MINOLTA-QMS magicolor 6100 Series Service Manual
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MINOLTA-QMS magicolor 6100 Series Service Manual

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magicolor 6100 Series Service Manual
1750039-001C
The essentials of imaging
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Summary of Contents for MINOLTA-QMS magicolor 6100 Series

  • Page 1 6100 Series Service Manual 1750039-001C The essentials of imaging www.minolta-qms.com...
  • Page 3 Safety and Revision Information magicolor 6100 Series Service Manual Page i...
  • Page 4 Page ii magicolor 6100 Series Service Manual...
  • Page 5 Caution: Any modifications or changes to this product not expressly approved in writing by the manufac- turer responsible for compliance to Federal Regulations could void the user's authority to operate this prod- uct within the Laws and Regulations of the Federal Communications Commission. Canadian Compliance magicolor 6100 Series Service Manual Page iii...
  • Page 6 This engine is provided with the ozone filter in order to reduce exhaust ozone in compliance with Product Safety Standards. The ozone filter must be replaced yearly; otherwise, it may cause a strong odor, which will likely have ill effects on bronchial tubes. Page iv magicolor 6100 Series Service Manual...
  • Page 7 Special Safety Information i.ii.i Introductory Information The warnings and cautions are made clear by “Signal Words” such as DANGER, WARNING and CAUTION. i.ii.i.i Definition of Signal Words magicolor 6100 Series Service Manual Page v...
  • Page 8 The ozone filter is provided in this printer to reduce the exhaust ozone. This filter must be replaced with a new filter periodically in accordance with the manual for this printer. Page vi magicolor 6100 Series Service Manual...
  • Page 9 Handle the toner cartridge, waste toner pack, and developing unit care- fully. CAUTION POWER CORD AND PLUG This printer is equipped with a 3-wire power cord and 3-pronged plug (bi- polar plug with grounding) for user safety. magicolor 6100 Series Service Manual Page vii...
  • Page 10 Do not step on or lean against the printer door. Failure to follow this guideline may cause the printer to tip over. This may cause injuries or it may damage the printer. Page viii magicolor 6100 Series Service Manual...
  • Page 11 6100 Series Service Manual Page ix...
  • Page 12 Page x magicolor 6100 Series Service Manual...

  • Page 13: Table Of Contents

    7.1 Replacement of Covers ..........7-5 7.2 Replacement of Printed Wire Boards (P.W.B) ......7-19 magicolor 6100 Series Service Manual...
  • Page 14 Index ..............I-3 magicolor 6100 Series Service Manual...

  • Page 15: Outline Of Product

    Section 1: Outline of Product magicolor 6100 Series Service Manual Page 1-1...
  • Page 16 Page 1-2 magicolor 6100 Series Service Manual...

  • Page 17: Name And Function Of Components

    Power Connection Connects to a power supply cable. Transfer Unit Door Acts as a rear enclosure. Open when clearing an inter- nal jam or performing maintenance. Interface Connector Panel Video controller PWB installation location. magicolor 6100 Series Service Manual Page 1-3...

  • Page 18: Name And Function Of Duplexer Components

    Reverse Input Paper Guide Open for clearing inner jams or performing mainte- nance. Paper reverse and transport guide. Paper Guide FU Open for clearing “DUPLEX JAM.” Paper transpor- tation guide in D-top unit. Page 1-4 magicolor 6100 Series Service Manual...

  • Page 19: Name And Function Of Lfu Components

    Guides paper from paper cassette to printer. Tray Latch Secures LFU to printer. Connector Pin Aligns the printer engine with the lower feeder unit. Signal Connector Activates lower feeder unit through electrical signal. magicolor 6100 Series Service Manual Page 1-5...

  • Page 20: Internal Structure Of The Printer

    Transfers the toner image from the transfer drum to paper. Paper Cassette Holds paper to be fed into the printer. Pick-up Roller Feeds paper automatically from the paper cassette. Optical Unit Creates a latent image on the OPC belt. Page 1-6 magicolor 6100 Series Service Manual...

  • Page 21: Internal Structure Of The Duplexer

    Registration Roller Performs registration for back side of paper. Shutter AS (U) Switches paper to the duplexer. Shutter AS (L) Switches paper from the duplexer. Sensor PT4 Senses paper. Sensor PT5 Senses paper. magicolor 6100 Series Service Manual Page 1-7...

  • Page 22: Description Of The Operator Panel

    Number Description LCD: 16 characters by 2 lines Message LED Online LED Ready LED Online Key Cancel Key Data LED (Red) Menu Key Media Key Select Key Scroll Key (Left) Scroll Key (Right) Page 1-8 magicolor 6100 Series Service Manual...
  • Page 23 Section 2: Product Specifications magicolor 6100 Series Service Manual Page 2-1...
  • Page 24 Page 2-2 magicolor 6100 Series Service Manual...

  • Page 25: Specifications

    *1:European customers must purchase and use a power cord complying with the following specifications. Applicable Figure Model Name Rating Approval Agency Area H05VV-F3G0.75 250VAC, 6A VDE, OVE, SEMKO, CEBEC, Europe (Con- NEMKO, DEMKO, FIMKO tinent) H05VV-F3-0.75 250VAC, 6A magicolor 6100 Series Service Manual Page 2-3...

  • Page 26: Printer Specifications

    Three-Color c). 8 Letter/A4; 4 Tabloid/A3 d). Four-Color d). 6 Letter/A4; 3 Tabloid/A3 Warm-Up Time (Ambient 210 seconds maximum Temperature 68° F or 20° Resolution 600 dpi (base unit) Feeding Method Cassette Feed Page 2-4 magicolor 6100 Series Service Manual...
  • Page 27 Letter, Legal, A4, Executive, B5, Label, Ledger Dimensions 19.5” (W) x 19” (D) x 4.5” (H) 500mm (W) x 484mm (D) x 116mm (H) Weight Approximately 17.6 lbs (11kg) 2.2.2 Duplexer Specifications Number Item Description/Specification Duplexer Option for printer magicolor 6100 Series Service Manual Page 2-5...
  • Page 28 Printer with Duplexer: 24.2” (W) x 24.4” (D) x 24” (H) 615mm (W) x 620mm (D) x 610mm (H) Weight Duplexer: Approx. 26.5 lbs. (12kg) Printer with Duplexer and Lower Feed Unit: Approx. 169.9 lbs. (77kg) Page 2-6 magicolor 6100 Series Service Manual...
  • Page 29 Long a. Printed side. b. Back side. Measurement Conditions: 63.5 to 81°F (17.5 ~ 27.0°C) and 50 ~ 70% RH Note: Keep the paper sealed. Do not open the paper until using it. magicolor 6100 Series Service Manual Page 2-7...

  • Page 30: Environmental Conditions

    63.5 ~ 81° F (17.5 ~ 27.0° 50 ~ 70% RH 17.5 20 27 30 32.5 40 Ambient Temperature ( ) C 2.3.1.2 Idle: 41~95°F (5.0~35.0°C), 10 ~ 80% RH (See the figure below.) Ambient Temperature( Page 2-8 magicolor 6100 Series Service Manual...
  • Page 31 The length of time the printer is exposed to the noted severe conditions must not exceed 48 hours. The printer must be stored under normal conditions for Š90 percent of the storage period. Severe conditions must make up ð10 percent of total stor- age time. magicolor 6100 Series Service Manual Page 2-9...
  • Page 32 Page 2-10 magicolor 6100 Series Service Manual...

  • Page 33: Installation

    Section 3: Installation magicolor 6100 Series Service Manual Page 3-1...
  • Page 34 Page 3-2 magicolor 6100 Series Service Manual...

  • Page 35: Conditions For Installation

    Fig. 3-1 shows the basic layout of the printer set up location suitable for the smooth operation and maintenance of printer. Stable Surface 20" (50cm) 8" (20cm) 6.4" (16cm) 28" 8" (20cm) (70cm) 28" (70cm) 32" (80cm) 4" (10cm) Fig. 3-1 magicolor 6100 Series Service Manual Page 3-3...

  • Page 36: 3.2 Unpacking

    5. Remove the upper packing (3) from the four noted locations. 6. Remove the power cord (18). 7. Remove the vinyl bag (5) wrapping the printer. 8. Using at least two people, lift and position the printer on a stable surface. Page 3-4 magicolor 6100 Series Service Manual...
  • Page 37 Fig. 3-2 magicolor 6100 Series Service Manual Page 3-5...
  • Page 38 Diagram Y (Yellow) Toner Cartridges M (Magenta) Yellow C (Cyan) Magenta K (Black) Cyan Black OPC Belt Cartridge Oil Bottle Cleaning Roller Cleaning Roller Siphon Cassette Envelope Adapter Paper Cassette with Envelope Adapter Page 3-6 magicolor 6100 Series Service Manual...
  • Page 39 Name of Parts Quantity 1 Lower Feeder Unit Upper Packing 2 Paper Cassette 3 Set-Up Guide (R) 4 Set-Up Guide (L) 5 Right Side Cover 6 Left Side Cover Base 9.5" Fig. 3-3 magicolor 6100 Series Service Manual Page 3-7...
  • Page 40 2. Open the top of the box. 3. Remove the upper packing. 4. Remove the duplex unit. 5. Remove the vinyl bag. Upper Packing Vinyl Bag Tape Weight: Approx. 44 lbs. (20 kg) Base Packing Fig. 3-4 Page 3-8 magicolor 6100 Series Service Manual...
  • Page 41 Cleaning Roller Lock Lever 5. Install the cleaning roller in the fusing unit. 6. Close the cleaning roller retainer lock lever. 7. Close the paper exit unit. Oil Bottle Lock Lever Fig. 3-8 magicolor 6100 Series Service Manual Page 3-9...
  • Page 42 4. Pull and remove the tension release Tension pins from both sides (left and right) Release Pins Protective Sheet from the belt cartridge. 5. Remove the protective sheet from the belt cartridge. Fig. 3-11 Page 3-10 magicolor 6100 Series Service Manual...
  • Page 43 Cyan (C), Magenta (M), Yel- low (Y), and Black (K). 5. Push each toner cartridge along the guides into the printer until you feel resistance. Fig. 3-15 6. Close the front door. magicolor 6100 Series Service Manual Page 3-11...
  • Page 44 Keep the volume below the upper limit marked on the label. Overloading media will result in paper feed jams or print quality failure. 4. Install the cassette cover and slide the cassette into the printer. Page 3-12 magicolor 6100 Series Service Manual...

  • Page 45: Installation

    It may result in a paper feed jam or bad print quality. 5. Load the envelopes in the adapter. 6. Slide the paper cassette into the printer. magicolor 6100 Series Service Manual Page 3-13...
  • Page 46 Do not lift up the trailing edge of the envelope adapter forcefully, otherwise, it may result in damaging the hook at the leading edge of the adapter. Adapter Cassette Base Cassette Base Hook Fig. 3-22 Page 3-14 magicolor 6100 Series Service Manual...
  • Page 47 At least two adults are needed to move the printer. Because this printer is a precision machine, carry it carefully, making sure not to bump or jar it excessively. magicolor 6100 Series Service Manual Page 3-15...
  • Page 48 LFU. The tray latch can be pivoted on its set screw. Fig. 3-28 E. Pivot the tray latch so that it is Claw hooked to the engine base. Tray Latch Fig. 3-29 Page 3-16 magicolor 6100 Series Service Manual...
  • Page 49 10. Turn the locking nut upward and Stopper fix the anchor bolt. Anchor Foot Fig. 3-34 CAUTION When lifting the printer, make sure that the connector of the LFU connector cable and tray latch are disconnected before lifting. magicolor 6100 Series Service Manual Page 3-17...
  • Page 50 4. Remove the LFU left and right access plates (Fig. 3-39 and Fig. 3-40). Caps Paper Exit Upper Cover Left Side Cover Fig. 3-35 Fig. 3-37 Fig. 3-36 Right Access Plate LFU Side Cover Left Access Plate Fig. 3-40 Fig. 3-39 Fig. 3-38 Page 3-18 magicolor 6100 Series Service Manual...
  • Page 51 2. Insert the fixing pins into the sockets of the LFU (see Fig. 3-43 and Fig. 3-44). Duplexer Handle Fixing Fixing Fig. 3-44 Fig. 3-43 Fig. 3-42 magicolor 6100 Series Service Manual Page 3-19...
  • Page 52 5. Secure the duplexer to the printer with the thumb screws (see Fig. 3-46). Thumbscrews Fig. 3-46 6. Close the upper unit. 7. Connect the interface connectors between the DPU and the printer (see Fig. 3-47 and Fig. 3-48). Fig. 3-47 Connector Cable Fig. 3-48 Page 3-20 magicolor 6100 Series Service Manual...
  • Page 53 8. Install the LFU left side cover (see Fig. 3-49). LFU Left Side Cover Fig. 3-49 magicolor 6100 Series Service Manual Page 3-21...
  • Page 54 Available in mono-color print of Y, M, C, K, and two-color print of R, G, and/or B. GRID 2). Stripe Pattern: Available in color print of Y, M, C, K, R, G, and B. STRIPE Page 3-22 magicolor 6100 Series Service Manual...
  • Page 55 Select the tray which will hold the media. 3.3.7.1.4 Operator Call When “Operator Call” is displayed on the operator panel, see the “Operator Call” information in section 8.2.1, and take the necessary actions. magicolor 6100 Series Service Manual Page 3-23...
  • Page 56 Page 3-24 magicolor 6100 Series Service Manual...

  • Page 57: Theory Of Operation

    Section 4: Theory of Operation magicolor 6100 Series Service Manual Page 1-1...
  • Page 58 Page 1-2 magicolor 6100 Series Service Manual...

  • Page 59: Basic Structure

    • Paper Cassette • Transport • Paper Discharger • Fuser • Paper Exit magicolor 6100 Series Service Manual Page 1-3...
  • Page 60 Fig. 4-1 Page 1-4 magicolor 6100 Series Service Manual...
  • Page 61 Toner Cartridge 4-3). Transfer Drum • The toner image is developed by cyan, yellow, and magenta toner. Com- binations of toner, moved to the transfer drum, develops different colors (see Fig. 4-3 Fig. 4-4). magicolor 6100 Series Service Manual Page 1-5...
  • Page 62 (see Fig. 4-5). The OPC belt is a main part of the print system (see Fig. 4- Photoconductor(OPC) Electrode Aluminum Deposit Layer Insulator Material (PET) Fig. 4-5 Belt Cartridge Toner Cartridges OPC Belt Transfer Drum Fig. 4-6 Optical Unit Page 1-6 magicolor 6100 Series Service Manual...

  • Page 63: Print System And Transfer/Transport System

    K C M Y 4 Transfer Drum (First Transfer) Transfer Drum K C M Y Transfer System Transfer Drum Cleaning 7 Second Transfer (Paper) Paper Discharge 10 Fusing Transport System 11 Paper Exit Fig. 4-7 magicolor 6100 Series Service Manual Page 1-7...
  • Page 64 Paper Exit Unit Ejects Paper into the Paper Exit Tray. Drum Cleaner Belt Cartridge Toner Cartridges Paper Exit Unit Fuser Paper Discharger Transfer Roller Transfer Drum Charger Cleaning Blade Optical Unit Erase Lamp Fig. 4-8 Page 1-8 magicolor 6100 Series Service Manual...
  • Page 65 Cleaning Unit FCBV Fuser Unit Toner OPC Belt Toner Cartridge Develop Paper Discharger Transfer Drum ACHV Transfer Roller Optical Unit THV (+) Charger Cleaning THV ( - ) Brade Paper Erase Lamp Fig. 4-9 magicolor 6100 Series Service Manual Page 1-9...
  • Page 66 3 Developing Process Charger 4 Transferring Process 5 Cleaning (Erasing Process) CBV Voltage for OPC Belt Bias CHV Voltage for Charging DBV Voltage for Dev. Roller Bias Remaining Voltage on the OPC Belt Fig. 4-10 Page 1-10 magicolor 6100 Series Service Manual...
  • Page 67 Process of Charging (see Fig. 4-12) The OPC belt is biased to -CBV. The charger unit generates a negative charge and uniformly charges the surface of the OPC belt. Cleaning Charging (Blade) Fig. 4-12 magicolor 6100 Series Service Manual Page 1-11...
  • Page 68 The areas exposed to the laser are discharged to the potential of -V An invisible electrostatic latent image is formed on the OPC belt (see Fig. 4-12). Charging Exposing Fig. 4-13 Page 1-12 magicolor 6100 Series Service Manual...
  • Page 69 Therefore, the toner is repelled by the surface of the OPC belt, where no development takes place. Dev .roller (-CBV)+(-DBV) Ton er (-CBV) O P C B e l t Fig. 4-14 magicolor 6100 Series Service Manual Page 1-13...
  • Page 70 OPC Belt Toner Cartridge Dev. roller Toner Toner Toner Fig. 4-15 Toner(M) Exposing Developing Fig. 4-16 Page 1-14 magicolor 6100 Series Service Manual...
  • Page 71 The drum is made of aluminum. The drum surface is coated with rubber as shown in Fig. 4-17. The transfer drum rotates, synchronously maintaining contact with the OPC belt. Transfer Drum Aluminum Rubber Fig. 4-17 magicolor 6100 Series Service Manual Page 1-15...
  • Page 72 After the drum transfer process is complete, the toner images are transferred onto the paper. Residual Charge OPC Belt Residual Toner Belt Belt Cleaning (Brade) Discharging DrumTransferring (Erase Lamp) Fig. 4-18 Page 1-16 magicolor 6100 Series Service Manual...
  • Page 73 The residual electric charge is discharged by shining LED light onto the OPC belt prior to proceeding to the next pro- cess. Belt Cleaning (Brade) Belt Discharging Drum Transferring (Erase Lamp) Fig. 4-19 magicolor 6100 Series Service Manual Page 1-17...
  • Page 74 OPC belt. Scavenged residual toner is collected and sent to the waste toner pack by the waste toner auger. Belt Cleaning B Drum Transferring Erase Lamp Fig. 4-20 Page 1-18 magicolor 6100 Series Service Manual...
  • Page 75 After of the paper transfer, the transfer roller moves away from the transfer drum. Paper Discharger Transfer Drum Transfer Roller VAC: Power Supply for Paper discharging THV: Power Supply for Transfer Roller Bias Toner Image Paper Fig. 4-21 magicolor 6100 Series Service Manual Page 1-19...
  • Page 76 The transported paper is separated from the transfer drum and transported to the fuser. Paper Discharger Transfer Drum Transfer Roller Toner Paper Fig. 4-22 Page 1-20 magicolor 6100 Series Service Manual...
  • Page 77 Cleaning Roller Cleaning Brush Waste Toner Feeder FCBV: Cleaning Roller Residual Power Supply for cleaning Toner Roller Bias FCBV Drum Cleaning Unit Transfer Drum Fig. 4-23 magicolor 6100 Series Service Manual Page 1-21...

  • Page 78: Optical System

    (Laser Diode Control) PD (Photodetector Sen- Used to detect laser beam start position. sor) BTD Mirror Guides the laser beam to the PD. (Beam Timing Detect) Optical unit box Dust-proof glass Developer belt Fig. 4-24 Page 1-22 magicolor 6100 Series Service Manual...
  • Page 79 Rated Output of Laser Diode 5 mW Wave Length of Laser Beam Approximately 785 Scanning Density 600 dpi. Scanning Width 310 mm. Rotations Per Minutes of Scanner 24,072 rpm. Motor Number of Polygon Mirror Faces magicolor 6100 Series Service Manual Page 1-23...

  • Page 80: Paper Transportation System

    Melts the toner images on the paper with the heat roller. The process fuses these toner images onto the paper. Paper Exit Roller Ejects the page from the printer after the paper fusing process is complete. Fig. 4-25 Page 1-24 magicolor 6100 Series Service Manual...

  • Page 81: Fuser

    Detects the temperature of the fuser roller’s surface. Thermal Fuse Prevents the fuser roller from being overheated. Oil Bottle Houses the silicone oil for fusing. Cleaning Roller Cleans the fuser roller. Fig. 4-26 magicolor 6100 Series Service Manual Page 1-25...
  • Page 82 The paper carrying the fused image is separated from the heat rollers and ejected from the printer. M: Magenta toner Y : Yellow toner C : Cyan toner Before Fusing Toner Image Paper R : Red M: Magenta G: Green Fixed Toner After Fusing Fig. 4-27 Page 1-26 magicolor 6100 Series Service Manual...

  • Page 83: Structure Of The Control System

    Processes I/O signals to and from the external controller (host). Operator/Control Panel Displays the printer operation status on the panel. Error Control Stops the printer safely, and displays the status of the defects if any error occurs with the printer. magicolor 6100 Series Service Manual Page 1-27...
  • Page 84 Fig. 4-28 Page 1-28 magicolor 6100 Series Service Manual...
  • Page 85 Low Voltage Power Provides the printer with the power for the printer control. Supply (LVPS) High Voltage Power Provides the printer with the high-voltage power necessary for the Supply (HVPS) printing process. Fig. 4-29 magicolor 6100 Series Service Manual Page 1-29...
  • Page 86 Switch Back Cover (Trans- DSW3 Used as a safety interlock switch that stops the fer Unit Door) Inter- motors when the transfer unit door is opened. lock Switch Fig. 4-30 Page 1-30 magicolor 6100 Series Service Manual...
  • Page 87 Transfer Cam Clutch TRCM Brings the transfer roller into contact with the trans- fer drum surface. Cleaner Cam Clutch FBCM Brings the cleaning brush into contact with the trans- fer drum surface. Fig. 4-31 magicolor 6100 Series Service Manual Page 1-31...
  • Page 88 Detects the fuser temperature. Sensor Exit Paper Full Sensor PFUL Detects tray full condition for exit tray. Toner Key Sensor Detects the presence of the key on a toner car- tridge. Fig. 4-32 Page 1-32 magicolor 6100 Series Service Manual...
  • Page 89 Senses the errors occurring in the printer and stops the printer as necessary. Interface Control Controls the receipt and transmission of signals from the exter- nal controller. Laser Control Controls the laser scanning and laser power. magicolor 6100 Series Service Manual Page 1-33...
  • Page 90 (BDT). This signal is to initiate the printing. MCTL P.W.B. OPC Belt PRINT Signal Frequency Control Circuit F - Ø Lens Scanner Motor Laser Beam Scanning Synchronizie Control Circuit Control Circuit LCD P.W.B. VIDEO Signal Fig. 4-34 Page 1-34 magicolor 6100 Series Service Manual...
  • Page 91 Used as a sensor circuit for temperature signal (for HON signal). Used as a sensor circuit for temperature signal (for processing). Used as a sensor circuit for shut-down by the thermistor (for THERR signal). Heats the roller. Heats the back-up roller. magicolor 6100 Series Service Manual Page 1-35...
  • Page 92 Turns off the relay RY1 when it is sensed too hot. THERR Detects the shut-down by the thermistor. Converts the temperature sensing signal to AD. RY-1 ACOFF-P RY-1 HON-N Fusing Unit THERR ACOFF HON GA/CPU Fig. 4-35 Page 1-36 magicolor 6100 Series Service Manual...
  • Page 93 If the “Heater On” signal continues after a given period of time, the operator panel displays “H3”, and the printer stops. If the temperature within the fuser becomes unusually hot, and when ACOFF signal is input, the operator panel displays “H4”, and the printer stops. magicolor 6100 Series Service Manual Page 1-37...
  • Page 94 The interface connector of the printer is connected to the host system (see Fig. 4-37). Operator Panel Duplex unit (Option) MCTL Host Controller Board System Lower Feeder(1) Unit (Option) DC Power Supply Lower Feeder(2) Unit (Option) Printer Fig. 4-37 Page 1-38 magicolor 6100 Series Service Manual...
  • Page 95 The table below shows the interface circuit for each signal. Table 4.1: Interface Circuit Number Interface Circuit Signal Name •VIDEO-N •VIDEO-P M5M34050 •HSYNC-N •HSYNC-P M5M34050 •PRREQ-N •COMMAND-N •ID1-N •ID2-N 0.01 F SN74LS14 •VSYNC-N 3.3K •IREADY-N •STATUS-N •KEY-STATUS-N SN7406 magicolor 6100 Series Service Manual Page 1-39...
  • Page 96 ID1-N Reserve RET (GND) KEY_STATUS-N Reserved Reserved Reserved Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved RET (GND) Reserved Page 1-40 magicolor 6100 Series Service Manual...
  • Page 97 For connection of the Fuser Heater (HP). 220V, 5A For connection of the Fuser Heater (HN). 4.6.3.2 Layout of Connector Pin Assignment (see Fig. 4-38) ACN3 ACN1 TAB2 ACN4 TAB1 ACN2 Main SW Inret White Black Fig. 4-38 magicolor 6100 Series Service Manual Page 1-41...
  • Page 98 +24V Output through Door Switch PGND Power Ground (+24V type ground) PGND Power Ground (+24V type ground) PGND Power Ground (+24V type ground) PGND Power Ground (+24V type ground) PGND Power Ground (+24V type ground) Page 1-42 magicolor 6100 Series Service Manual...
  • Page 99 ACN3 (Molex : 5566-06A) Pin No. Signal Name Interface +5V-2 +5V-2 Output +5V-2D +5V-2D Output +5V-2D +5V-2D Output SGND Signal Ground (+5V type ground) SGND Signal Ground (+5V type ground) SGND Signal Ground (+5V type ground) magicolor 6100 Series Service Manual Page 1-43...
  • Page 100 CBV(-) 200~900 Developing Bias (Y, M) DBV(-A) 200~400 Developing Bias (C, K) DBV(-B) 200~400 Second Transfer THV(+) 400~3,000 Transfer Roller Cleaning THV(-) Paper Discharging ACV(~) 4.9k Paper Discharging DCV(+) Drum Cleaning FCBV 200~1,000 Page 1-44 magicolor 6100 Series Service Manual...
  • Page 101 DBVYMPWM-N DBV PWM Control Signal THVPWM-N THV PWM Control ON Signal DBVCKPWM-N CBV PWM Control Signal Transfer Voltage Select Signal FCBVPWM-N FCBV PWM Control Signal Thermistor Temperature Sensor Signal Thermistor Temperature Sensor Signal magicolor 6100 Series Service Manual Page 1-45...
  • Page 102 D501 D101 VR701 VR001 D801 IC102 IC101 VREF IC201 IC801 D701 IC801 T201 IP001 IC701 D208 T702 IC001 D001 D204 D200 D503 D502 D201 FCBV D301 IP101 D400 D405 BCN1 T401 Fig. 4-39 Page 1-46 magicolor 6100 Series Service Manual...
  • Page 103 Developer Ozone Inter lock Switch Feeding Position Position Cam Clutch L C D Sensor 1 Sensor 2 Clutch P.W.B Note: Circled reference numbers refer to wire tables found in Section 4.6.5.2. Fig. 4-40 magicolor 6100 Series Service Manual Page 4-47...
  • Page 104 Page 4-48 magicolor 6100 Series Service Manual...
  • Page 105 Ozone Fan Motor IOD3 IOD3 P.W.B. DVLK Developer Clutches PCLU Upper Paper Feeding Clutch DVLY (K, Y, M, C) DVLM DVLC PCLU Upper Paper Feeding Clutch RECL Registration Clutch FUCL Fuser Clutch FBCL Cleaning Clutch magicolor 6100 Series Service Manual Page4-49...
  • Page 106 IOD1 P.W.B DCN17 High Voltage Power Supply BCN1 (18 pins) IOD1 DCN17 (18) (see Fig. 4-40). Pin Number Signal Pin Number Signal +24v-1 PGND FUTEMP PGND ACVON-N PWMON-N CHVON-N CHVERR CBVPWM-N THVRON-N DBV(MC)PWM-N THVPWM-N DBV(KY)PWM-N THV-I FCBVPWM-N AC_DCON-N Page 4-50 magicolor 6100 Series Service Manual...
  • Page 107 4.6.4.2.3 For Factory Use Only DCN3 (4P) DCN3 (see Fig. 4-40). Pin Number Signal TESTO1 TESTI1 TESTO2 TESTI2 4.6.4.2.4 IOD1 P.W.B. (DCN5) IOD1 DCN5 (see Fig. 4-40). Pin Number Signal REARDOPEN-P TOPDOPEN-P magicolor 6100 Series Service Manual Page4-51...
  • Page 108 DMRDY-N DBV(KY) PWM-N I/ODATA4 FCBVPWM-N (REVI1) PKCLL2ON-P THVRON-N AC_DCON-N THVPWM-N PKCLL1ON-P THV-I ELON-P PBSEN-N HPSEN-N OILLES-P CTFANON-P FUTEMP HTFANON-P HON-N +5v-1R ACOFF-P SGND ACSYNC-N SGND SGND PGND +5v-1 PGND +5v-1 +24v-1 +5v-1D +24v-1 Page 4-52 magicolor 6100 Series Service Manual...
  • Page 109 Paper Feed Sensor (PT1) Drum Encoder Sensor (EN) OHP Sensor (OHP) DCN4 PT1 OHP (see Fig. 4-40). Pin Number Signal Pin Number Signal +5v-D HPSEN-N SGND +5v-D PT1-N SGND +5v-D PEU-P SGND +5v-D OHPSENU SGND SGND magicolor 6100 Series Service Manual Page4-53...
  • Page 110 Erase Lamp, DCN7. (see Fig. 4-40). Pin Number Signal Pin Number Signal TLES(K)-P TLES(Y)-P TLES(M)-P TLES(C)-P TLES-G SGND LEDON-P TLESCHK SGND +24V-1 ELON-N 4.6.4.2.10 IOD1 P.W.B. Controller Fan DCN18 (see Fig. 4-40). Pin Number Signal CTFANON-P PGND CTFANERR Page 4-54 magicolor 6100 Series Service Manual...
  • Page 111 DCN14 Heater Fan (HTFAN), Paper Exit Sensor (PT2), Cleaning Roller Sensor (CRS), Paper Full Sensor (PFUL) (see Fig. 4-40). Pin Number Signal Pin Number Signal +5v-D PT2-N SGND +5v-D CLROL-N SGND +5v-D PEFULL-N SGND HTFANON-P PGND HTFANERR magicolor 6100 Series Service Manual Page4-55...
  • Page 112 ECN1: MCTL IOD2 (22 26) (see Fig. 4-40). Pin Number Signal Pin Number Signal DCL(C)ON-P DCL(M)ON-P DCL(Y)ON-P DCL(K)ON-P PSL(KY)ON-P PSL(MC) ON-P MMCLK MMON-N MMREV-N MMENC RECLON-P AHUMB ISCK IDATA ILOAD FBCLON-P FBSLON-P TRSLON-P OZFANON-P FUCLON-P PKCLU1ON-P PKCLU2ON-P Page 4-56 magicolor 6100 Series Service Manual...
  • Page 113 Pin Number Signal +24v-1 DCL(M)ON-N 4.6.4.2.17 IOD2 P.W.B Developer Clutch (Y) ECN14 (see Fig. 4-40). Pin Number Signal +24v-1 DCL(Y)ON-N 4.6.4.2.18 IOD2 P.W.B. Developer Clutch (K) ECN13 (see Fig. 4-40). Pin Number Signal +24v-1 DCL(K)ON-N magicolor 6100 Series Service Manual Page4-57...
  • Page 114 PSL(MC) ON-N +24v-1 +24v-1 PSL(KY) ON-N 4.6.4.2.20 IOD2 P.W.B. Fuser Clutch ECN9 (see Fig. 4-40). Pin Number Signal +24v-1 FUCLON-N 4.6.4.2.21 IOD2 P.W.B. Cleaner Clutch ECN11 (see Fig. 4-40). Pin Number Signal +24v-1 FBCLON-N Page 4-58 magicolor 6100 Series Service Manual...
  • Page 115 +24v-1 RECLON-N 4.6.4.2.24 IOD2 P.W.B. Waste Toner Sensor ECN17 (see Fig. 4-40). Pin Number Signal TBFL1-N SGND WTLEDON SGND 4.6.4.2.25 IOD2 P.W.B. Cleaner Cam Clutch ECN10 (see Fig. 4-40). Pin Number Signal +24v-1 FBSLON-N magicolor 6100 Series Service Manual Page4-59...
  • Page 116 4.6.4.2.27 IOD2 P.W.B. Paper Feeding Clutch ECN4 (see Fig. 4-40). Pin Number Signal +24v-1 PKCLU1ON-N 4.6.4.2.28 IOD2 P.W.B. Main Motor ECN12 (see Fig. 4-40). Pin Number Signal MMRDY-N MMON-N MMCLK PGND +24v-1 SGND +5v-1 MMENC MMREV-N Page 4-60 magicolor 6100 Series Service Manual...
  • Page 117 PGND PGND +24v-1 +24v-1 SGND +5v-1 4.6.4.2.30 MCTL P.W.B. I3CN IOD1 P.W.B DCN13 I3CN MCTL IOD1(10 26) (see Fig. 4-40). Pin Number Signal TMLEDON-P TMASEN1 TMSOLON-P TMASEN2 SIN2 (REVI2) TMSOLERR SOUT2(REVO1) DCOFF2-N(REVO2) FDCLL1ON-P(REV03) FDCLL2ON-P(REV04) magicolor 6100 Series Service Manual Page4-61...
  • Page 118 4.6.4.2.32 Power Supply Unit ACN3 MCTL P.W.B. POCN ACN3 (see Fig. 4-40). Pin Number Signal +5v-2 +5v-2D +5v-2D SGND SGND SGND 4.6.4.2.33 Power Supply Unit Interlock Switch ACN2 (see Fig. 4-40). Pin Number Signal DSW-O DSW-I Page 4-62 magicolor 6100 Series Service Manual...
  • Page 119 4.6.4.2.35 MCTL P.W.B PACN PANEL P.W.B. (16 pins) PACN MCTL PANEL(16 26) (see Fig. 4-40). Pin Number Signal Pin Number Signal PAI/ODATA0 PAI/ODATA1 PAI/ODATA2 PAI/ODATA3 PAI/ODATA4 PAI/ODATA5 PAI/ODATA6 PAI/ODATA7 LCDRS LCDE PASWRDN PALEDWRN SGND +5v-1 LCDBLED magicolor 6100 Series Service Manual Page4-63...
  • Page 120 SGND DUMBUSY2-N SGND D-STATUS SGND +24vOFF-P DUPCHK-N DUMBUSY1-N PT-1 DUPRES-N SGND PGND PGND +24v-2 +24v-2 +5v-1D SGND +5v-1 4.6.4.2.37 IOD1 P.W.B. Toner Key Sensor DCN15 (see Fig. 4-40). Pin Number Signal TONEROK-N SGND Page 4-64 magicolor 6100 Series Service Manual...
  • Page 121 4.6.4.2 Duplexer Wiring Diagram DSOL (L) Motor (2) DPM2 Interlock Switch Paper Sensor Paper Sensor D-FAN +24v- Duplex Unit CNDUP DPCN4 Motor (1) DPCN1 DPM1 From Printer DUP P.W.B. Relay P.W.B. DPCN2 DPCN6 DSOL(U) Fig. 4-41 magicolor 6100 Series Service Manual Page 4-65...
  • Page 122 Page 4-66 magicolor 6100 Series Service Manual...
  • Page 123 CN1: DUP Relay P.W.B. (see Fig. 4-41). Pin Number Signal Pin Number Signal PGND +24v-1 SGND +5v-1 DPFANERR DPFULLSK PT-4 DPFANON-P OUT1-1A DPSLON-N OUT1-1B OUT1-2A REVO1 OUT1-2B +5v-1 REVI1 PT-5 SGND OUT2-2A OUT2-1A OUT2-2B OUT2-1B magicolor 6100 Series Service Manual Page 4-67...
  • Page 124 (see Fig. 4-41). Pin Number Signal +24v-1 DPSL2ON-N 4.6.4.3.5 CN4: DFAN (see Fig. 4-41). Pin Number Signal DPFANON-P DPFANERR PGND 4.6.4.3.6 CN5: Motor (1) (see Fig. 4-41). Pin Number Signal OUT1-1B OUT1-1A OUT1-2A OUT1-2B Page 4-68 magicolor 6100 Series Service Manual...
  • Page 125 (see Fig. 4-41). Pin Number Signal +5v-1 PT-5 SGND 4.6.4.3.8 CN5: Motor (2) (see Fig. 4-41). Pin Number Signal OUT2-2B OUT2-1A OUT2-2A OUT2-2B 4.6.4.3.9 CN3: DSOL (U) (see Fig. 4-41). Pin Number Signal OUT1 OUT2 magicolor 6100 Series Service Manual Page 4-69...
  • Page 126 Inter lock Switch. Second LFU Second Paper Size Sensor PSC-L Second Paper Empty Sensor PEC-L Second Paper Pick-up clutch. PKCL Second Paper Feeding clutch. FDCL LFSW1 LFSW2 Inter lock Switch. LFU3 WIRING DIAGRAM Page 4-70 magicolor 6100 Series Service Manual...
  • Page 127 SGND CASTDOPEN-N +24v-1 PKCLL2ON-N FDCLL2ON-N PSL4 (PSLL1) PSL5 (PSLL2) PSL6 (PSLL4) PSCST2 (PSLL5) PEL2-P OCST2-N OHPSENL2 +5v-D SGND 4.6.4.5.2 CCN2 : IOD3 - Paper Pick-up Clutch Pin Number Signal PKCLL1ON-N +24v-1DSW +24v-1DSW FDCLL1ON-N magicolor 6100 Series Service Manual Page 4-71...
  • Page 128 CCN3: IOD3 - Cassette Paper Size Sensor Signal Signal Number Number +5v-D PSL1 PSL2 PSL3 PSCST1 (PSL5) SGND +5v-D PEL1-P SGND +5v-D SGND OCST1-N 4.6.4.5.4 CCN4: IOD3 (Upper) - Door Switch Pin Number Signal DSWOUT (+24v-1) DSWIN Page 4-72 magicolor 6100 Series Service Manual...
  • Page 129 4.6.4.5.5 CCN5 - IOD3 (Upper) - IOD3 (Lower) Signal Signal Number Number +24v-1 PKCLL2ON-N FDCLL2ON-N PSL4 (PSLL1) PSL5 (PSLL2) PSL6 (PSLL4) PSCST2 (PSLL5) PEL2-P OCST2-N OHPSENL2 +5v-D SGND CASTDOPEN-N magicolor 6100 Series Service Manual Page 4-73...
  • Page 130 Page 4-74 magicolor 6100 Series Service Manual...

  • Page 131: Periodic Maintenance

    Section 5: Periodic Maintenance magicolor 6100 Series Service Manual Page 5-1...
  • Page 132 Page 5-2 magicolor 6100 Series Service Manual...

  • Page 133: General

    Do not confuse different screw types and length. • Do not use any solvent for cleaning the inside or outside of the printer. • Do not dispose of waste toner with flammable substances. Do not throw toner into a fire. magicolor 6100 Series Service Manual Page 5-3...
  • Page 134 Precision Driver Set (#1 ~ #6) For general use Pliers for C Ring Removal of C Rings Ruler (150mm) For general use Digital Multimeter For general use Toner Cleaner For cleaning Soft Bristle Brush For cleaning Page 5-4 magicolor 6100 Series Service Manual...

  • Page 135: Cleaning For Periodic Maintenance

    • Dustproof Glass of Optical Unit • Printer Interior WARNING Before starting any maintenance work, unplug the power supply cord from the outlet. There is a risk of electric shock if working while the printer is plugged in. magicolor 6100 Series Service Manual Page 5-5...
  • Page 136 2. Clean the printer's base, using maintenance cleaner and dry cloth. Normal time (in minutes) for replacement of noted parts. Technical level required for maintenance or replacement: A: Beginner; B: Experienced; C: Expert. Page 5-6 magicolor 6100 Series Service Manual...
  • Page 137 3. Using a clean, lint-free cloth, clean the registration roller incorporated in the transfer unit. CAUTION Do not use alcohol or other solvents for cleaning the reg- istration roller. Registration Roller Fig. 5-1 Registration Roller Fig. 5-2 magicolor 6100 Series Service Manual Page 5-7...
  • Page 138 2. Open the transfer unit. 3. Using a clean, lint-free cloth, clean the transfer roller. CAUTION Strictly refrain from using alcohol or other solvents for cleaning the transfer roller. Registration Roller Fig. 5-3 Transfer Roller Fig. 5-4 Page 5-8 magicolor 6100 Series Service Manual...
  • Page 139 6. Install the charger unit in the transfer unit. CAUTION Do not cut the corona wire when cleaning the discharger unit. Paper Discharger Transfer Unit Cotton Swab Corona Cotton cloth Guide Charger case Fig. 5-6 magicolor 6100 Series Service Manual Page 5-9...
  • Page 140 Clean the corona wire with the wire brush. Slide the brush in the direction of the arrow several times. c. Clean the belt cartridge case. OPC Belt Wire Brush Cleaning Area Corona Wire Corona Case Belt Cartridge Case Fig. 5-7 Page 5-10 magicolor 6100 Series Service Manual...
  • Page 141 Do not use alcohol or other solvents for cleaning the dustproof glass. This will cause poor image quality. Optical Unit Cover Dustproof Cover Laser WARNING Label Dustproof Glass Optical Unit Cleaning Area Fig. 5-9 magicolor 6100 Series Service Manual Page 5-11...
  • Page 142 4. Remove the OPC belt cartridge. 5. Vacuum the toner from the printer base with a toner vacuum. 6. Clean the printer interior with a lint-free cloth. 7. Reinstall the consumables. Printer Interior Toner Vacuum Fig. 5-10 Page 5-12 magicolor 6100 Series Service Manual...

  • Page 143: Periodic Maintenance Cycles And Procedures

    After completion of maintenance, clear the maintenance code displayed on the operator panel. b. Normal time required for replacement of specific parts. c. Technical level required for replacement and maintenance (A: Beginner; B: Experienced; C: Expert). magicolor 6100 Series Service Manual Page 5-13...
  • Page 144 C: PK 120K CHECKUP 120K Page Maintenance Required C: P1 120K CHECKUP 120K Page Maintenance Required C: P2 120K CHECKUP 120K Page Maintenance Required C: PD 120K CHECKUP 120K Page Maintenance Required Page 5-14 magicolor 6100 Series Service Manual...
  • Page 145 1. Open the top door. Front Door Fig. 5-11 1. Unlock the belt cartridge Guide lock lever on both sides (left and right). Belt Cartridge Lock Lever Belt Cartridge Lock Levers Fig. 5-12 magicolor 6100 Series Service Manual Page 5-15...
  • Page 146 1. Turn the power switch on. 1. Clear the REPLACE BELT error via the Service Mode CLEAR CARE mode, or the ADMINISTRATION/CONSUMABLES/ITEM REPLACED menu. 1. The error message resets, and the warming-up process starts. Page 5-16 magicolor 6100 Series Service Manual...
  • Page 147 Fuser Removal Procedures: After turning off the power switch, unplug the power cord from the outlet. Open the paper exit unit. Remove the two thumbscrews from the fuser (see Fig. 5-17). Thumb Screws Fig. 5-17 magicolor 6100 Series Service Manual Page 5-17...
  • Page 148 Secure the fuser with the thumbscrews. After the warm-up process, clear the code “REPLACE FUSER” by the Service Mode “CLEAR CARE” mode or via Page 5-18 magicolor 6100 Series Service Manual...
  • Page 149 1. Transfer unit (one) 5.3.4.4 Procedures 5.3.4.4.1 Sequence of Disassembling After turning off the power, remove the power cord from the outlet. Open the transfer door. Transfer Roller Transfer Roller Lock Lever Fig. 5-20 magicolor 6100 Series Service Manual Page 5-19...
  • Page 150 Plug the power cord in the outlet. Push the power switch On. Upon completion of warming-up, clear the code “120K CHECKUP” with Service Mode CLEAR CARE Mode or via “ADMINISTRATION/CONSUMABLES/PM SERVICE/ 120K PM SERVICE.” Page 5-20 magicolor 6100 Series Service Manual...
  • Page 151 (see Fig. 5-23). 5.3.5.4.3 Sequence of Assembly Close the transfer unit door. Upon completion of warming-up, clear the code “120K CHECKUP” with the Service Mode CLEAR CARE Mode or via “ADMINISTRATION/CONSUMABLES/PM SERVICE/ 120K PM SERVICE.” magicolor 6100 Series Service Manual Page 5-21...
  • Page 152 1. Clean lint-free cloth (2 ~ 3) 1. Drum cleaner (1) 5.3.6.4 Replacement Procedures 1. Turn off the power. 1. Open the top door. 1. Remove the cleaner cover (see Fig. 5-24). Cleaner Cover Fig. 5-24 Page 5-22 magicolor 6100 Series Service Manual...
  • Page 153 Fig. 5-26 Close the top door. Turn on the power. Upon completion of warming-up, clear the code “120K CHECKUP” with the Service Mode CLEAR CARE Mode or via “ADMINISTRATION/CONSUMABLES/PM SERVICE/ 120K PM SERVICE.” magicolor 6100 Series Service Manual Page 5-23...
  • Page 154 2. Remove the ozone filter from the ozone filter cover. 3. Install a new ozone filter in the filter cover. 4. Replace the new ozone filter cover. Right Side Cover Filter Cover Ozone Filter Fig. 5-27 Page 5-24 magicolor 6100 Series Service Manual...
  • Page 155 For proper performance of the optional lower feeding unit (LFU), the following parts should be replaced as noted. Part Name Part Code Replacement Cycle Paper Feeding Roller 825126142 Every 120k Prints Separator Pad 825126528 Every 120k Prints magicolor 6100 Series Service Manual Page 5-25...
  • Page 156 This should be done by a service technician upon request of the customer or at periodic maintenance. After the replacement, confirm the improvement of print quality by printing a test print. Page 5-26 magicolor 6100 Series Service Manual...
  • Page 157 Section 6: Operation and Adjustments through the Operator Panel magicolor 6100 Series Service Manual Page 6-1...
  • Page 158 Page 6-2 magicolor 6100 Series Service Manual...

  • Page 159: Operation Of And Adjustments Through The Operator Panel

    Name of Key or Button LCD: 16 characters by 2 lines Message LCD Online LCD Ready LCD Online Key Cancel Key Data LCD Menu Key Media key Select Key Scroll Key (Left) Scroll Key (Right) magicolor 6100 Series Service Manual Page 6-3...

  • Page 160: Display Modes

    ALIGN TONER CG MISINSTALLED FUSER MIS-INSTALLED ALIGN FU UNIT CLEANING ROLLER ALIGN FUSER CL ROLLER MISINSTALLED BELT CARTRIDGE ALIGN BELT CG MISINSTALLED TRANSFER UNIT MISINSTALLED ALIGN TR ROLLER OUTPUT BIN JAM MEDIA JAM Page 6-4 magicolor 6100 Series Service Manual...
  • Page 161 Refers to the color of toner to be replaced. e. Refers to the toner cartridge that is misinstalled. f. “Error Code” depends on the error. See section 8, “Troubleshooting” for com- plete list of error codes. magicolor 6100 Series Service Manual Page 6-5...
  • Page 162 LP Tune Up Each Image Set THV Tune Up Next Life Set DBV Tune Up DVM Tune Up CBV Tune Up FBV Tune Up REG Tune Up VDO Tune Up ACV Tune Up Fig. 6-2 Page 6-6 magicolor 6100 Series Service Manual...

  • Page 163: Operation Of Normal Mode

    (upper cassette, lower cassette, etc.) • Engine is in standby mode. • Message LED is on. PUT “SIZE” PAPER IN ANY BIN • Refill empty cassette with the appropriate size media. magicolor 6100 Series Service Manual Page 6-7...
  • Page 164 • Engine is idle. FUSER OIL LOW • Message LED is on. • Replace the fuser oil bottle with a new bottle. Use OPERATOR CONTROL/CONSUMABLES/ITEM REPLACED/ FUSER OIL to clear the message. Page 6-8 magicolor 6100 Series Service Manual...
  • Page 165 • The noted toner cartridge is not installed properly. • Engine is in standby mode. “COLOR” TONER • Message LED is on. MISINSTALLED • Reinstall the toner cartridge correctly. • This message will be automatically cleared after closing the front door. magicolor 6100 Series Service Manual Page 6-9...
  • Page 166 • An engine door is open (for example, Top, Front, Rear, or Optional Bin). • Engine halts and “DOOR OPEN” is displayed. “NOTED” DOOR OPEN • Message LED is on. • Close the indicated door, and the message will be cleared. Page 6-10 magicolor 6100 Series Service Manual...
  • Page 167 • An error has been detected with the item indicated in the service message. See section 8, CALL FOR SERVICE “ERROR” “Troubleshooting,” for full details of errors. • Engine is at standstill. • Message LED is on. magicolor 6100 Series Service Manual Page 6-11...

  • Page 168: Service Mode

    2. After scrolling to the desired mode, press the Select key for execution. 3. Press the Media key if you want to cancel the present mode. SERVICE MODE TEST PRINT SERVICE MODE NEXT CARE INFO SERVICE MODE FACTORY MODE Fig. 6-3 Page 6-12 magicolor 6100 Series Service Manual...
  • Page 169 7. Press the SELECT key so that the display changes from screen D) to screen E). 8. Press the MEDIA key to stop the test print. 9. Power up the printer to bring it back to normal printing mode. magicolor 6100 Series Service Manual Page 6-13...
  • Page 170 To clear screens (c) through (g) press the Media key several times. NEXT 240K KIT Press the Media key again at screen (b) to return to the Service Mode. 240000P The LCD changes as shown in (b) ---> (a) Page 6-14 magicolor 6100 Series Service Manual...
  • Page 171 TYPE=< A / B / C > then press the Select key. SERVICE MODE Press the Clear key to clear the screen (b). CASSETTE TYPE The LCD changes as shown in (b) ---> (c) magicolor 6100 Series Service Manual Page 6-15...
  • Page 172 : : : : . . Press the Media key to clear the screen (c). The total page count can also be changed for the LFU (d) SERVICE MODE and the Duplexer (e) ---> (f) TEST PRINT Page 6-16 magicolor 6100 Series Service Manual...
  • Page 173 SERVICE MODE TEST PRINT Press the Media key to return to the Service mode. The LCD changes as shown in (d) ---> (e) magicolor 6100 Series Service Manual Page 6-17...
  • Page 174 CARED 240K KIT ? YES/NO 36 CLEAR CARE No.=< FC, BL, FU, OW> Press the Media key to clear the CLEAR CARE mode. The LCD changes as shown in (h) ---> (i) SERVICE MODE TEST PRINT Page 6-18 magicolor 6100 Series Service Manual...
  • Page 175 Select key if the OHP sensor signal should be ignored. The LCD changes as shown in (b) ---> (c) SERVICE MODE In the normal operation, the mode is preset to MANAGE. DP CHECK magicolor 6100 Series Service Manual Page 6-19...
  • Page 176 40 DP CHECK 41 BD CHECK 42 FU CHECK 43 MARGIN ADJUST 44 LIFE PERIOD SET 45 NVRAM TUNE UP 46 NVRAM INITIAL 47 TOTAL PAGE SET 48 EACH IMAGE SET 49 NEXT LIFE SET Page 6-20 magicolor 6100 Series Service Manual...
  • Page 177 The LCD changes as shown in (d) Press the Media key one more time to return to the FACTORY MODE status of screen (a). The LCD changes as shown in (d) ---> (e) DP CHECK magicolor 6100 Series Service Manual Page 6-21...
  • Page 178 The LCD changes as shown in (d) FAIL 39 FACTORY MODE Press the Media key to stop the BD CHECK mode. The LCD changes as shown in (b) ---> (d) DP CHECK Page 6-22 magicolor 6100 Series Service Manual...
  • Page 179 LCD, otherwise, “FAIL” is displayed. OIL:GOOD The LCD changes as shown in (b) 39 FACTORY MODE Press the Media key to stop the FU CHECK mode. The LCD changes as shown in (b) ---> (c) DP CHECK magicolor 6100 Series Service Manual Page 6-23...
  • Page 180 The LCD changes as shown in (d) ---> (e) 39 FACTORY MODE (f ) Press the Media key again to return to FACTORY DP CHECK MODE. The LCD changes as shown in (e) ---> (f) Page 6-24 magicolor 6100 Series Service Manual...
  • Page 181 Press the Media key one more time to return to FACTORY MODE. 44 LIFE PERIOD The LCD changes as shown in (g) ---> (h) No.=< 1 2 3 4 5 6 7 8 9 > magicolor 6100 Series Service Manual Page 6-25...
  • Page 182 Table 6-17: NVRAM Tune Up Menu NVRAM TUNE UP LP TUNE UP THV TUNE UP DBV TUNE UP DVM TUNE UP CBV TUNE UP FBV TUNE UP REG TUNE UP VDO TUNE UP ACV TUNE UP Page 6-26 magicolor 6100 Series Service Manual...
  • Page 183 45 NVM TUNE UP Press the Media key to complete the tune-up work. (f ) No.=< 1 2 3 4 5 6 7 8 9 > The LCD changes as shown in (e) ---> (f) magicolor 6100 Series Service Manual Page 6-27...
  • Page 184 Press the Media key to end this procedure. 45 NVM TUNE UP (f ) The LCD changes as shown in (e) ---> (f) No.=< 1 2 3 4 5 6 7 8 9 > Page 6-28 magicolor 6100 Series Service Manual...
  • Page 185 45 NVM TUNE UP Press the Media key to finish this procedure. (f ) No.=< 1 2 3 4 5 6 7 8 9 > The LCD changes as shown in (e) ---> (f) magicolor 6100 Series Service Manual Page 6-29...
  • Page 186 The LCD changes as shown in (c) 45 NVM TUNE UP No.=< 1 2 3 4 5 6 7 8 9 > Press the Media key to complete this procedure. The LCD changes as shown in (c) ---> (d) Page 6-30 magicolor 6100 Series Service Manual...
  • Page 187 45 NVM TUNE UP No.=< 1 2 3 4 5 6 7 8 9 > Press the Media key to wrap up the tune-up work for FBV. The LCD changes as shown in (c) ---> (d) magicolor 6100 Series Service Manual Page 6-31...
  • Page 188 -< 4 3 2 1 0 1 2 3 4 >+ Press the Media key to complete this procedure. 45 ACV TUNE UP The LCD changes as shown in (c) ---> (d) No.=< 1 2 3 4 5 6 7 8 9 > Page 6-32 magicolor 6100 Series Service Manual...
  • Page 189 39 FACTORY MODE 45 NVRAM TUNE UP 47 TOTAL PAGE SET DP CHECK 48 EACH IMAGE SET 49 NEXT LIFE SET When setting NVRAM TUNE UP, LP TUNE UP should be set at “+4”. magicolor 6100 Series Service Manual Page 6-33...
  • Page 190 SET displayed in the LCD, and then press the Select key to select the value. 39 FACTORY MODE The LCD changes as shown in (c) ---> (d) DP CHECK Page 6-34 magicolor 6100 Series Service Manual...
  • Page 191 Y / M / C / K Press the Media key to exit from the EACH IMAGE SET 39 FACTORY MODE mode. DP CHECK The LCD changes as shown in (d) ---> (e) magicolor 6100 Series Service Manual Page 6-35...
  • Page 192 No.=< 1 2 3 4 5 6 7 8 9 > Press the Media key to complete the procedure of NEXT 39 FACTORY MODE LIFE SET. DP CHECK The LCD changes as shown in (e) ---> (f) Page 6-36 magicolor 6100 Series Service Manual...

  • Page 193: Adjustment Procedures

    4. If the specification value is not met, implement the following adjust- ment. Execute “43 MARGIN ADJUST” in the FACTORY MODE. 5. After the above adjustment, execute “GRID PRINT” and confirm the margin. Leading Edge Left margin Imageable Area Fig. 6-4 magicolor 6100 Series Service Manual Page 6-37...
  • Page 194 Confirm if measurements meet the specification value. (C+D)/2 < Default Value ð3.0 ±1.5mm. If measurements do not meet the specification value, imple- ment the Adjustment Method described in section 6.5.1.4. Guaranteed Left margin Print Area Fig. 6-5 Page 6-38 magicolor 6100 Series Service Manual...
  • Page 195 1. Make the adjustment in Normal Mode. See the Operation Manual for complete instructions. 2. Make the adjustment in Service Mode (for authorized service person- nel only). This manual explains about the “adjustment from the oper- ator panel” as follows: magicolor 6100 Series Service Manual Page 6-39...
  • Page 196 Is the left margin 3.0 ± 0.5 ? Execute "Left3" (left margin adjustment) in Factory Mode, 43 Margin Adjust. Is the left margin 3.0 ± 0.5 ? Adjustment of left margin is complete. Page 6-40 magicolor 6100 Series Service Manual...
  • Page 197 CBV TUNE UP Adjustment of OPC belt bias Development efficiency Adjustment of cleaning FBV TUNE UP Drum cleaning efficiency roller bias Adjustment of paper ACV TUNE UP Drum jam prevention discharging output bias magicolor 6100 Series Service Manual Page 6-41...
  • Page 198 1. Execute 48 EACH IMAGE in the Factory Mode. 2. Reset the number of printouts for each color. 3. Execute 35 EACH IMAGE to confirm that the desired number of images is now set. Page 6-42 magicolor 6100 Series Service Manual...
  • Page 199 Total Print Count LFU PAGE SET Print Count from LFU DPL PAGE SET Print Count from Duplex EACH IMAGE SET Formed Image Count of 4 Colors NEXT LIFE SET Print Count for Maintenance Replacement Parts magicolor 6100 Series Service Manual Page 6-43...
  • Page 200 Page 6-44 magicolor 6100 Series Service Manual...

  • Page 201: Replacement Procedures

    Section 7: Replacement Procedures magicolor 6100 Series Service Manual Page 7-1...
  • Page 202 Page 7-2 magicolor 6100 Series Service Manual...
  • Page 203 8. Confirm that all the parts and covers are installed or assembled properly prior to start- ing the test run after replacement of the maintenance parts. 9. When handling any P.W.B. use ESD precautions. NOTE: See section 8.0 “Troubleshooting,” and section 9.0, “Spare Parts Break- down,” for reference. magicolor 6100 Series Service Manual Page 7-3...
  • Page 204 F3 x 6 head screw with 6 mm flange Cross-recessed F4 x 6 head screw with 6 mm For fuser flange Cross-recessed FST3 x 10 head S tight screw 10 mm For fuser with flange Page 7-4 magicolor 6100 Series Service Manual...

  • Page 205: Replacement Of Covers

    Cover 7.1.10 Rear View Left-upper Side Cleaner Cover Cover 7.1.12 7.1.1 Left Side Upper Rear Cover Cover 7.1.3 7.1.9 Transfer Unit Left Base Door Cover Cover 7.1.7 7.1.11 Rear Cover 7.1.8 Fig. 7-2 magicolor 6100 Series Service Manual Page 7-5...
  • Page 206 3. By pressing the exterior of the left side cover, unlatch the three inter- locks from the Left-upper side cover. Left-upper Side Cover PUSH Interlock Left Side Cover Fig. 7-3 Fig. 7-4 7.1.1.3 Assembly Procedures 1. Assemble the left-upper side cover in reverse order of disassembly. Page 7-6 magicolor 6100 Series Service Manual...
  • Page 207 3. Slide the right side cover to the arrow direction (see Fig. 7-6). 4. Remove the right side cover. Right Side Cover Right Side Cover Fig. 7-6 Fig. 7-5 7.1.2.3 Assembly Procedures 1. Reinstall the right side cover in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-7...
  • Page 208 4. Remove the left side cover. Slowly pull up the left side cover, and unhook the hook from the top cover. Top Cover Left-front Side Cover Fig. 7-7 7.1.3.3 Assembly Procedures 1. Reinstall the left side cover in reverse order of disassembly. Page 7-8 magicolor 6100 Series Service Manual...
  • Page 209 6. Pulling the left front side cover upward, remove the hook from the frame. 7. Remove the left front side cover. Left-front Side Cover Fig. 7-8 7.1.4.3 Assembly Procedures 1. Reinstall in the reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-9...
  • Page 210 4. Remove two screws (BT4X10) (upper side and at right side) from the left side cover. 5. Remove the top cover. Left Upper Side Cover Top Cover Fig 7-9 7.1.5.3 Assembly Procedures 1. Reinstall the top cover in reverse order of disassembly. Page 7-10 magicolor 6100 Series Service Manual...
  • Page 211 6. Remove the paper exit cover assembly from the paper exit unit. 7.1.6.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Paper Exit Top Cover Paper Exit Cover Assembly Paper Exit Front Cover Paper Exit Frame Assembly Fig. 7-10 magicolor 6100 Series Service Manual Page 7-11...
  • Page 212 5. Remove four fixing screws (BT3x8) from the back cover. 6. Remove the back cover from the transfer unit. 7.1.7.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Transfer Door Transfer Unit Cover Fixing Screw Fig. 7-11 Page 7-12 magicolor 6100 Series Service Manual...
  • Page 213 1. Unplug the power cable. 2. Remove one set screw (BT4x10) from the rear cover. 7.1.8.3 Assembly Procedures 1. Install a new rear cover. 2. Plug in the power cable. Rear Cover Power Cable Fig. 7-12 magicolor 6100 Series Service Manual Page 7-13...
  • Page 214 5. Remove two hooks from the Upper-rear cover. 6. Remove the Upper-rear cover. 7.1.9.3 Assembly Procedures 1. Install a new upper rear cover. 2. Reassemble in reverse order of disassembly. Hooks Upper Rear Cover Right Side Cover Fig. 7-13 Page 7-14 magicolor 6100 Series Service Manual...
  • Page 215 (left and right) of the base plate (see Fig. 7-15). Join the projecting part of right base cover Base Plate meet the 3 hole locations in the base plate bottom (see Fig. 7-15). Projecting Part Hole Right Base Cover Hook Fig. 7-15 magicolor 6100 Series Service Manual Page 7-15...
  • Page 216 (left and right) of the base plate (see Projecting Part Fig. 7-17). Join the projecting part of left base cover to the 3 hole locations in the base plate bot- Left Base tom (see Fig. 7-17). Cover Hook Fig. 7-17 Page 7-16 magicolor 6100 Series Service Manual...
  • Page 217 (see Fig. 7-18) 1. Open the top door. 2. Holding the tabs, remove the cleaner cover. 7.1.12.3 Assembly Procedures 1. Install a new cleaner cover. 2. Close the top door. Cleaner Cover Fig. 7-18 magicolor 6100 Series Service Manual Page 7-17...
  • Page 218 7.1.13.3 Assembly Procedures 1. Install the front cover to the front frame unit. 2. Attach the front cover with the two screws. Front Cover Front Inner Cover Fig. 7-19 Fig. 7-20 Page 7-18 magicolor 6100 Series Service Manual...

  • Page 219: Replacement Of Printed Wire Boards (P.w.b)

    Replacement of Printed Wire Boards (P.W.B) Layout of Printed Wire Boards Erase Lamp Panel P.W.B. 7.2.4 IOD2 P.W.B. 7.2.3 High Voltage IOD1 P.W.B. Power Supply 7.2.2 7.2.6 MCTL P.W.B. 7.2.1 Low Voltage Power Supply 7.2.5 Fig. 7-21 magicolor 6100 Series Service Manual Page 7-19...
  • Page 220 7. Confirm the operation and print quality by implementing the test print. 8. Input the previous information (before replacement) to the RAM of MCTL P.W.B. as necessary (see section 6.4 for the details). Page 7-20 magicolor 6100 Series Service Manual...
  • Page 221 Left-upper Side Cover Left Side Cover Shield Cover B Shield Case A Assembly MCTL P.W.B. Fig. 7-22 magicolor 6100 Series Service Manual Page 7-21...
  • Page 222 5. Execute the test print in Service Mode. 6. Confirm the operation and print quality of printer. CAUTION When replacing the IOD1 P.W.B, pay attention that no damage is caused by electrostatic charge. Page 7-22 magicolor 6100 Series Service Manual...
  • Page 223 Left-upper Side Cover Top Cover Upper Shield Cover Connecters IOD1 P.W.B Fig. 7-23 magicolor 6100 Series Service Manual Page 7-23...
  • Page 224 1. Reinstall in reverse order of disassembly. 2. Connect the power supply cable. 3. Turn on the power supply switch of printer. 4. Run the test print in the service mode. 5. Confirm the printer operation and print quality. Page 7-24 magicolor 6100 Series Service Manual...
  • Page 225 Right Side Cover IOD2 P.W.B. Fig. 7-24 magicolor 6100 Series Service Manual Page 7-25...
  • Page 226 4. Install the panel case to the top cover. 5. Connect the power supply cable. 6. Turn on the power switch of the printer. 7. Execute the test print in Service Mode. 8. Confirm the panel switch and indicator. Page 7-26 magicolor 6100 Series Service Manual...
  • Page 227 Left-upper Side Cover Panel Case LCD Cover Panel Button Shield Plate Panel P.W.B Panel Shield Plate Top Cover Left-upper Side Cover Fig. 7-25 magicolor 6100 Series Service Manual Page 7-27...
  • Page 228 1. Reinstall the LVPS in reverse order of disassembly 2. Confirm the ground wire is connected to the frame. 3. Connect the power supply cable. 4. Turn the power supply switch On. 5. Confirm the print operation and print quality. Page 7-28 magicolor 6100 Series Service Manual...
  • Page 229 Shield Cover A Left Side Cover Control Fan Assembly Shield Cover B Shield Cover F Shield Case A Assembly (Front Side) (Rear Side) Back Cover Low Voltage Power Supply Left Base Cover Fig. 7-26 magicolor 6100 Series Service Manual Page 7-29...
  • Page 230 The High Voltage Power Supply generates high voltage (5kV). You may get shocked if you touch the unit while it is powered on. Therefore, turn on the unit only after hav- ing installed the left side cover. Page 7-30 magicolor 6100 Series Service Manual...
  • Page 231 Shield Cover A Left Side Cover Control Fan Assembly Shield Cover B Shield Case A Assembly High Voltage Power Supply High Voltage Power Supply (Front Side) (Rear Side) Back Cover LVPS Fig. 7-27 magicolor 6100 Series Service Manual Page 7-31...
  • Page 232 CAUTION The erase lamp has directional characteristics. If it is installed in the wrong direction, the transfer drum may be damaged. Right Side Left Side (as viewed from the front side) Fig. 7-29 Page 7-32 magicolor 6100 Series Service Manual...
  • Page 233 Replacement of Motor Units Layout of Motors Ozone Fan 7.3.8 Heater Fan 7.3.7 Main Motor 7.3.1 Developer Drive Controller Fan Motor 7.3.6 Scanner Motor 7.3.5 Fig. 7-30 magicolor 6100 Series Service Manual Page 7-33...
  • Page 234 7. Remove the main motor from the main motor assembly. Separate the motor and BD Gear Unit. 7.3.1.3 Assembly Procedures 1. Install the main motor assembly to the engine frame. 2. Reassemble in reverse order of disassembly. Page 7-34 magicolor 6100 Series Service Manual...
  • Page 235 Top Cover Right Side Cover BD Gear Assembly Main Motor Main Motor Assembly Fig. 7-31 magicolor 6100 Series Service Manual Page 7-35...
  • Page 236 6. Remove four set screws (ST3x6) from the main drive unit. 7. Remove the main gear unit from the frame. 7.3.2.3 Assembly Procedures 1. Install the main drive unit on the engine frame. 2. Reassemble in reverse order of disassembly. Page 7-36 magicolor 6100 Series Service Manual...
  • Page 237 Top Cover Right Side Cover BD Gear Assembly Main Motor Main Gear Unit IOD2 P.W.B. Fig. 7-32 magicolor 6100 Series Service Manual Page 7-37...
  • Page 238 3. Disconnect one connector (CN1) from the developer motor P.W.B. 4. Remove four fixing screws (ST3x6) from the developing motor. 5. Remove the developing motor from the developer driving unit. 7.3.3.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-38 magicolor 6100 Series Service Manual...
  • Page 239 Developer Clutch Developer Developer Motor Gear Unit Fig. 7-33 magicolor 6100 Series Service Manual Page 7-39...
  • Page 240 (ST3x6) from the MD stopper. 10. Remove the developer gear unit from the frame. 7.3.4.3 Assembly Procedures 1. Install the clutches and cam clutches to the developer gear unit. 2. Reassemble in reverse order of disassembly. Page 7-40 magicolor 6100 Series Service Manual...
  • Page 241 Cover RF Bottom Stay (R) Developer Clutch Developer Gear Unit Developer Motor Front Stay (R) MD Stopper Bottle Holder MD Stopper Fig. 7-34 magicolor 6100 Series Service Manual Page 7-41...
  • Page 242 The optical unit is replaced as a whole unit; no adjust- ment is required. Confirm that all the covers have been installed before testing or operating the printer. This will prevent acciden- tal laser exposure. Page 7-42 magicolor 6100 Series Service Manual...
  • Page 243 Laser WARNING Label Hook Optical Unit Fig. 7-35 magicolor 6100 Series Service Manual Page 7-43...
  • Page 244 Ozone Filter PS Fan Motor Fan Case Interlock Switch Exhaust Side Fig. 7-36 Fig. 7-37 7.3.6.3 Assembly Procedures 1. Install the fan motor into the fan case. 2. Reassemble in reverse order of disassembly. Page 7-44 magicolor 6100 Series Service Manual...
  • Page 245 Fan Motor Ozone Filter Paper Exit Fuser Fan Frame Ass'y Case Exhaust Side Fig. 7-38 CAUTION: When installing the fan motor, make sure the label of the motor faces towards the exhaust side. magicolor 6100 Series Service Manual Page 7-45...
  • Page 246 Waster Toner Feeder Pipe Stay (R) Exhaust Side Ozone Fan Ozone Fan Ozone Fan Case Case A'ssy Ozone Fan Duct Exhaust Side Fig. 7-40 Fig. 7-39 7.3.8.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-46 magicolor 6100 Series Service Manual...
  • Page 247 Cleaner Clutch (FBCL)7.4.1 Transfer Cam Clutch (TRCM) 7.4.1 Registration Clutch (RECL) 7.4.1 Paper Feed Clutch (PCLU) 7.4.2 Black Developer Clutch 7.4.3 Yellow Developer Clutch 7.4.3 Magenta Developer Clutch 7.4.3 Cyan Developer Clutch 7.4.3 Fig. 7-41 magicolor 6100 Series Service Manual Page 7-47...
  • Page 248 Fuser Clutch (FUCL) Cleaner Clutch (FBCL) TR Cam Clutch (TRCM) Clutch Washer Registration Clutch (RECL) Fig. 7-42 7.4.1.3 Assembly Procedures 1. Install new clutches at the appropriate locations. 2. Reassemble in reverse order of disassembly. Page 7-48 magicolor 6100 Series Service Manual...
  • Page 249 Registration Clutch Paper Feeding Clutch Fig. 7-43 7.4.2.3 Assembly Procedures 1. Install the new paper feeding clutch onto the shaft. 2. Install the washer onto the shaft. 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-49...
  • Page 250 1. Prepare a new clutch. This clutch is common for all four colors. 2. Install the new clutch to the appropriate location. 3. Install the washer onto the shaft. 4. Reassemble in reverse order of disassembly. Page 7-50 magicolor 6100 Series Service Manual...
  • Page 251 Drum Encoder Sensor 7.5.10 Paper Feed Sensor PT1 Waste Toner Sensor 7.5.4 7.5.12 Paper Empty Sensor 7.5.6 Interlock Switch (Front) 7.5.1 Paper Size Sensor Toner Key Sensor 7.5.7 7.5.16 OHP Sensor 7.5.6 Fig. 7-45 magicolor 6100 Series Service Manual Page 7-51...
  • Page 252 3. Remove the switch from the switch base. Switch Base Interlock Switch Fig. 7-46 7.5.1.3 Assembly Procedures 1. Install the new switch onto the switch base. 2. Reassemble in reverse order of disassembly. Page 7-52 magicolor 6100 Series Service Manual...
  • Page 253 Fan Case A Interlock Switch Fan Case B Fig. 7-47 7.5.2.3 Assembly Procedures 1. Assemble the new switch onto the controller case. 2. Install the actuator lever. 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-53...
  • Page 254 1. Install a new interlock switch to the transfer electrode base. 2. Reassemble in reverse order of disassembly. CAUTION: The interlock switch is important for safety. After instal- lation, verify that the switch operates normally. Page 7-54 magicolor 6100 Series Service Manual...
  • Page 255 Paper Guide 7.5.4.3 Assembly Procedures 1. Install a new paper feeding sensor to the feeder stay. 2. Connect the harness connectors to the paper feeding sensor. 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-55...
  • Page 256 Release Arm Fig. 7-50 7.5.5.3 Assembly Procedures 1. Install a new paper sensor (PT2) onto the paper guide. 2. Connect the harness connector to the paper sensor. 3. Reassemble in reverse order of disassembly. Page 7-56 magicolor 6100 Series Service Manual...
  • Page 257 Paper Guide Fig. 7-51 7.5.6.3 Assembly Procedures 1. Install a new paper empty sensor (PE) or a new OHP sensor (OHP) onto the upper-left paper guide. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-57...
  • Page 258 4. Disconnect all the connectors from the paper size sensor. 5. Remove the paper size sensor. Transfer Unit Paper Size Sensor Paper Guide Fig. 7-52 7.5.7.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-58 magicolor 6100 Series Service Manual...
  • Page 259 8. Disconnect all the connectors from the drum jam sensor. 9. Remove the drum jam sensor from the stay B. Drum Jam Sensor (DPJ) Fig. 7-53 7.5.8.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-59...
  • Page 260 4. Remove two set screws (ST3x6) from the oil sensor. 5. Remove the oil sensor. Oil Sensor Fig. 7-54 7.5.9.3 Assembly Procedures 1. Install a new oil sensor. 2. Reassemble in reverse order of disassembly. Page 7-60 magicolor 6100 Series Service Manual...
  • Page 261 Paper Exit Frame Ass'y Drum Encoder Sensor EN Sensor Holder Fig. 7-55 7.5.10.3 Assembly Procedures 1. Install a new drum encoder sensor onto the sensor holder. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-61...
  • Page 262 Fig. 7-56 7.5.11.3 Assembly Procedures 1. Assemble the new belt marker sensor to the PBS Base. 2. Connect the harness connector with the belt marker sensor. 3. Reassemble in reverse order of disassembly. Page 7-62 magicolor 6100 Series Service Manual...
  • Page 263 5. Remove the bottle holder (see section 7.3.4.2[6]) (LED) (TR) Waste Toner Sensor Bottle Holder Waste Toner Bottle Fig. 7-57 7.5.12.3 Assembly Procedures 1. Prepare a new bottle holder. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-63...
  • Page 264 3. Remove the low voltage power supply (LVPS) (see sec- tion 7.2.5). 4. Remove three set screws (ST3x6) of toner sensor P.W.B. 5. Disconnect the connector from the TTR toner sensor P.W.B. 6. Remove the toner sensor P.W.B. Page 7-64 magicolor 6100 Series Service Manual...
  • Page 265 3. Reassemble in reverse order of disassembly. 7.5.13.3.2 TTR 1. Connect the connector to the new TTR toner sensor P.W.B. 2. Install the toner sensor P.W.B. to the engine frame (L). 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-65...
  • Page 266 1. Install the sensor onto the base. 2. Connect the harness connectors to the cleaning roller sensor. 3. Confirm that hooks a, b, and c are hooked firmly onto the sensor base. 4. Reassemble in reverse order of disassembly. Page 7-66 magicolor 6100 Series Service Manual...
  • Page 267 5. Remove the paper full sensor. Unhook the installation base, and remove the switch. Paper Full Sensor Harness Cover Paper Exit Frame Fig. 7-60 7.5.15.3 Assembly Procedures 6. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-67...
  • Page 268 6. Remove four set screws (ST3x6) from the toner key sensor. 7. Remove the toner key sensor. Toner Key Sensor Fig. 7-61 7.5.16.3 Assembly Procedures 1. Install the new toner key sensor. 2. Reassemble in reverse order of disassembly. Page 7-68 magicolor 6100 Series Service Manual...

  • Page 269: Replacement Of Rollers, Drums, And Other Components

    Put the transfer unit shaft in the hole on the left side (viewed from the front). b. Sliding the transfer unit towards the left, put the right side of the shaft into the hole. magicolor 6100 Series Service Manual Page 7-69...
  • Page 270 1. Install the new registration roller into the hole of the transfer unit frame. 2. Install a bearing on each end. 3. Install the gear on the right side. 4. Install the fixing washer and the bearing. Page 7-70 magicolor 6100 Series Service Manual...
  • Page 271 4. Install the stay ‘A’ assembly. 5. Reassemble in reverse order of disassembly. CAUTION: Do not touch the transfer drum surface with your bare hands. Do not scratch the surface of the drum. magicolor 6100 Series Service Manual Page 7-71...
  • Page 272 Separator Pad Transfer Unit Paper Guide(UL) Fig. 7-65 CAUTION: Do not touch the surface of the new paper feed roller and separator pad. 7.6.4.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-72 magicolor 6100 Series Service Manual...
  • Page 273 3. Open the front door, and install the hinge support to the frame. 4. Tighten the remaining screws (2 locations at left and right sides) to the front cover unit supports. 5. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-73...
  • Page 274 5. Remove the paper exit cover (see section 7.1.6). 6. Remove the fixing washers at both ends. 7. Remove the bearings from both ends. 8. Remove the paper exit roller from the frame. Support Pin (SP4X3, 2 pcs.) Fig. 7-67 Page 7-74 magicolor 6100 Series Service Manual...
  • Page 275 3. Install the left and right bearings on the paper exit roller shaft. 4. Mount the bearings onto the frame. 5. Install the washers on the left and right side of the paper exit roller. 6. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-75...
  • Page 276 Fig. 7-68 7.6.7.3 Assembly Procedures 1. Install the new discharger brush into the paper exit unit. 2. Reassemble in reverse order of disassembly. CAUTION: Do not damage the bristles of the discharger brush. Page 7-76 magicolor 6100 Series Service Manual...
  • Page 277 8. Remove the set screw (ST4x6) of stay 'A'. 9. Pull up the stay 'A' assembly along the guide. Stay 'A' Assembly Fig. 7-69 7.6.8.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-77...
  • Page 278 6. Remove the fuser connector. Fuser Connector BCN2 Frame Assembly Fig. 7-70 7.6.9.3 Assembly Procedures 1. Install a new fuser connector. 2. Reassemble in reverse order of disassembly. Page 7-78 magicolor 6100 Series Service Manual...
  • Page 279 7. Pull out the toner drive assembly toward you. Ozone Duct Assembly Main Gear Unit Toner Drive Assembly Fig. 7-71 7.6.10.3 Assembly Procedures 1. Install the toner drive assembly to the engine frame. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-79...

  • Page 280: Replacement Of The Fuser

    Thermal Cut Off Thermal Cut Off D125 D115 Tube Tube Fuser Connector P Back-up Roller Fuser Heater (420W) Fuser Roller Fuser Heater (560W) Tube T. Adjustment P.W.B Thermister Fig. 7-72 Page 7-80 magicolor 6100 Series Service Manual...
  • Page 281 Wattages for the heater lamps are different between the fuser roller side and back-up roller side. Each wattage is marked on the insulator of the lamp’s electrode: Fuser roller side: 560W Back-up roller side: 420W magicolor 6100 Series Service Manual Page 7-81...
  • Page 282 F Cover (R) Fuser Unit Fig. 7-73 7.7.2.3 Assembly Procedures 1. Prepare a new oil pan unit. 2. Install the new oil pan unit onto the fuser. 3. Reassemble in reverse order of disassembly. Page 7-82 magicolor 6100 Series Service Manual...

  • Page 283: Duplexer Replacement Procedures

    S Tight Screw Sheet Metal Cross-Recessed-Head- M4X30 4X30 Tapping Screw (Pan M4X6 Frame Head) Flat Head Tapping FT3X10 3X10 Plastic Screw Cross-Recessed-Head- BT4X10 4X10 Bottom Cover Tapping Screw Cross-Recessed-Head- M4X8 M4X8 Frame Tapping with washer magicolor 6100 Series Service Manual Page 7-83...
  • Page 284 (see Fig. 7-74) 1. Remove two set screws (TS4x8) from the lower-right cover. 2. Remove the lower-right cover from the duplexer. Lower-right Cover Fig. 7-74 7.8.1.1.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-84 magicolor 6100 Series Service Manual...
  • Page 285 1. Remove two set screw (ST4x8) from the lower-left cover. 2. Remove the lower-left cover from the duplexer. Lower-left Cover Fig. 7-75 7.8.1.2.3 Assembly Procedures 1. Install the new lower-left cover. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-85...
  • Page 286 1. Remove two set screws (ST4x8) from the top-right cover. 2. Remove the top-right cover from the duplexer. Top-right Cover Fig. 7-76 7.8.1.3.3 Assembly Procedures 1. Install the new top-right cover. 2. Reassemble in reverse order of disassembly. Page 7-86 magicolor 6100 Series Service Manual...
  • Page 287 1. Remove the lower-left cover (see section 7.8.1.2). 2. Remove two set screws (ST4x8) from top-left cover. 3. Remove the top-left cover from the duplexer. Cover Top (L) Fig. 7-77 7.8.1.4.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-87...
  • Page 288 3. Remove three set screws (TS3x8) from the top-rear cover paper guide. 4. Remove the top-rear cover paper guide from the top-rear cover. Top-rear Cover Top-rear Cover Fig. 7-79 Fig. 7-78 7.8.1.5.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-88 magicolor 6100 Series Service Manual...
  • Page 289 (see Fig. 7-80 and Fig. 7-81) 1. Remove four set screws (TS3x8) from the top cover. 2. Remove the top cover. Fig. 7-81 Fig. 7-80 7.8.1.6.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-89...
  • Page 290 2. Remove four set screws (TS3x8) from lower-rear cover. 3. Remove the lower-rear cover from the hinge metal fix- ture. Paper Guide RVS Lower-rear Cover Lower-rear Cover Fig. 7-83 Fig. 7-82 7.8.1.7.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-90 magicolor 6100 Series Service Manual...
  • Page 291 4. Remove the harness inside the bottom cover. 5. Remove the bottom cover from the base. Harness Cover Lower-rear Cover Bottom Bottom Cover Cover Fig. 7-85 Fig. 7-84 7.8.1.8.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-91...
  • Page 292 8. Remove the harness connected with the connector CN2 of Relay P.W.B. Reverse Paper Reverse Paper Guide Guide Reverse Input Paper Guide Lower-rear Cover Paper Guide Bottom Fig. 7-87 Fig. 7-86 7.8.1.9.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-92 magicolor 6100 Series Service Manual...
  • Page 293 4. Remove the reverse input paper guide. Reverse Paper Guide Reverse Input Paper Guide Reverse Input Paper Guide Reverse Paper Guide Fig. 7-89 Fig. 7-88 7.8.1.10.2 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-93...
  • Page 294 3. Remove two set screws (ST3x6) from the bottom paper guide. 4. Remove the bottom paper guide. Bottom Paper Guide Reverse Paper Guide Fig. 7-90 7.8.1.11.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-94 magicolor 6100 Series Service Manual...
  • Page 295 4. Remove one set screw (M4x) support pin from both sides. 5. Separate the top unit from the lower unit. D-Shaped Hole Top Unit Lower Unit Fig. 7-92 Fig. 7-91 7.8.2.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-95...
  • Page 296 3. Remove four set screws (ST3x6) from the Duplexer P.W.B. 4. Remove the Duplexer P.W.B. Duplexer P.W.B. Bottom Paper Guide Fig. 7-94 Fig. 7-93 7.8.3.1.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-96 magicolor 6100 Series Service Manual...
  • Page 297 3. Remove four set screws (ST3x6) from the Relay P.W.B. 4. Remove the Relay P.W.B. Bottom Paper Guide Relay P.W.B Fig. 7-96 Fig. 7-95 7.8.3.2.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-97...
  • Page 298 6. Remove two set screws (ST3x6) from the motor (1). 7. Remove the motor (1) from the frame. Motor (1) Motor (1) Fig. 7-98 Fig. 7-97 7.8.4.1.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-98 magicolor 6100 Series Service Manual...
  • Page 299 4. Remove the protective cover. 5. Remove two set screws (ST3x6) from the motor (2). 6. Remove the motor (2) from the frame. Motor (2) Fig. 7-99 7.8.4.2.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-99...
  • Page 300 5. Remove two set screws (M4x30, 2 pcs.) from the fan. 6. Remove the Fan Motor from the frame. Fan Motor Fig. 7-100 7.8.4.3.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-100 magicolor 6100 Series Service Manual...
  • Page 301 4. Remove the harness from the clamp. 5. Remove two set screws (ST3x6) from the upper solenoid assembly. Upper Solenoid Assembly Fig. 7-101 7.8.5.1.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-101...
  • Page 302 Relay P.W.B Harness Fig. 7-102 CAUTION: Put the Actuator in the hole of the Switching Shutter L while assembling the Lower Solenoid Assembly. 7.8.5.2.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-102 magicolor 6100 Series Service Manual...
  • Page 303 Switch 1 Switch 2 Fig. 7-103 7.8.6.1.3 Assembly Procedures 1. Attach the harness connector to the new interlock switch. 2. Attach the interlock switch to the frame. 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-103...
  • Page 304 3. Remove the harness connector from the appropriate interlock switch. Switch 3 Switch 4 Fig. 7-104 7.8.6.2.3 Assembly Procedures 1. Connect the harness connector. 2. Attach the appropriate interlock switch to the frame. 3. Reassemble in reverse order of disassembly. Page 7-104 magicolor 6100 Series Service Manual...
  • Page 305 Sensor Cover Paper Sensor Fig. 7-105 7.8.6.3.3 Assembly Procedures 1. Attach and connect the new Paper Sensor PT5 to the reverse paper guide unit. 2. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-105...
  • Page 306 4. Remove the Paper Sensor Low from the bottom paper guide assembly. Bottom Paper Guide (Botttom View) Paper Sensor Low PT4 Bottom Paper Guide Fig. 7-107 Fig. 7-106 7.8.6.4.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-106 magicolor 6100 Series Service Manual...

  • Page 307: Replacement Of Lower Feed Unit Parts

    3. Remove the paper guide assembly (PGA) by removing the set screw (ST3x6). 4. Disconnect the Paper Sensor connector. 5. Remove the Paper Sensor by removing two set screws (ST3x6). Paper Sensor Fig. 7-108 7.9.1.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-107...
  • Page 308 (ST3x6). 4. Disconnect the paper size sensor connector. 5. Remove the paper size sensor. Paper Size Sensor Fig. 7-109 7.9.2.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-108 magicolor 6100 Series Service Manual...
  • Page 309 (ST4x10 (1 pc.). b. Remove two set screws (TS4x10). c. Lift the right base cover straight up so that it comes out of the adjuster base pin smoothly, and then remove the right base cover. magicolor 6100 Series Service Manual Page 7-109...
  • Page 310 Paper Feeder Clutch Fig. 7-111 7.9.3.3 Assembly Procedures 1. Install the paper transportation clutch. 2. Install the paper feeder clutch. 3. Reassemble in reverse order of disassembly. Page 7-110 magicolor 6100 Series Service Manual...
  • Page 311 6. Remove the Separator Pad. Separator Pad Paper Feeder Roller Fig. 7-112 7.9.4.3 Assembly Procedures 1. Install the new Separator Pad. 2. Install the new Paper Feeder Roller. 3. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-111...
  • Page 312 2. Remove the LFU paper guide by removing four set screws (ST3x6). 3. Disconnect the switch connector. 4. Remove the switch by removing one set screw (ST3x16). Interlock Switch Interlock Switch Fig. 7-113 7.9.5.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. Page 7-112 magicolor 6100 Series Service Manual...
  • Page 313 3. Disconnect five connectors from the IOD3 P.W.B. assembly. 4. Remove the IOD3 P.W.B. Assembly by removing four set screws (ST3x6). IOD3 PWB Assembly Fig. 7-114 7.9.6.3 Assembly Procedures 1. Reassemble in reverse order of disassembly. magicolor 6100 Series Service Manual Page 7-113...
  • Page 314 Page 7-114 magicolor 6100 Series Service Manual...

  • Page 315: Troubleshooting

    Section 8: Troubleshooting magicolor 6100 Series Service Manual Page 8-1...
  • Page 316 Page 8-2 magicolor 6100 Series Service Manual...

  • Page 317: Troubleshooting Outline

    Power cycle printer. Problem solved? Operator Call Other Printer Imaging Failure Section 8.2 Error Code Section 8.5 Paper Transport Error Printer Error Power Failure Section 8.3 Section 8.4 Check power source and cable. Fig. 8-1 magicolor 6100 Series Service Manual Page 8-3...

  • Page 318: Operator Call Error Codes

    The x (color) toner is low. There Redistribute the toner in the is enough toner left to print x TONER LOW cartridge, or replace the approximately 100 pages before cartridge. the printer stops. Page 8-4 magicolor 6100 Series Service Manual...
  • Page 319 Media has jammed in the DRUM JAM Locate and remove the jam. transfer drum area. Media has jammed in the Locate and remove the jam. DUPLEX JAM duplexer. magicolor 6100 Series Service Manual Page 8-5...
  • Page 320 The printer is on line, but no normal operation modes. IDLE jobs are in process. The printer is on line and printing jobs already in the INPUT IDLE PRINTING queue. No new jobs are arriving at the communication interfaces. Page 8-6 magicolor 6100 Series Service Manual...
  • Page 321 8-10 FUSER OIL LOW/EMPTY 8-11 CHECK CLEANING ROLLER MISPRINT 8-12 PAPER/NOPRQ/MEDIA/DUPLEX 8-13 ALIGN TONER CG Y/M/C/K 8-14 ALIGN FU UNIT 8-15 ALIGN BELT CG 8-16 ALIGN FUSER CL ROLLER 8-17 ALIGN TR ROLLER magicolor 6100 Series Service Manual Page 8-7...
  • Page 322 Error Message 8-18 ALIGN LFU 8-19 MISFEED JAM 8-20 INNER JAM 8-21 OUTER JAM 8-22 DRUM JAM 8-23 DUPLEX JAM 8-24 CLOSE PANEL FRONT/TOP 8-25 REAR DOOR OPEN 8-26 DUPLEX UNIT PANEL OPEN Page 8-8 magicolor 6100 Series Service Manual...
  • Page 323 Replace Paper Sensor (PE). Is Error Code 11 cleared ? Replace IOD1 P.W.B. Is Error Code 11 cleared ? Check and replace associated wiring and hardware. Is Error Code 11 cleared ? Complete Fig. 8-2 magicolor 6100 Series Service Manual Page 8-9...
  • Page 324 • OHP is not available from the lower paper cassette. • If printing is carried out with the unavailable paper size, "CHECK MEDIA" appears. (For example, 2-UP print mode is set, but the configuration is A3 paper.) Fig. 8-3 Page 8-10 magicolor 6100 Series Service Manual...
  • Page 325 Replace Paper Sensor (PE). Is Error Code 11 cleared ? Replace IOD1 P.W.B. Is Error Code 11 cleared ? Complete Note UPP: Upper cassette LF1 : Lower (1) cassette LF2 : Lower (2) cassette Fig. 8-4 magicolor 6100 Series Service Manual Page 8-11...
  • Page 326 • If the unprintable print mode (out of specification) is set, "CHECK MEDIA FOR DUPLEX" appears. (For example, the configuration is set as Label Stock to be printed by High Speed Mode.) Fig. 8-5 Page 8-12 magicolor 6100 Series Service Manual...
  • Page 327 Replace Paper Size Sensor (PSU) . Is Error Code 12 cleared? Replace IOD1 P.W.B. Is Error Code 12 cleared ? Check and replace associated wiring and hardware. Is Error Code 12 cleared ? Complete Fig. 8-6 magicolor 6100 Series Service Manual Page 8-13...
  • Page 328 Does the lever of exit full sensor operate normally ? Check the harness connection. Replace the sensor. Check the sensor lever. Is the code 12 cleared ? Replace the IOD1 PWB. Complete Fig. 8-7 Page 8-14 magicolor 6100 Series Service Manual...
  • Page 329 "16" ALIGN TONER CG indicated on the panel? Check the Harness Connector and replace the Toner Sensor. Is Error Code 13 cleared ? Check and replace associated wiring and hardware. Is Error Code 13 cleared ? Complete Fig. 8-8 magicolor 6100 Series Service Manual Page 8-15...
  • Page 330 Is the Harness Connector of the Sensor Switch disconnected? Connect the connector. Replace IOD2 P.W.B. Is Error Code 14 cleared ? Check and replace associated wiring and hardware. Is Error Code 14 cleared ? Complete Fig. 8-9 Page 8-16 magicolor 6100 Series Service Manual...
  • Page 331 Is the Fusing Unit properly installed ? Reset the Fusing Unit. Replace the Oil Sensor. Is Error Code 14 cleared ? Check the Harness & Replace IOD1 P.W.B. Is Error Code 14 cleared ? Complete Fig. 8-10 magicolor 6100 Series Service Manual Page 8-17...
  • Page 332 Is the Cleaning Roller Sensor damaged? Replace the Cleaning Roller Sensor. Is Error Code 14 cleared ? Replace IOD1 P.W.B and check the harness. Is Error Code 14 cleared ? Complete Fig. 8-11 Page 8-18 magicolor 6100 Series Service Manual...
  • Page 333 Note • If the paper runs out at the continuous print while the transmission of print data, "MISPRINT" appears. • If different media are mixed in the paper cassette, "MISPRINT" appears. Fig. 8-12 magicolor 6100 Series Service Manual Page 8-19...
  • Page 334 Is the connector of toner sensor TTR side failed ? Replace the P.W.B. TTP/TPD Is the message "16 ALIGN TONER CG Y/M/C/K" cleared ? Replace the P.W.B. IOD1 Is the message "16 ALIGN TONER CG Y/M/C/K" cleared ? Complete Fig. 8-13 Page 8-20 magicolor 6100 Series Service Manual...
  • Page 335 Is the connector damaged ? connector. Confirm the installation of fuser unit. Is the message "16 ALIGN FU UNIT" cleared ? Replace the MCTL P.W.B. Is the message "16 ALIGN FU UNIT" cleared ? Complete Fig. 8-14 magicolor 6100 Series Service Manual Page 8-21...
  • Page 336 Is the connector ECN12 of IOD2 connected with the connector of main motor ? Connect the connector. Replace the main motor. .Is the message "16 ALIGN BELT CG" cleared ? Complete Fig. 8-15 Page 8-22 magicolor 6100 Series Service Manual...
  • Page 337 Confirm the operation after connecting the connector of sensor side. Is the message "16 ALIGN FUSER ROLLER" cleared ? Replace the IOD1 P.W.B. Is the message "16 ALIGN FUSER ROLLER" cleared ? Fig. 8-16 Complete magicolor 6100 Series Service Manual Page 8-23...
  • Page 338 Confirm the installation of transfer roller. Is the message "16 ALIGN TR ROLLER " cleared ? Replace the high voltage power supply unit. Is the message "16 ALIGN TR ROLLER " cleared ? Complete Fig. 8-17 Page 8-24 magicolor 6100 Series Service Manual...
  • Page 339 Is the harness securely connected between Connect the connector. LFU and IOD1 P.W.B. ? Reset the power supply. Is "16 ALIGN LFU" cleared ? Replace the IOD1 P.W.B. Is "16 ALIGN LFU" cleared ? Complete Fig. 8-18 magicolor 6100 Series Service Manual Page 8-25...
  • Page 340 Does PT1 Sensor Lever operate smoothly ? Replace Paper Feeding Roller / Separator Pad. Is Error Code 17 cleared ? Check and replace associated wiring and hardware. Is Error Code 17 cleared ? Complete Fig. 8-19 Page 8-26 magicolor 6100 Series Service Manual...
  • Page 341 Replace the PT1 Sensor Lever. Is Error Code 17 cleared ? Check the Harness of the PT1 Sensor Lever, and Replace the IOD1 P.W.B. Is Error Code 17 cleared ? Complete Fig. 8-20 magicolor 6100 Series Service Manual Page 8-27...
  • Page 342 Does the PT2 Sensor Lever operate smoothly? Replace the PT2 Sensor Lever. Is Error Code 17 cleared ? Check the Harness of the PT2 Sensor and Replace the IOD1 P.W.B. Is Error Code 17 cleared ? Complete Fig. 8-21 Page 8-28 magicolor 6100 Series Service Manual...
  • Page 343 Replace the Drum Jam Sensor. Is Error Code 17 cleared ? Check the Harness and replace if necessary. Is Error Code 17 cleared ? Replace the IOD1 P.W.B. Is Error Code 17 cleared ? Complete Fig. 8-22 magicolor 6100 Series Service Manual Page 8-29...
  • Page 344 Reassemble. the paper guide ? Replace PT4 or PT5 sensor. Is the code 17 cleared ? Check the harness and replace the Relay P.W.B. Is the code 17 cleared ? Complete Fig. 8-23 Page 8-30 magicolor 6100 Series Service Manual...
  • Page 345 Is the Interlock loose ? Tighten the Interlock. Is the Harness disconnected ? Connect the Harness properly. Replace one or both of the switches. Is Error Code 18 cleared ? Complete Fig. 8-24 magicolor 6100 Series Service Manual Page 8-31...
  • Page 346 Confirm the Interlock "DSW3". Is the Interlock loose ? Tighten the Interlock. Is the Harness disconnected ? Connect the Harness properly. Replace the Switch. Is Error Code 18 cleared ? Complete Fig. 8-25 Page 8-32 magicolor 6100 Series Service Manual...
  • Page 347 Connect the harness Is the harness connector disconnected ? properly. Is the relay P.W.B connector DPCN4 disconnected ? Replace the applicable switches. Is the code 18 cleared ? Complete Fig. 8-26 magicolor 6100 Series Service Manual Page 8-33...

  • Page 348: Paper Transport Errors

    Duplex Unit Shutter (U) Fusing Unit Printer Top Unit Lower Unit Paper Cassette (250 Sheets) Reverse Paper Guide Rear-lower Cover Shutter (L) Paper Cassette Transfer Unit Paper Pick-up Rollers (500 Sheets) Fig. 8-27 Page 8-34 magicolor 6100 Series Service Manual...
  • Page 349 Is the fusing unit installed in place? place. Fusing Unit Is there any paper between the rollers? Remove the paper. Replace the existing oil bottle Is fusing oil still in the oil bottle? with a new bottle. magicolor 6100 Series Service Manual Page 8-35...
  • Page 350 Check Item Result? Corrective Action Paper Is recommended paper being used? Use recommended paper. Paper Exit Is the top cover firmly locked by the Open and close the top cover Unit lock lever? again. Page 8-36 magicolor 6100 Series Service Manual...

  • Page 351: Printer Errors (Non-Operator Call Errors)

    Locate the error code in Table 8-6, and then proceed through the troubleshooting flowcharts. Error occurs. Confirm the error message. Press the CLEAR switch. Error occurs again? Since this is a temporary error, Begin troubleshooting the printer may be used procedures. without corrective action. Fig. 8-28 magicolor 6100 Series Service Manual Page 8-37...
  • Page 352 8-42 Brush Cleaner Solenoid Error 8-43 Brush Cleaner Clutch Error 8-44 Clutch Error of Fusing Unit 8-45 Belt Sensor Error 8-46 Erase Lamp Error 8-47 Control Fan Error 8-48 Ozone Fan (1) Error Page 8-38 magicolor 6100 Series Service Manual...
  • Page 353 Beam Sensor Error 8-54 Scanner Motor Error 8-55 Laser Power Error 8-56 DCTL Error 8-57 Duplexer Motor Error (DPM1, DPM2) 8-58 P3 Duplexer Solenoid Error (L) 8-59 Duplex Solenoid Error 8-60 Duplex Fan Error magicolor 6100 Series Service Manual Page 8-39...
  • Page 354 Fig. 8-29 Page 8-40 magicolor 6100 Series Service Manual...
  • Page 355 Fig. 8-30 magicolor 6100 Series Service Manual Page 8-41...
  • Page 356 Fig. 8-31 Page 8-42 magicolor 6100 Series Service Manual...
  • Page 357 Fig. 8-32 magicolor 6100 Series Service Manual Page 8-43...
  • Page 358 Fig. 8-33 Page 8-44 magicolor 6100 Series Service Manual...
  • Page 359 Fig. 8-34 magicolor 6100 Series Service Manual Page 8-45...
  • Page 360 Fig. 8-35 Page 8-46 magicolor 6100 Series Service Manual...
  • Page 361 Fig. 8-36 magicolor 6100 Series Service Manual Page 8-47...
  • Page 362 Fig. 8-37 Page 8-48 magicolor 6100 Series Service Manual...
  • Page 363 Fig. 8-38 Page 8-49 magicolor 6100 Series Service manual...
  • Page 364 Fig. 8-39 Page 8-50 magicolor 6100 Series Service Manual...
  • Page 365 Fig. 8-40 magicolor 6100 Series Service Manual Page 8-51...
  • Page 366 Fig. 8-41 magicolor 6100 Service Manual Page 8-52...
  • Page 367 Fig. 8-42 magicolor 6100 Service Manual Page 8-53...
  • Page 368 Fig. 8-43 Page 8-54 magicolor 6100 Series Service Manual...
  • Page 369 Fig. 8-44 magicolor 6100 Service Manual Page 8-55...
  • Page 370 Fig. 8-45 Page 8-56 magicolor 6100 Series Service Manual...
  • Page 371 Fig. 8-46 magicolor 6100 Service Manual Page 8-57...
  • Page 372 Fig. 8-47 Page 8-58 magicolor 6100 Series Service Manual...
  • Page 373 Fig. 8-48 magicolor 6100 Series Service Manual Page 8-59...
  • Page 374 Fig. 8-49 magicolor 6100 Service Manual Page 8-60...
  • Page 375 Fig. 8-50 magicolor 6100 Service Manua Page 8-61...
  • Page 376 Fig. 8-51 Page 8-62 magicolor 6100 Series Service Manual...
  • Page 377 Fig. 8-52 magicolor 6100 Service Manual Page 8-63...
  • Page 378 Fig. 8-53 Page 8-64 magicolor 6100 Series Service Manual...
  • Page 379 Fig. 8-54 magicolor 6100 Series Service Manual Page 8-65...
  • Page 380 Fig. 8-55 Page 8-66 magicolor 6100 Series Service Manual...
  • Page 381 Confirm the harness between DUPL P.W.B and MCTL. Connect the harness and Is the harness and connector connected connector properly. properly? Replace the DUPL P.W.B. Is the code P1 cleared ? Completed Fig. 8-56 magicolor 6100 Series Service Manual Page 8-67...
  • Page 382 Replace the DUPL P.W.B. Is the code P4 cleared ? Complete Motor (1) Interlock Switch CNDU DPCN4 Motor (2) CN2 CN3 CN4 CN5 CN6 DPCN1 DUP P.W.B Relay P.W.B DPM1 DPCN2 DPCN6 Fig. 8-57 Page 8-68 magicolor 6100 Series Service Manual...
  • Page 383 Is the code P3 cleared ? Replace the DUPL P.W.B. Is the code P3 cleared ? Completed DSOL (L) Interlock Switch CNDU DPCN4 CN2 CN3 CN4 CN5 CN6 DPCN1 DPCN2 DPCN6 DUP P.W.B Relay P.W.B Fig. 8-58 magicolor 6100 Series Service Manual Page 8-69...
  • Page 384 Replace the D-Solenoid Is the code P5 cleared ? Replace the DUPL P.W.B. Is the code P5 cleared ? Completed Interlock Switch CNDU DPCN4 DPCN1 DUP P.W.B Relay P.W.B DPCN2 DPCN6 DSOL(U) Fig. 8-59 Page 8-70 magicolor 6100 Series Service Manual...
  • Page 385 Replace the D-Fan Motor. Is the code P6 cleared ? Replace the DUPL P.W.B. Is the code P6 cleared ? Completed Interlock Switch D-FAN CNDU DPCN4 DPCN1 DUP P.W.B Relay P.W.B DPCN2 DPCN6 Fig. 8-60 magicolor 6100 Series Service Manual Page 8-71...

  • Page 386: Imaging Failures

    2. Examine the developer bias pole to see if it is broken or deformed. 3. Replace the belt cartridge (see section 3.3.2). 4. Replace the high voltage power supply unit (HVPS) (see section 7.2.6). Page 8-72 magicolor 6100 Series Service Manual...
  • Page 387 2. The OPC belt is deformed and is wavy. OPC Belt Cartridge Toner Cartridge (K,Y,M,C) Fig. 8-64 8.5.2.3 Countermeasures 1. Replace the toner cartridge with a new toner cartridge. 2. Replace the belt cartridge with a new belt cartridge. magicolor 6100 Series Service Manual Page 8-73...
  • Page 388 Main Gear Unit Fig. 8-66 8.5.3.3 Countermeasures 1. Replace the Main Gear Unit with a new unit (see section 7.3.2). 2. Replace the OPC belt cartridge with a new cartridge (see section 3.3.2). Page 1-74 magicolor 6100 Series Service Manual April 2001...
  • Page 389 1. Confirm the printer is installed on a level surface. 2. Shake the toner cartridge horizontally several times. 3. Replace the toner cartridge with a new cartridge. 4. Inspect the open/close motion of the front door. magicolor 6100 Series Service Manual Page 8-75...
  • Page 390 3. Close the transfer unit and ensure it locks at both sides. 4. Confirm that the fusing unit is mounted properly. 5. Replace the fusing unit. Page 1-76 magicolor 6100 Series Service Manual April 2001...
  • Page 391 1. Print a test print. 2. Check the toner cartridge of the specific color that has caused the white line. Replace the toner cartridge, if necessary. 3. Remove the foreign particles adhering to the developer roller. magicolor 6100 Series Service Manual Page 8-77...
  • Page 392 2. Clean the dust proof glass. 3. Remove the toner cartridges and belt cartridge (see section 3.3.3 and section 3.3.2). 4. Clean the dust proof glass (see section 5.2.2.6). Page 1-78 magicolor 6100 Series Service Manual April 2001...
  • Page 393 1. Wipe off any oil on or around the transfer unit. 2. Replace the transfer drum (see section 7.6.3). 3. If the oil adhesion is excessive, replace the belt cartridge, cleaning brush, and toner cartridge. magicolor 6100 Series Service Manual Page 8-79...
  • Page 394 1. Remove the belt cartridge and clean the charger unit on the OPC. 2. Remove any particles adhering to the surface of developer roller. 3. Replace the belt cartridge with a new cartridge if steps 1 and 2 do not resolve the problem. Page 1-80 magicolor 6100 Series Service Manual April 2001...
  • Page 395 Paper Discharger Unit D Guide Fig. 8-80 8.5.10.3 Countermeasures 1. Clean the paper discharger unit (see section 5.3.5.4.1). 2. Clean the D guide and D separator pawl. 3. Remove and vacuum the drum cleaner. magicolor 6100 Series Service Manual Page 8-81...
  • Page 396 8.5.11.3 Countermeasures 1. Do not apply shock or vibration to the printer. 2. The surface on which the printer is placed should be stable. 3. Replace the optical unit (see section 7.3.5). Page 1-82 magicolor 6100 Series Service Manual April 2001...
  • Page 397 OPC belt passes over the cleaning blade. OPC Belt Cartridge Cleaning Belt Belt Seam Fig. 8-84 8.5.12.3 Countermeasures 1. Replace the belt cartridge (see section 5.3.2). magicolor 6100 Series Service Manual Page 8-83...
  • Page 398 1. Check that the transfer unit is mounted properly, and that both sides of the transfer unit are fixed by hooks. 2. Replace the TR cam clutch with a new clutch (see section 7.4). 3. Replace the transfer unit (see section 7.6.1). Page 8-84 magicolor 6100 Series Service Manual...
  • Page 399 Check for blockage in the waste toner auger. Vacuum and remove the excess waste tone. 2. Remove and clean the toner cartridge. 3. Replace the belt cartridge with a new cartridge if steps 1 and 2 do not resolve the problem. magicolor 6100 Series Service Manual Page 8-85...
  • Page 400 5. Replace the damaged transfer drum with a new drum (see section 7.6.3). 6. Replace the toner cartridge with a new cartridge (see section 3.3.3). 7. Replace the transfer unit with a new unit (see section 7.6.1). Page 8-86 magicolor 6100 Series Service Manual...
  • Page 401 2. Defective toner cartridge. Toner Cartridge Developer Roller Developer Blade Fig. 8-92 8.5.16.3 Countermeasures 1. Confirm that the toner cartridge can be inserted smoothly. 2. Replace the toner cartridge. magicolor 6100 Series Service Manual Page 8-87...
  • Page 402 8.5.17.3 Countermeasures 1. Reseat the OPC belt cartridge properly. 2. Replace the OPC belt cartridge with a new cartridge. 3. Replace the cleaning brush with a new brush. 4. Replace the Drum Cleaner solenoid. Page 8-88 magicolor 6100 Series Service Manual...
  • Page 403 2. Confirm if the transfer unit is firmly locked. 3. Confirm if the transfer roller is properly installed. 4. Replace the toner cartridge. 5. Replace the high voltage power supply with a new unit (see section 7.2.6). magicolor 6100 Series Service Manual Page 8-89...
  • Page 404 3. Failure of High Voltage Power Supply. Drum Cleaner Fig. 8-98 8.5.19.3 Countermeasures 1. Check if the drum cleaner is properly installed. 2. Replace the failed High Voltage Power Supply (see section 7.2.6). Page 8-90 magicolor 6100 Series Service Manual...
  • Page 405 1. Cleaning roller is stained. 2. Fuser roller is deteriorated. Cleaning Roller Fuser Bottle Fig. 8-100 8.5.20.3 Countermeasures 1. Replace the cleaning roller (see section 3.3.1). 2. Replace the fuser unit (see section 5.3.3). magicolor 6100 Series Service Manual Page 8-91...
  • Page 406 1. Replace fuser oil bottle. 2. Clean the fuser roller and back-up roller. 3. Replace the cleaning roller (see section 3.3.1). 4. Replace the fuser unit with a new unit (see section 5.3.3). Page 8-92 magicolor 6100 Series Service Manual...
  • Page 407 1. Confirm that no foreign particles are stuck at the opening of optical unit. 2. Replace the transfer solenoid (see section 7.8.5.2). 3. Replace the belt cartridge. 4. Replace the high voltage power supply (HVPS) (see section 7.2.6). magicolor 6100 Series Service Manual Page 8-93...
  • Page 408 Backup Roller Fig. 8-106 8.5.23.3 Countermeasures 1. Adjust the mode on the host side or the control panel to match the print media used. 2. Use the recommended paper. 3. Replace the fuser unit. Page 8-94 magicolor 6100 Series Service Manual...

  • Page 409: Spare Parts Breakdown

    Section 9: Spare Parts Breakdown magicolor 6100 Series Service Manual Page 9-1 April 2001...
  • Page 410 Page 9-2 magicolor 6100 Series Service Manual...
  • Page 411 Power Cord (JP) Paper Cassette 825126636 Cleaner Cover 825126657 Transfer Unit Door Cover 825126626 Transfer Unit 825126625 Envelope Adaptor 1710389-001 Controller (Crown) 2293279-901 Controller (DeskLaser) 2293282-901 See Fig. 9-1 for an illustration of these parts. magicolor 6100 Series Service Manual Page 9-3...
  • Page 412 Page 9-4 magicolor 6100 Series Service Manual...
  • Page 413 Fig. 9-1 Diagram for Consumables and Supplies (See Table 9-1 for part numbers) 1 6 1 7 9 1 0 1 1 magicolor 6100 Series Service Manual Page 9-5...
  • Page 414 6100 Series Service Manual Page 9-6...
  • Page 415 MCTL P.W.B. 825126649 16’ MCTL P.W.B. (EC) 3F 825126709 For Flicker High Voltage Power 825126652 Supply(HVPS) Panel Button 825126111 Panel P.W.B. 825126112 Discharge Brush 825126613 Cooling Fan (EX) 825126659 Paper Exit Filter 851126660 magicolor 6100 Series Service Manual Page 9-7...
  • Page 416 Paper Exit Unit 825126609 Paper Exit Roller 825126612 Paper Exit Full Sensor 825126167 Panel Case Assembly 825126606 EP3 CR Sensor Lever 825126174 BC Terminal 3 825126704 See Fig. 9-2 for an illustration of these parts. Page 9-8 magicolor 6100 Series Service Manual...
  • Page 417 Diagram of Engine Parts (Breakdown #1) Fig. 9-2 (See Table 9-2 for part numbers) 16’ magicolor 6100 Series Service Manual Page 9-9...
  • Page 418 6100 Series Service Manual Page 9-10...
  • Page 419 825126635 Interlock Switch 825126817 Front, Back, Top Toner Sensor Assembly (P.W.B.) 825126647 IOD2 P.W.B. 825126651 Cooling Fan (PS) 825126655 Controller Cooling Fan (OZ) 825126163 Ozone Waste Toner Feeder (U) 825126618 Optical Unit 825126629 magicolor 6100 Series Service Manual Page 9-11...
  • Page 420 Fuser Cover (L) 3 825126705 Fuser Cover (R) 3 825126706 FU3 Felt A’ssy 825126774 FU3 Cover F A’ssy 825126673 SL3 BR Felt A/ssy 825126715 See Fig. 9-3 for an illustration of these parts. Page 9-12 magicolor 6100 Series Service Manual...
  • Page 421 Fig. 9-3 Diagram of Engine Parts (Breakdown #2) (See Table 9-3 for part numbers) 31 32 33 14’ magicolor 6100 Series Service Manual Page 9-13...
  • Page 422 6100 Series Service Manual Page 9-14...
  • Page 423 Paper Feeding Roller 825126142 120,000 pages Separator Pad 825126528 120,000 pages OHP Sensor 825126648 Paper Empty Sensor 825126167 Paper Sensor PT1 825126167 Paper Size Sensor 825126646 See Fig. 9-4 for an illustration of these parts. magicolor 6100 Series Service Manual Page 9-15...
  • Page 424 Page 9-16 magicolor 6100 Series Service Manual...
  • Page 425 Fig. 9-4 Diagram for Engine Parts (Breakdown #3) (See Table 9-4 for part numbers) magicolor 6100 Series Service Manual Page 9-17...
  • Page 426 6100 Series Service Manual Page 9-18...
  • Page 427 Motor 825126230 DPM1; DPM2 Fan Motor 825126687 Upper Solenoid 825126688 Lower Solenoid 825126689 Interlock Switch 825126817 D-SW1 d~D-SW4 Sensor PT4 825126690 Sensor PT5 825126691 See Fig. 9-5 for an illustration of these parts. magicolor 6100 Series Service Manual Page 9-19...
  • Page 428 Page 9-20 magicolor 6100 Series Service Manual...
  • Page 429 Fig. 9-5 Diagram of Duplexer Spare Parts Breakdown (See Table 9-5 for part numbers) magicolor 6100 Series Service Manual Page 9-21...
  • Page 430 6100 Series Service Manual Page 9-22...
  • Page 431 Drives the paper transportation roller. LF3 Rear Cover Assy 825126668 Rear cover IOD3 PWB Assy 825126669 IO Board Interlock Switch 825123817 Micro switch for printer door See Fig. 9-6 for an illustration of these parts. magicolor 6100 Series Service Manual Page 9-23...
  • Page 432 Page 9-24 magicolor 6100 Series Service Manual...
  • Page 433 Fig. 9-6 Diagram of Lower Feed Unit Spare Parts Breakdown (See table 9-6 for part numbers) magicolor 6100 Series Service Manual Page 9-25...
  • Page 434 6100 Series Service Manual Page 9-26...

  • Page 435: Index

    Index magicolor 6100 Series Service Manual Page I-1...
  • Page 436 Page I-2 magicolor 6100 Series Service Manual...
  • Page 437 E7 8-38 FUCL 7-48 E8 8-38 Paper Feeding Clutch (PCLC) 7-49 E9 8-38 RECL 7-48 EL 8-38 TRCM 7-48 F0 8-38 Clutches (FUCL, FBCL, RECL, FBCM, F2 8-38 TRCM), Replacement 7-48 F4 8-39 magicolor 6100 Series Service Manual Page I-3...
  • Page 438 Fan Motor, Replacement 7-100 D1 8-38 Interlock Switches (1 & 2), Replacement 7- D2 8-38 D3 8-38 Interlock Switches (3 & 4), Replacement 7- D4 8-38 D5 8-38 Lower Solenoid, Replacement 7-102 D6 8-38 Page I-4 magicolor 6100 Series Service Manual...
  • Page 439 Functions of Printer Components 4-8 Clutch Error of Magenta Developing Unit Fuser Connector, Replacement 7-78 8-38 Fuser Oil Caution 5-18 Clutch Error of Yellow Developing Unit 8- Fuser, Replacement 5-17 Fuser, Theory 4-25 magicolor 6100 Series Service Manual Page I-5...
  • Page 440 Wrinkle / Image Migration 8-76 IOD3 P.W.B. Assembly, Replacement 7- Imaging Failures 8-72 Initial Setting of NVRAM 6-43 Paper Feeder Clutch, Replacement 7-109 Inner Jams 8-35 Paper Feeder Roller, Replacement 7-111 Installation Paper Sensor PEL, Replacement 7-107 Page I-6 magicolor 6100 Series Service Manual...
  • Page 441 Developer Motor 7-38 FUSER OIL LOW 8-5 Heater Fan 7-45 IDLE 8-6 Main Gear Unit 7-36 INNER JAM 8-5 Main Motor 7-34 INPUT IDLE PRINTING 8-6 Optical Unit 7-42 MISFEED JAM 8-5 Ozone Fan 7-46 magicolor 6100 Series Service Manual Page I-7...
  • Page 442 REAR DOOR OPEN 8-8 Parts Breakdown, Consumables and Supplies Operator Panel 1-8 Operator Panel, description of 1-8 Parts Breakdown, Duplexer 9-19 Operator Panel, Operation and Adjustments 6- Parts Breakdown, Engine Breakdown #1 9-7 Page I-8 magicolor 6100 Series Service Manual...
  • Page 443 Replacement, Duplexer Rear Cover, Replacement 7-13 Bottom Cover 7-91 Recommended Media 2-7 Bottom Paper Guide 7-94 Registration Roller Cleaning 5-7 Duplexer P.W.B. 7-96 Registration Roller, Replacement 7-70 Duplexer Paper Sensor PT5 7-105 Replacement magicolor 6100 Series Service Manual Page I-9...
  • Page 444 Total Page Reset 6-34 Belt Marker Sensor 7-62 Setting of NVRAM Data 6-41 Cleaning Roller Sensor CRS 7-66 Spare Parts Breakdown 9-3 Drum Encoder Sensor (EN) 7-61 Specifications, Duplexer 2-5 Drum Jam Sensor DPJ 7-59 Page I-10 magicolor 6100 Series Service Manual...
  • Page 445 Wrinkle / Image Migration 8-76 Transfer Drum Structure 4-15 Transfer Drum, Replacement 5-26, 7-71 Transfer Roller 4-19 Transfer Roller Cleaning 5-8 Transfer Roller, Replacement 5-19 Xerographic Process 4-9 Transfer Unit Door Cover, Replacement 7-12 magicolor 6100 Series Service Manual Page I-11...
  • Page 446 Page I-12 magicolor 6100 Series Service Manual...

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