser temperature control the printer’s tar get temperature is set. The heat roller surface temperature is controlled to match the target temperature by turning the heater lamp on/off.
The heat roller surface temperature is detected by two sensors. A non-contact sensor in the middle of the roller is checked for 60ms and the Temperature Sensor at the edge of the roller is checked for 20ms to maintain an even temperature across the roller. If the results of the 80ms cycle show the temperature is higher than the target, the heater lamp is turned off. If the detection result is low, the heater lamp is turned on.
For the target temperature, different temperatures are set for standby, printing, and process control. The target temperature is also changed according to the inside temperature detected with the temperature/humid ity sensor, print count, print mode, input power supply voltage and paper type.
Cool Down
During printing, the temperature distribution of the heat roller becomes uneven between paper and non-paper. To make the heat roller temperature as even as possible, a wait time is provided and the heater lamp is kept off. This is called the cool down.
A cool down is executed according to the number of sheets continuously printed when a set, printing with a certain type and size of print media is completed, and when the print media type or size is changed. The cool down, which results in a pause, occurs evenly in the middle of several hundred sheets of continuous printing.
Page 53
R
P
54
Page 54
Theory of Operation 2-15
Paper Path Route
6250-493
Paper Tray 4
Paper feed by
"Paper Pick Assy (T4)"
Paper Tray 3 Paper Tray 2
Tray 1 (MPT)
Paper feed by
"Tray1 Feed Roller"
and
"Paper Feed (Retard) Roller"
Paper transfer by
"Turn Roll"
and
"Pinch Roll"
Paper feed by
"Paper Pick Assy (T3)"
Paper transfer by "Tray 3 Turn Roll"
and "Tray 3 Turn Chute Assy"
Print output
Paper transfer to duplex path by
reversing "Exit Roll" and "Mid Roll"
Paper transfer by "Duplex Rollers"
to Print Output
Paper transfer by the
"Tray 2 Turn Roll"and "Tray 2 Turn Chute Assy"
Paper transfer by the "Chute Assembly, Registration (REGI) (Metal and Registration Rolls)
Paper transfer by the "Imaging Unit IDT2" and "Transfer Roller"
Paper transfer by the "Fuser Assembly "Exit Roll" and "Pinch Roll"
Paper transfer by the "Chute Assembly, Exit" and "Chute Assembly, Out"
Paper transfer by the "Fuser Assembly" (Heat Roll and Fuser Belt)
Paper feed by
"
Paper Pick Assy
(T2)"
Paper feed by "Paper Feed Rollers" (Nudge and Retard)
(Tray 4)
Paper transfer by "Tray 4 Turn Roll"
and
"Tray 4 Turn Chute Assy"
Paper feed by "Paper Feed Rollers" (Nudge and Retard)
(Tray 3)
Paper feed by "Paper Feed Rollers" (Nudge and Retard)
(Tray 2)
OPTIONAL FEEDERS
Page 55
64
Page 56
Theory of Operation 2-17
Main Drive Assembly - Transmission Route
MAIN DRIVE ASSY
CLUTCH ASSY TURN
ROLL ASSY TURN GEAR IDLLER FEED
GEAR FEED H1
ROLL ASSY FEED
PAPER FEEDER
CHUTE REGI
Regi.Clutch
CLUTCH TURN
ROLL TURN
HOUSING ASSY RETARD
GEAR MSI
ROLL ASSY FEED
CHUTE ASSY OUT
IMAGING UNIT
IDT1 (2)
IDT2
TRANSFER
ROLLER
GEAR IDLER IN
GEAR IDLLER
GEAR FEED1
Regi.Roll
Drum (4)
6250-047
Page 57
2
Page 58
Theory of Operation 2-19
Paper Tray 2
1. Paper (Retard) Feed Roller: The paper retard feed roller prevents more than
1 sheet at a time from printing. The paper feed retard roller and the paper feed nudge roller are interchangeable parts in all trays.
2. Side Guides Right and Left: The side guides move against media to align or
register the width of print media in the paper feed direction.
3. Rear Guide: The rear guide moves to determine the length of print media in the
paper feed direction. The paper size switch uses this rear guide to detect the paper size.
6250-055
1
2
3
2
Page 59
6
Page 60
Theory of Operation 2-21
8. Gear Idler Feed: See Paper Pick Rollers.
9. Feed Solenoid: Controls the operation (rotation/stop) of the Feed Ro ller
Assembly by controlling the rotations of the Gear Feed.
10. Low Paper Sensor: The actuator lowers as print media is used in the tray.
When the actuator lowers to a pre-determined postion, it blocks the sensor beam to trigger a low paper status. The actuator position can be seen from the front of the paper tray allowing confirmation of the print media quantity.
11. Paper Feed Roll: See paper Pick Rollers.
12. Roll Turn Assembly: The roll turn assembly receives drive energy from the
main drive through the turn clutch and transports the print media out of the paper tray to the registration roller.
High-Capacity Feeder Trays 3 and 4
Note
The callouts in the following figure refer to the identifying numbers in the preceding paragraphs. The T3 and T4 in the callouts identify the tray. Tray 2 paper pick assembly has a different part number than the HCF Tray 3 and Tray 4 paper pick assembly.
6250-446
12(T3)
11(T3)
3(T3)
2(T3)
4(T3)
9(T3)
5(T3)
5(T4)
9(T4)
4(T4)
2(T4)
11(T4)
3(T4)
12(T4)
Page 61
Note
05
Page 62
Theory of Operation 2-23
1. HCF Feeder Circuit Board: Controls the paper pick-up operation of each tray
based on communication with the Engine Control Board and information from the sensors and switches.
Major Functions:
Communicates with the Engine Control Board.
Receives information transmitted from the sensors and switches.
Controls the Feeder Drive Assembly.
Controls the paper pick process.
Distributes the DC voltage power supplied from the print engine to each
component.
2. Feeder Drive Assembly: Supplies the drive to the Tray 3 and 4.
3. Low Paper Sensor: The actuator lowers as print media is used in the tray.
When the actuator lowers to a pre-determined postion, it blocks the sensor beam to trigger a low paper status. The actuator position can be seen from the front of the HCF allowing confirmation of the print media quantity.
6250-447
1
2
3(T4)
3(T3)
Page 63
6
Page 64
Theory of Operation 2-25
HCF Drive and Gears - Transmission Route
DRIVE ASSY FEEDER
GEAR IDLER IN
GEAR IDLER
GEAR IDLER IN
GEAR IDLER
GEAR IDLER
GEAR IDLER FEED
GEAR FEED H1
GEAR FEED1
CLUTCH ASSY TURN
PICK UP ASSY T3
GEAR IDLER FEED
GEAR FEED H1
GEAR FEED1
PICK UP ASSY T4
CLUTCH ASSY TURN
FRONT
6250-444
LOWER FEEDER DRIVE ASSY
PICK UP ASSY T3
GEAR IDLLER IN
CLUTCH ASSY TURN
ROLL ASSY TURN
GEAR IDLLER FEED
GEAR FEED H1
GEAR FEED 1
GEAR IDLER GEAR IDLLER
ROLL ASSY FEED
CLUTCH ASSY TURN
ROLL ASSY TURN GEAR IDLLER FEED
GEAR FEED H1
ROLL ASSY FEED
PICK UP ASSY T4
GEAR IDLER IN
GEAR IDLLER
GEAR FEED1
6250-443
Page 65
4
D
3
Page 66
Theory of Operation 2-27
Retard Housing Assembly
1. Roll Turn: The roll tur n is rotat ed by the main drive assembly, through the turn
clutch to feed paper from Tray 1 to the re gistration chute, (Registration Roll - See “Xerographics” on page 2-35.).
2. Turn Clutch: Transfers drive energy from the main drive assembly to the roll
turn through a friction clutch.
6250-057
1
2
Page 67
Page 68
Theory of Operation 2-29
Chute Assembly Out
1. Full Stack (Output Tray Full) Sen sor: Detects a full output tray (over
accumulation of print media) by the position of the actuator . This is only checked when the paper is feeding into the exit.
2. Duplex Jam Sensor: Detects when print media has reached and passed
through the duplex roller based on the position of the actuator.
3. Duplex Roller: The duplex roller rotates under drive from the duplex motor and
feeds the print media returned from the chute assembly exit to the roll turn in the retard housing assembly.
4. Gear (Main Drive): See Feed Roll Assembly.
5. Tray 1 Gear: See Feed Roll Assembly.
6. Feed Roll Assembly: When the Tray 1 feed soleniod energizes, the Tray 1
gear and the idler gear are engaged by the force of the spring solenoid. The feed roll rotates from the drive of the Main Drive Assembly and feeds paper from
6250-059
1
2
3
4
5
6
7
8
Page 69
Page 70
Theory of Operation 2-31
Duplex Motor Drive and Gear - Transmission Route
1. Chute Assy Out 4. Gear 40/42 7. Motor Duplex 10. Gear 42
2. Chute Assy Exit 5. Gear Roll 8. Gear 48 11. Gear 30
3. Gear 48 6. Gear Roll 9. Gear 40/42
DUPLEX MOTOR ASSY
GEAR ROLL
EXIT ROLL
GEAR ROLL
MID ROLL
GEAR 30
DUPLEX ROLL
CHUTE ASSY EXIT
CHUTE ASSY OUT
GEAR 48
GEAR 40/42
GEAR 48
GEAR 40/42
GEAR42
6250-050
FRONT
6250-066
5
6
7
8
4
3
9
10
11
1
2
Page 71
6
Page 72
Theory of Operation 2-33
Transfer Roller and Fuser Assembly
1. Fuser Assembly: Using heat and pressure, the fuser assembly fixes the
transferred toner onto print media.
Parts of the Fuser Assembly:
2. Exit Sensor: Detects passage of the print media after fusing.
3. Fuser Fan: Cools the fuser assembly to prevent overheating.
4. Transfer Roller: Consists of the transfer roller and a waste toner recovery
system. The transfer roller transfers the image from IDT2 in the imaging unit onto the print media.
Heat Roll Heat Lamp
Thermostat Temperature Sensor
Belt Unit Exit Roll Assembly
Exit Sensor CRUM
6250-061
1
2
3
4
Page 73
9
Page 74
Theory of Operation 2-35
Xerographics
1. Imaging Unit: The Imaging Uni t carri es out the operations of the printing
process, such as charging, developing, and primary transfer. The Imaging Unit consists of the following parts:
2. Laser Unit: The Laser Unit receives image data and generates laser beams to
form an electrostatic latent image on the surface of each of the four imaging unit drums. The Laser Unit Assembly consists of the following parts:
LD Assembly Scanner Assembly SOS Board Lens Mirror Window
3. Chute Assembly Registration: See “Chute Assembly Registration (REGI)”
on page 2-32.
Drum (Y M C K ) Developer (Y M C K )
Charge Roller (Y M C K ) Refresher (Y M C K )
IDT1 (2) IDT2
IDT1 Cleaner (2) IDT2 Cleaner
6250-062
1
2
3
Page 75
2
Page 76
Theory of Operation 2-37
Imaging Unit - Left Side View
1. IDT2
2. IDT2 Refresher/Cleaner
3. IDT1
4. IDT1 Refresher/Cleaner
5. Drum Refresher/Cleaner
6. Developer
7. Charge Roller
6250-07
3
76 5
4
3
2
1
Page 77
3
)
Page 78
Theory of Operation 2-39
Toner Cartridge Assembly - cont’d
1. Agitato r Assemb ly
2. Toner Motor
3. Aug er Assembly
4. Auger Tube
6250-071
43 1 2
Page 79
51
48
Page 80
Theory of Operation 2-41
Electrical
1. Engine Control Board: Controls printing operation based on the
communication with the Image Processor Board and input from the sensors and switches. Incorporates functions of the High-Voltage Power Supply.
Major Functions:
Communicates with the Image Processor Board
Receives information from the sensors and/or switches.
Controls the Laser Unit.
Supplies high-voltage to the Imaging Unit to perform charging,
development, primary transfer and secondary transfer
2. Image Processor Board: Receives data from the workstation or host,
rasterizes the data and passes it on to the Engine Control Board. The microprocessors on the Image Processor Board, generate the control signals used by the Engine Control Board. The system NVRAM chip is also located on this board and stores several printer parameters.
3. Motor Driver Board: Controls motors through the signals received from the
Engine Control Board and sends information from the sensors and switches to the Engine Control Board. Power from the low-voltage power supply is supplied to the Engine Control Board through the Motor Driver Board. The interlock switch is mounted on the Motor Driver Board.
6250-065
1
2
3
4
5
6
Page 81
Page 82
3
Chapter
Error Messages and Codes
In this chapter...
Introduction
Servicing Instructions
Service Diagnostics
Error Messages and Codes Troubleshooting Procedures Table
Page 83
Note
Page 84
Error Messages and Codes 3-3
Servicing Instructions
The Service Flowchart below is an overview of the path a service technician should take when servicing the printer and printer optional equipment.
Step 1 - Identify the Problem
1. Verify the reported problem does exist. Verify failure symptoms/behavior/noises
with cusotmer/end user.
2. Check for any error codes and write them down.
3. Print normal customer prints and service test prints.
4. Make note of any print quality problems in the test prints.
5. Make note of any mechanical or electrical abnormalities present.
6. Make note of any unusual noise or smell coming from the printer.
7. Print a Printer Status Page, if the printer is able to print.
8. View the fault history under the Service Tools Menu
9. Verify the AC input power supply is within proper specifications by measuring the
voltage at the electric outlet while the printer is running.
Step 2 - Inspect and Clean the Printer
1. Switch OFF printer power.
2. Disconnect the AC power cord from the wall outlet.
3. Verify the power cord is free from damage and is connected properly.
4. Remove the Imaging Unit and protect it from light.
5. Inspect the printer interior and remove any foreign matter such as paper clips,
staples, pieces of paper, dust or loose toner.
Do not use solvents or chemical cleaners to clean the printer interior.
Do not use any type of oil or lubricant on printer parts.
Use only an approved toner vacuum.
6. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water.
7. Inspect the interior of the printer for damaged wires, loose connections, toner
leakage, and damaged or obviously worn parts.
8. If a toner cartridge appears obviously damaged or empty, replace with a new one.
Step 3 - Find the Cause of the Problem
1. Use the Error Messages and Codes troubleshooting procedures to find the cause
of the problem.
2. Use Diagnostics to check printer and optional components.
3. Use the Wiring Diagrams and Plug/Jack Locator to locate test points.
4. Take voltage readings at various test points as instructed in the appropriate
troubleshooting procedure.
5. Use the "Print Engine Test Print" on page 5-9, to isolate problems to the Engine or
the Image Processor Board.
Step 4 - Correct the Problem
1. Use the Parts List to locate a part number.
2. Use the Disassembly Procedures to replace the part.
Step 5 - Final Check
1. Test the printer to be sure you have corrected the initial problem and verify there
are no additional problems present.
Page 85
P
k
03
Page 86
Error Messages and Codes 3-5
6. Befo re measur ing voltages make sure the printer is switched ON, the Imaging
Unit and the paper trays are in place, and the interlock switches are actuated, unless a troubleshooting procedure instructs otherwise.
7. All voltage values given in the troubleshooting procedures are approximate
values. The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter.
8. When a troubleshooting procedure instructs you to replace a non-spared
component and that component is part of a parent assembly, you should replace the entire parent assembly.
9. Ensure that you are using a supported media size and typ e, refer to "Media and
Tray Specifications" on page 1-14.
Voltage Measurements
1. Power and signal grounds are connected to the frame ground. All circuit
troubleshooting can be performed using the metal frame (chassis) as the grounding point. To locate connectors or test points, refer to the section "Plug/ Jack Locator Maps" on page 10-2 or "W iring Diagrams " on page page 10-12 for more information.
Unless otherwise specified, the following voltage tolerances are used within this section:
Stated Measured
+3.3 VDC +3.135 to +3.465 VDC
+5.0 VDC +4.75 to +5.25 VDC
+24.0 VDC +21.6 to +26.4 VDC
0.0 VDC Less than +0.5 VDC
Page 87
Page 88
Error Messages and Codes 3-7
Service Diagnostic Front Panel Button Descriptions
Button Function
BACK Returns to the prior higher level menu structure, if available.
If help text is displayed on the front panel, pressing BACK will restore the current menu item and remove the help text.
CANCEL Terminates the current test.
Cancels current INFO display.
INFO Provides help information, if available.
Pressing INFO again restores the current menu item and removes the help text.
UP Scrolls up one menu item within a menu list. This control does not ‘wrap’.
Used to increment data in tests requiring user input.
DOWN Srolls down one menu item within a menu list.
This control does not ‘wrap’, the end of a menu list is designated by three asterisks. Used to decrement data in tests requiring user input.
OK Enters the highlighted menu. Executes the current test item.
Used to select a data value entered by the user.
Page 89
p
t
g
d
y
Page 90
Error Messages and Codes 3-9
Service Diagnostic Tests
Test Front Panel Display and Test Definition
Print Service Menu Map - Prints the service diagnostics menu map and exits service
diagnostics.
General Status - Provides the following print engine status:
Status <No Status to Report>
NOTE This is current status since
entering diagnostics only. It is not a Fault Log. If Ready is reached, the register is cleared.
No Status to Report = the printer
is online and ready to print. Displays an engine status that will prevent printing. Status is displayed sequentially, one line at a time.
Engine Board ROM Version
Engine FW: #.#.# Displays the engine firmware
version installed.
Printer Configuration
Memory: ###MB Hard Drive: Not Installed or Installed HCF: Installed Not Installed
Displays current memory installed. Detects presence of Hard Drive option. Detects presence of High-Capacity Feeder option.
Ambient Temperature/ Humidity
Temperature: XX
o
C
Humidity: ## %
Displays the current Temperature and Humidity for the printer.
Fuser Temperature
Temperature: XX
o
C
Displays the printers current Fuser temperature.
Fault History Device Status
Jams Hardware Errors Firmware Errors Fan Motors CTD (ADC) Sensor Errors Fuser Failure Laser Failure Life Over Tr ay s Miscellaneous CRUMS
Displays Fault occurrence since last power cycle.
Test Prints - Prints test prints stored in the Engine Control Board. The prints are used by
service personnel to identify, repair and validate the operability of the printer.
Page 91
Page 92
Error Messages and Codes 3-11
Developer Motor
Caution: Do NOT allow this motor to run any longer than necessary to verify operation.
Normal Speed Half Speed One Third Speed
Audible verification of motor functionality.
Caution: Only run the developer
motor test once per power cycle to avoid excessive amounts of toner being forced inside the developer resulting in possible damage.
HCF/LTA Motor Normal Speed
Half Speed Normal Speed Continuous Half Speed Continuous
Audible verification of motor functionality.
To n e r M o t o r Ye l l o w To n e r M o t o r Magenta To n e r M o t o r Cyan To n e r M o t o r Black
Normal Speed Audible verification of motor
functionality.
Caution: Only run the Toner Motor
tests once per power cycle to avoid toner spillage inside the Imaging Unit cavity and packing the auger tubes with toner.
Rear Fan High Speed
Low Speed High Speed Continuous Low Speed Continuous
Audible verification of motor functionality. Check for airflow.
Fuser Fan High Speed
Low Speed High Speed Continuous Low Speed Continuous
Audible verification of motor functionality. Check for airflow.
Sensor/Switch Tests - Tests the functionality of the sensors and switches by giving service
personnel the ability to input actuation and state changes of all sensors and switches.
Interlock Switch
Sensor is: ON Sensor is: OFF
Front Door OPEN Front Door CLOSED
Registration Sensor
Sensor is: OFF Sensor is: ON
This test continuously cycles paper through the printer. The sensor state changes from off to on as the paper passes through the Registration Chute.
Note: This test can also be used
as a paper path transport test when troubleshooting Jam conditions.
Test Front Panel Display and Test Definition
Page 93
Page 94
Error Messages and Codes 3-13
Tray 2 Low Paper Tray 3 Low Paper Tray 4 Low Paper
Size: XXXX
Paper is Not Low
Paper is Low
Move the Rear Guide in the paper tray to the desired paper size and verify the sensor output matches the paper size selected.
Insert and fill Tray [2] [3] [4] with paper to the fill line. Insert one sheet of paper in Tray [2] [3] [4] to change the sensor state.
Tray 1 ( M P T ) No Paper Sensor
Paper is Not Present Paper is Present
Insert Paper into Tray 1. Toggle the Tray 1 No Paper Actuator (PL6.1.37) to change the state.
Tray 2 N o Paper Sensor Tray 3 N o Paper Sensor Tray 4 N o Paper Sensor
Paper is Not Present Paper is Present
Insert Tray [2] [3] [4] with an adequate amount of paper. Toggle the No Paper Actuator.
Transfer Roll To n e r F u l l Sensor
Toner Waste [Not] Full Block the Toner Full Sensor
(PL5.1.13) to change the sensor state.
Image Unit Not Installed Sensor
Image Unit is [Not] Present Open Door C to change the state
of the Switch.
Fuser Fan Alarm Sensor
Fuser Fan Alarm Sensor is: OK Failure
Status only
Note: Perform a test print
immediately prior to performing this test.
Rear Fan Alarm Sensor
Rear Fan Alarm Sensor is: OK Failure
Status only
Note: Perform a test print
immediately prior to performing this test.
CTD (ADC) Sensor
Dark Value: # Light Value: ### Sensor OK
Status only Remove the transfer roller to observe change of state.
Test Front Panel Display and Test Definition
Page 95
Page 96
Error Messages and Codes 3-15
Tray 1 ( M P T ) Feed Solenoid Tray 2 Feed Solenoid Tray 3 Feed Solenoid Tray 4 Feed Solenoid
Solenoid is: ON Solenoid is: OFF
Audible verification of the Solenoid function.
Maintenance - Cleans the Intermediate Transfer Unit within the Imaging Unit.
Clean Imaging Unit IDT 1 Clean Imaging Unit IDT 2
Printing..... “Printing” is displayed on the Front
Panel during the IDT cleaning cycle. The test continuously cycles paper
through the printer until the Cancel
button is pressed.
NVRAM Access - This menu lets you read, set or reset the following values:
PostScript NVRAM Reset
Resetting PostScript NVRAM... Are you sure? Ye s NO
Restores the Printers setup values to their factory defaults. For more information on resetting NVRAM, See “Resetting NVRAM” on page 6-4.
MCU NAVRAM Store/Restore
Save Engine NAVRAM
Restore Engine NAVRAM
Saves critical engine parameters; printer installation date, printer page count, imaging unit life count, transfer roller life count to Image Processor Board before replacing the Engine Control Board. Restores previously saved critical engine parameters to the Engine Control Board after replacement.
To n e r I n s t a l l Dates
Black Toner Install Date Cyan Toner Install Date Magenta Toner Install Date Yellow Toner Install Date
Allows toner cartridge install dates to be viewed, or to be changed when current value is corrupted or obviously incorrect.
Toner CRUM Check
(<Color> Not) Genuine Xerox Toner Verifies that genuine Xerox toner is
installed in the printer.
CRU Life Reset
Sets life count of transfer roller to unused.
Resets the life count stored in NAVRAM.
Test Front Panel Display and Test Definition
Page 97
Page 98
Error Messages and Codes 3-17
Error Messages and Codes Summary Table
Error Type Front Panel Message Help Text/Code
Jam Errors
Jam at Fuser Jam F/152
Jam at Duplex Jam D/153
Jam at Registration Roller Jam RR/154
Misfeed at Tray 1 (MPT) Jam T1/155
Misfeed at Tray 2 Jam T2/156
Misfeed at Tray 3 Jam T3/157
Misfeed at Tray 4 Jam T4/158
Door and Cover Errors
Close Front Door
Consumable/Routine Maintenance Item Errors
Install or Reseat Imaging Unit
Replace Imaging Unit or Imaging Unit is at End of Life
Install or Reseat Transfer Roller
Replace Transfer Roller or Transfer Roller is at End of Life
Install or Reseat Fuser
Replace Fuser or Fuser is at End of Life
Install or Lock [Y] [M] [C] [K] Toner Cartridge
Replace [Y] [M] [C] [K] Toner Cartridge or [Y] [M] [C] [K] Toner Cartridge Empty
Dusty Density Sensor
Remove Ribbon From [Y] [M] [C] [K] Toner Cartridge
Tray and Media Errors
Output Tray is Full, Unload Paper
Insert Tray [2] or Tray [2] missing
Insert Tray [3] [4] or Tray [3] [4] missing
Tray [2] Paper is Low
Tray [3] [4] Paper is Low
Tray 1 (MPT) Out of Paper/Load Paper
Tray [2] [3] [4] Out of Paper/Load Paper
Page 99
Page 100
Error Messages and Codes 3-19
Jam Errors
Jam at Fuser: Jam F
Reseat the Fuser.
Remove the Fuser and check for any obstructions, media or debris.
Cycle printer power.
If the problem persists, follow the procedure below.
Warning
To a v oid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing Step 2 of the following troubleshooting procedure..
Troubleshooting Reference
Applicable Parts Wiring and Plug/Jack Map References
Fuser, PL 8.1.1 “Drive Section” on page 10-18
Exit Sensor/Actuator, PL 8.1.7 “Fuser Assembly” on page 10-21
Motor Driver Board, PL 12.1.12 “Map 1” on page 10-6
Troubleshooting Procedure
Steps Actions and Questions Yes No
1
Check the following for evidence of fault or damage: Exit Actuator & Sensor, PL 8.1.7 Fuser Assembly, PL 8.1.1 Front Cover, PL 1.1.2 Chute Assembly In, PL 5.1.1 Transfer Roller, PL 8.1.12 Imaging Unit, PL 9.1.3
Replace the part(s) concerned.
Go to Step 2.
2
Remove the Fuser and check for broken or bent pins.
Replace the parts concerned.
Go to Step 3.
3
Reinstall the Fuser. Does error recur after the Fuser Assembly has been replaced?
Go to Step 4. Complete.
4
Use service diagnostics to test the Exit Sensor. Does the sensor function correctly?
Go to Step 9. Replace the
Fuser Assembly. Go to Step 5.
5
Does error recur after the Fuser is replaced Go to Step 6. Complete.
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