Xerox Phaser 6100 Service Manual
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Xerox Phaser 6100 Service Manual

Color laser printer
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6100
P h a s e r
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C o l o r L a s e r P r i n t e r
Service
Manual
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X E R

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Summary of Contents for Xerox Phaser 6100

  • Page 1 6100 P h a s e r ® C o l o r L a s e r P r i n t e r Service Manual X E R...

  • Page 3: Service Manual

    Phaser 6100 Color Laser Printer Service Manual Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do...
  • Page 4 Copyright © 2004, Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc.

  • Page 5: Table Of Contents

    Contents 1 Precautions 1. Precautions ................1-1 1.1 Service Terms .
  • Page 6 Front View ............4-2 Rear View .
  • Page 7 6.4.11 Developer Drive Assembly (PL 9.1.8)......... . . 6-29 6.4.12 DEVE Drive Board (PL 9.13.20) and DEVE Cover Open Switch (PL 9.15.36) (Door A Interlock) .
  • Page 8 7.6.2.6 HVPS Tests ........... 7-17 7.6.2.7 Regi.Set Test .
  • Page 9 9.23 Xerox Kits and Accessories ........

  • Page 11: Precautions

    Precautions Precautions 1. Precautions In order to prevent accidents and damage to the printer, please read all the precautions listed in this section carefully before servicing the printer. 1.1 Service Terms 1.1.1 Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action.

  • Page 12: Symbols Marked On The Product

    Precautions 1.2 Symbols Marked on the Product DANGER high voltage. Protective ground (earth) symbol. Hot surface on or in the printer. Use caution to avoid personal injury. The surface is hot while the printer is running. After turning off the power, wait 30 minutes. 30 min.

  • Page 13: Power Safety Precautions

    Precautions 1.3 Power Safety Precautions 1.3.1 Power Source For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 260 volts RMS between the supply conductors or between either supply conductor and ground.

  • Page 14: Electrostatic Discharge (Esd) Precautions

    Precautions 1.4 Electrostatic Discharge (ESD) Precautions Some semiconductor components , and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

  • Page 15: Warning Labels

    Precautions 1.5.2 Warning Labels Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place. 1.5.3 Safety Interlocks Make sure all covers and the printer’s front panel are in place and all interlock switches are functioning correctly after you have completed a printer service call.

  • Page 16: Servicing Fuser Components

    This product, if used properly in accordance with the user's instructions is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

  • Page 17: Reference Information

    2. Reference Information This section contains a tools list, list of abbreviations used in this manual, and a clearance required specification when installing the Phaser 6100 printer. 2.1 Tools for Troubleshooting the Printer The following tools are recommended for safe and easy troubleshooting as described in this service manual.

  • Page 18: Acronyms And Abbreviations

    Reference Information 2.2 Acronyms and Abbreviations Definition Definition Analog-to-digital Conversion Firmware Access Point FCF/FCT Tray 1 or First Cassette Feeder Alternating Current FISO Front In, Side Out ASIC Circuit Application Specific Integrated FPOT First Print Out Time Ass’y Assembly Windows Graphic Device Interface BIOS Basic Input Output Sytem Graphic Interchange Format...
  • Page 19 Reference Information Definition Definition LVPS Low Voltage Power Supply Or SMPS Megabyte Q’ty Quantity Megahertz Random Access Memory MPBF Mean Prints Between Failure Read Only Memory MPF/MPT Multi-purpose Tray SCF/SCT Tray 2 Or Second Cassette Feeder Network Interface Card SMPS Switching Mode Power Supply or LVPS Network Printer Card SPGPm...

  • Page 20: Selecting A Location For The Printer

    Reference Information 2.3 Selecting a Location for the Printer Leave enough room to open the printer trays, covers, and allow for proper ventilation. Provide the proper environment A sturdy, level surface Away from the direct airflow of air conditioners, heaters, or ventilators. Free from extreme fluctuations in temperature, sunlight, or humidity.

  • Page 21: Printer Serial Number Format

    Reference Information 2.4 Printer Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: Component's part number Product type or model number Serial number of the printer Serial numbering.
  • Page 22 Reference Information...

  • Page 23: Specifications

    Specifications Specifications The specifiations in this manual are correct at the time of printing. Product specifications are subject to change without notice. 3.1 General Specifications Item Description Print Method Non-impact electro-photography Developing system Non-magnetic, Mono-component, Non-contact method Exposure System Semiconductor laser diode beam scanning Fuser (toner fixing) Thermal rollers fusing with pressure (heat lamp: 800 watts) Resolution...

  • Page 24: Controller Specification

    Specifications 3.2 Controller Specification Item Description Processor SPGPM (Samsung Printer Graphic Processor) Clock speed 120 MHz Memory The controller has 64 MB SDRAM and 4 MB flash ROM on Board. 1 DIMM expansion slot for SDRAM DIMM Package: DIMM; 100-pin Type: SDRAM DIMM Type: Unbuffered (SEC Custom, support other products within SEC) Error Checking: Non-parity...

  • Page 25: Environmental Range

    Specifications 3.4 Environmental Range Items Operating Storage (packaged) Optimum Temperature 15 ~ 30 C (59 ~ 86 5 ~ 35 C (41 ~ 95 20 - 25 Humidity 20 - 80% RH 20 - 80 % RH 30 - 70% RH Altitude 2,500 meters (8,200 feet) 3.5 Periodically Replaced Parts...

  • Page 26: Media Specifications

    Specifications 3.6 Media Specifications 3.6.1 Paper Size and Weights The supported media types for this printer include, but are not limited to: labels, envelopes, cardstock, plain paper, transparency, letterhead and colored paper. Paper Type Size Tray Support 210 x 297mm All Trays Letter 8.5”...

  • Page 27: Paper Size And Weights (Cont'd)

    Specifications 3.6.1 Paper Size and Weights (cont’d) Tray Support Media Types / Capacity Sizes Weight Paper; 250 sheets (20 lb) A4, Letter 16 ~ 24 lb Tray 1 Tray 2 Paper; 500 sheets (20 lb) 60 ~ 90 gsm Paper; 100 sheets A4, Letter, Legal, Folio, Executive, 16 ~ 43 lb Envelope;...
  • Page 28 Specifications...

  • Page 29: Product Summary

    Summary of Product Product Summary 4.1 System Structure 4.1.1 Major Assemblies of the Printer Service Manual 4-1...

  • Page 30: Front View

    Summary of Product Front View Control Panel Deve OEM Waster Toner Sensor Board CRUM Waster Toner Motor Reader Rear View Deve Drive Deve Drive Deve Drive Deve Drive Fuser Fan Fuser Fan Board Board Main Drive Main Drive Deve Cover Deve Cover Open S/W Open S/W...
  • Page 31 Paper Discharge: Friction Pad Method Paper Size: Legal, Folio, A4, Letter, Executive, JIS B5, A5, A6, Statement, Monarch (7 3/4), #9, C5, B5 Envelope, DL Paper Weight and Type: See the approved Xerox media specifications in Section 3. Paper Empty Sensor Service Manual 4-3...
  • Page 32 Summary of Product 7) Feeder Paper Arrangement: Side Registration. Drive: Main Motor DC Paper Management: Feed Clutch 8) Duplex Unit The duplex unit is used to reverse paper feed to print the on backside of paper. The duplex unit is not an option. The transfer roller is part of the duplex unit.
  • Page 33 19) DEVE_OEM Board (CRUM Reader) The DEVE_OEM board verifies the toner cartridges are new, used and whether they are Xerox parts. An error message will display on the front panel if the toner cartridge is a non-Xerox toner cartridge.

  • Page 34: Motor And Fan Layout

    Summary of Product 4.1.2 Motor and Fan Layout 1. Main Motor 1. Main Motor 1. Main Motor 2. DEVE Motor 2. DEVE Motor 2. DEVE Motor 3. Fuser Fan 3. Fuser Fan 3. Fuser Fan 4. Waste Toner Motor 4. Waste Toner Motor 4.

  • Page 35: Clutch And Solenoid Layout

    Summary of Product 4.1.3 Clutch and Solenoid Layout Duplex Solenoid Transfer Belt Cleaning Solenoid Cartridge Solenoid(C, M, Y, K) Cartridge Solenoid(C, K, Y, M) Transfer Belt Transfer Belt Black Deve Black Deve Home Solenoid Home Solenoid Clutch Clutch Yellow Deve Clutch Yellow Deve Clutch Magenta Deve Clutch Magenta Deve Clutch...

  • Page 36: Sensor And Switch Layout

    Summary of Product 4.1.4 Sensor and Switch Layout Exit Sensor EXIT Ass'y EXIT Unit Duplex Path Duplex Path Fuser Unit Fuser Unit Transfer Transfer Belt Belt DEV. - Black DEV. - Black Transfer Roller DUPLEX DUPLEX DEV. - Yellow DEV. - Yellow Imaging Imaging Feed Sensor...

  • Page 37: Main Board

    Summary of Product 4.1.5 Main Board Service Manual 4-9...
  • Page 38 Summary of Product FLASH MEMORY ENGINE CONTROL DIMM SPGPm Main Control 4-10...
  • Page 39 Summary of Product (W-LAN) Flash Memory NOT SUPPORTED LPEC1 Engine SDRAM Control SPGPm 64MB Bloc k SDRAM DIMM 34MB~128MB 5 pin UART Panel EEPROM USB 2.0 16x2 LCD 2048 bytes 1) CPU BLOCK A 120MHz - 32bit RISC processor is used to manage commands and data supplied by the host. This is converted into a bitmap image which is passed to the engine block for printing.
  • Page 40 Summary of Product USB 2.0 interface USB 1.1 backward compatible UDC (USB Device Controller) block and USB Physical block are integrated Both of High Speed (480 Mbps) and Full Speed (12 Mbps) are supported 2 DMA channels support: one RX Channel and one TX Channel 3) Memory Block The operating program runs from memory (see below).

  • Page 41: Lvps (Smps) Board

    Summary of Product 4.1.6 LVPS (SMPS) Board The LVPS board supplies DC power for driving the whole system, it also contains an AC heater control unit that supplies power to the fuser. 1) DC output Main board, control panel, Tray 1, developer drive board, interlocks, sensors imaging components, motors, clutches, solenoides and HVPS.

  • Page 42: Hvps (High Voltage Supply) Board

    Summary of Product 4.1.7 HVPS (High Voltage Supply) Board The HVPS uses the +24 volts supplied by the LVPS to generate the high voltages used by the charge roller, toner cartridge, imaging unit (T1), transfer belt (T2), and transfer roller. For the best print-quality images, these hifh voltages must be controlled and maintained accurately.
  • Page 43 Summary of Product 1) Charging Voltage: Charger Function: Charges the surface of the drum to about -500 volt ~ 800 volt. Output voltage: -200 V~-2.0K V DC +/- 3% (Duty is changeable, no loading) Error type: If the correct voltage was not present, the surface of the drum is not charged. As a result, toner on the developer roller transferred to the drum could produce entirely black prints.
  • Page 44 Summary of Product 4-16...

  • Page 45: System Outline

    System Outline System Outline 5.1 Color Laser Printing Process 5.1.1 Imaging Unit (Drum Charge Section) The imaging unit contains the drum, waste toner cleaning assembly and charge roller. Imaging Unit OPC Drum Charge Roller Cleaning Blade Waste Toner Cartridge -1000V ~ -1500V Eraser Lamp Cleaning Roller Charge Roller...

  • Page 46: Lsu (Exposure)

    System Outline 5.1.2 LSU (Exposure) The latent image is formed on the drum using an image data stream to switch the laser beam On or Off. Where no image is required the beam is off, where toner is required the beam is turned on. When the laser is on and the beam strikes the drum surface, the charge is reduced to -50 V, where the beam is switched off the charge on the drum surface remains at -600 V.
  • Page 47 System Outline 2) Developing The latent image is formed as described below. Yellow Color Yellow Color Developing and Image Transfer Developing Sequence: Y, M, C, and K T1 Process Magenta Color Magenta Color Developing and Image Transfer The image is created using a four color pass process.

  • Page 48: Image Transfer

    System Outline 5.1.4 Image Transfer The toner image formed on the drum and transferred to the transfer belt is called the primary image transfer or T1. When the final color image has been placed on the transfer belt it is then transferred onto the paper by the transfer roller, this is called the secondary image transfer or T2.
  • Page 49 System Outline Name Description Transfer Roller (T2) The transfer roller transfer the final toner image from the transfer belt to the paper. The HVPS applies the image transfer bias voltage to the transfer roller allowing transfer of the image from the belt onto the paper. When the image is to be transferred from the transfer belt to the paper, the transfer roller pressure contact solenoid is activated and this activates a cam which moves the transfer roller into contact with...
  • Page 50 System Outline 4. CTD Sensor OPC Drum TONER Transfer Unit CTD Sensor PBS (Polarized Beam Splitter) OPC DRUM PD (Photo Diode) 5) Secondary Image Transfer, Transfer Roller (T2) Image Transfer Belt Charge Removal Bias Image Transfer Roller OPC DRUM Paper HVPS Image Transfer Bias...

  • Page 51: Fuser (Fusing Process)

    System Outline 5.1.5 Fuser (Fusing Process) Toner that has been through the primary and Heat Roller Heat Lamp secondary image transfer processes is fused or fixed to the paper.. (500W) The fuser consists of two heat lamps, two heat rollers, one thermistor, and two thermostats. The fuser melts the toner onto the paper using pressure Heat Lamp Paper...

  • Page 52: Exit

    System Outline 5.1.6 Exit After passing through the fuser, media is ejected into the output tray. Any static electrical charge is removed by static discharge brushes. When operating in duplex print mode, after printing the front side of the page, the paper exit roller reverses to feed the paper back into the printer in order to print on the back side of the paper.

  • Page 53: System Start-Up Sequence

    System Outline 5.2 System Start-Up Sequence The printer uses 4 different colored toners (Yellow, Magenta, Cyan, Black) and is a color laser printer. Engine firmware controls the print processes, drives the print engine, paper feed, developer, fuser, and paper exit systems. It has both color and mono printing modes.

  • Page 54: Ready

    System Outline 5.2.3 Ready 1) Host interface is monitored for print commands 2) Heat control Target temperature (165° C). Every 40 seconds, temperature value for the previous 250ms is read and a proportional control process is carried out. 3) Printer is in “Ready” mode entered after warm-up or after completing a print job. 4) System Error check 5) Power save state is entered after timeout Wakeup condition...

  • Page 55: Print

    System Outline 6) Motor Torque Check 7) Check and Set a High Voltage Condition (T1, T2, Charger) 8) Initialize Printing Parameters Paper size, copies, trays Image pixels, image times, y-offset, x-offset Sensors Color print mode: Except legal & OHP/Legal/OHP Simplex/Duplex Mono print mode: Simplex/Duplex/OHP 5.2.5 Print After sensing the transfer belt home position the following tasks are performed:...

  • Page 56: Post-Print

    System Outline 5.2.6 Post-Print This is the last stage of the printing process. Its functions are described below. Clean transfer rollers. Stops all virtual timers. Re-initialize parameters used in the print process. Stops motors. 5-12...

  • Page 57: Disassembly

    6.1.1 Precautions for Disassembly/Reassembly Use only approved Xerox spare parts. Ensure that the part number, product name, any voltage, current or temperature ratings are correct. Failure to do so could result in damage to the printer, circuit overload, fire or electric shock.

  • Page 58: Maintenance And Supplies

    Disassembly 6.2 Maintenance and Supplies There are parts in this printer that have a limited life compared to the life of the printer, these parts must be periodically replaced. The table shows the life of each part and is measured using A4/Letter paper. When servicing a printer, always check the status of these parts using the control panel and ensure that parts are replaced at the appropriate times.

  • Page 59: Printer Cleaning

    Disassembly 6.2.2 Printer Cleaning The printer should be cleaned regularly, especially if it is used in a dusty environment. This ensures that print-quality remains high and failures due to contamination are less likely to occur. Clean the printer with a soft, lint free, cloth dipped in a mild detergent. Do not touch the transfer roller when cleaning the inside of the printer.

  • Page 60: Information Related To Disassembly And Reassembly

    Disassembly 6.3 Information Related to Disassembly and Reassembly Before diassembling the printer: Caution Do not use a power screwdriver for reassembling the printer. The plastic screw holes in the chassis can become damaged or stripped. If holes are already damaged, use spare untapped holes. This printer uses 19 different screw types, please refer page 6-5 for a list of all the screws used.

  • Page 61: Screws Used In The Printer (Hardware Kit)

    Disassembly 7) Fuser Unit Warning: The fuser melts toner onto the paper at a very high temperature, use care when handling the Fuser When removing the fuser from a printer that has recently been operating, let the fuser or severe burns can result. cool before handling.

  • Page 62: Removing Consumables

    Disassembly 6.3.2 Removing Consumables This section shows you how to open the covers (front cover, DEVE cover, exit cover, and duplex cover) and how to remove and replace the consumable parts (toner cartridge, transfer belt, and imaging unit). Orientation of the Printer Doors Pull the side handle to open the DEVE cover (Door A) and then press down firmly until the toner cartridges are ejected.
  • Page 63 Disassembly Caution Do not damage the rollers. Keep the toner cartridges on a flat surface. Open the exit cover by pressing the cover open button. Exit Cover Door B DEVE Cover Door A Service Manual 6-7...
  • Page 64 Disassembly Remove the transfer belt by releasing the lock levers on both sides. Lever Lever Transfer Belt To remove the imaging unit, carefully lift the unit using the handle provided. Imaging Unit Caution Ensure the drum surface is not scratched or damaged, while removing from the printer or after placing it on a flat surface.

  • Page 65: Replacing The Waste Toner Cartridge (Pl 9.1.57)

    Disassembly 6.3.4 Replacing the Waste Toner Cartridge (PL 9.1.57) Push in the top corners of the front cover. Lift the latch at the top of the waste toner cartridge and pull the top edge forward, then lift the cartridge out. Note Do not spill toner from the waste toner cartridge.
  • Page 66 Disassembly Remove the toner caps and fit them to the inlets as shown below. Toner Cap 6-10...

  • Page 67: Top Cover (Pl 9.1.17) And Front Cover (Pl 9.1.15)

    Disassembly 6.4.1 Top Cover (PL 9.1.17) and Front Cover (PL 9.1.15) Remove Tray 1. Open DEVE Cover (Door A), Exit Cover (Door B), and Duplex (Door C). Exit Cover Door B DEVE Cover Door A Duplex Cover Door C Remove 2 screws (3-10 silver) from the top cover. Screw Top Cover Screw...
  • Page 68 Disassembly Rotate the top cover, towards Door A, to release it from the two tabs at the base of the cover and remove as shown. Open the front cover. Remove 7 screws (3-10 silver) located inside the front cover. Note To access the bottom, right front screw, tray 1 needs to be removed from the printer.
  • Page 69 Disassembly Close the front cover door. Push the cover down, and using a flathead screwdriver remove the cover from the posts on the bottom to release it from the printer. Post Post Remove the front cover. Service Manual 6-13...

  • Page 70: Control Panel (Pl 9.2.19)

    Disassembly 6.4.2 Control Panel (PL 9.2.19) Remove the front cover (6.4.1). Remove 3 ((A) 3-8 gold). Disconnect the wiring harness connector. Rotate the control panel to release it from the tabs and remove the control panel from the printer. Connector Screw Screw Screw...

  • Page 71: Rear Cover (Pl 9.1.16)

    Disassembly 6.4.3 Rear Cover (PL 9.1.16) Open the duplex cover, the DEVE cover and the exit cover. (Refer to 6.3.3) Remove the top cover. (Refer to 6.4.1) Remove 10 screws. A: Top 2 EA (3 * 10 Silver) B: Side 3 EA (3 * 10 Silver) C: Bottom 3 EA (4 * 10 Silver) D: Rear 2 EA (3 * 10 Silver) E: Side 2 EA (3 * 6 Gold) - Only for the DN Model.

  • Page 72: Duplex Cover - Door C (Pl 9.6.0)

    Disassembly 6.4.4a Duplex Cover - Door C (PL 9.6.0) Remove the Front and Rear Covers (6.4.3) Open Door C. Remove the top 2 hinge screws (3*10 silver) on either side of each hinge rail. Disconnect the links from the door. Holding the door at a 90 angle, snap the front hinge out.

  • Page 73: Duplex Unit (Pl 9.6.2) And Transfer Roller (Pl 9.1.54)

    Disassembly 6.4.4b Duplex Unit (PL 9.6.2) and Transfer Roller (PL 9.1.54) Remove the Duplex Cover Assembly (Door C) (6.4.4a) Release the 4 hooks on the right and left side of the duplex unit with a flat-blade screwdriver. Remove the duplex assembly from the door. Hook Hook Duplex...

  • Page 74: Fuser (Pl 9.1.9)

    Disassembly 6.3.5a Fuser (PL 9.1.9) Warning If the printer has been printing recently, the fuser will be hot. Open the exit cover and let the fuser cool before removing it. Open the DEVE cover (Door A). Note Before opening the exit cover, completely open the DEVE cover until it is at a 90 angle to the main frame and the toner cartridges are ejected.

  • Page 75: Fuser Base Cover (Pl 9.13.29)

    Disassembly 6.4.5b Fuser Base Cover (PL 9.13.29) Remove the fuser (6.4.5a). Remove 3 screws (3-10 silver). Lift the base cover off. Screws Service Manual 6-19...

  • Page 76: Exit Cover - Door B (Pl 9.5.0)

    Disassembly 6.4.6 Exit Cover - Door B (PL 9.5.0) Open the duplex cover (Door C). With the exit cover closed, remove the E-ring and the hinge pin. Caution Do not lose the hinge pins. Note The diagram shows the door open and covers off for reference only. Remove the exit cover.

  • Page 77: Low-Voltage Power Supply - Lvps/Smps (Pl 9.1.19)

    Disassembly 6.4.7a Low-Voltage Power Supply - LVPS/SMPS (PL 9.1.19) Remove the rear cover (6.4.3) Remove 5 screws (3-6 machine, gold) from the main board shield. Screw Screw Screw Screw Main PBA Bracket Screw Screw Remove 2 screws (3-10 machine, silver) connected to the parallel port and then remove the main board shield. Screw Screw Service Manual 6-21...
  • Page 78 Disassembly Remove 5 screws from the LVPS. A: Right side 2EA (3 * 6 Gold) B: Left side 1EA (3 * 10 Silver) C: Bottom 1EA (4 * 10 Silver) Remove 2 screws (3*10 silver) from the harness guide and free the harness, then remove the guide. Harness Guide Screw LVPS...

  • Page 79: Main Controller Board (Pl 9.1.10)

    Disassembly 6.4.7b Main Controller Board (PL 9.1.10) Perform steps 1 and 2 from procedure 6.4.7a. Warning Move the NVRAM Chip from the old board TO the new board. Failure to perform this step will result in the loss of important customer information, like page count and consumable life usage information. Disconnect all harness connected to the main board.

  • Page 80: Fuser Fan Assembly (Pl 9.1.27)

    Disassembly 6.4.8 Fuser Fan Assembly (PL 9.1.27) Remove the top cover. (6.4.1) Remove the rear cover. (6.4.3) Remove the main board shield. (6.4.7) Remove 3 screws (3*10 silver). Disconnect and free the harness from the main board and then remove the fuser fan. Screw Screw Fuser Fan...

  • Page 81: Main Drive Assembly (Pl 9.1.7)

    Disassembly 6.4.9 Main Drive Assembly (PL 9.1.7) Remove the rear cover. (6.4.3) Remove the fuser. (6.4.5) Remove the LVPS. (6.4.7a) Remove the fuser fan. (6.4.8) Remove all harnesses from the harness guides. Two harnesses need to be freed from the bottom of the bracket. Remove the LVPS cover bracket.
  • Page 82 Disassembly Remove the washer and then remove the drum gear and pin. (The drum gear can be found inside the printer after removing the imaging unit.) Note Take care that the pin is not lost as you remove the gear. Pin-Drive Gear-Drive Washer-Plain...

  • Page 83: Hvps (High Voltage Power Supply) (Pl 9.1.20)

    Disassembly 6.4.10 HVPS (High Voltage Power Supply) (PL 9.1.20) Warning High Voltage! Be sure to follow the steps outlined in Section 1.5.4 when servicing this assembly Remove the front cover and top cover. (6.4.1) Remove the rear cover. (6.4.3) Remove the main board shield. (6.4.7b) Remove and free the CN7 harness from the main board.
  • Page 84 Disassembly Remove 5 screws (3-6 machine gold) and then remove the HVPS. Screw Screw Screw Screw Screw 6-28...

  • Page 85: Developer Drive Assembly (Pl 9.1.8)

    Disassembly 6.4.11 Developer Drive Assembly (PL 9.1.8) Remove the rear cover. (6.4.3) Remove the main board. (6.4.7b) Remove 5 screws securing the main board bracket. Left, 2 EA 3*6 machine screw, gold Top Right, 2 EA 3*10 silver Bottom, 1 EA 4*10 silver Harness Guide Screw 3x 10 White...
  • Page 86 Disassembly Disconnect the harness from the DEVE Motor. Screw Screw Screw Screw Remove 4 harnesses connected to the DEVE drive board, then remove the DEVE drive assembly. Remove 5 screws (3*10 silver) from the DEVE drive assembly. 6-30...

  • Page 87: Deve Drive Board (Pl 9.13.20) And Deve Cover Open Switch (Pl 9.15.36) (Door A Interlock)

    Disassembly 6.4.12 DEVE Drive Board (PL 9.13.20) and DEVE Cover Open Switch (PL 9.15.36) (Door A Interlock) Warning High Voltage! Be sure to follow the steps outlined in Section 1.5.4 when servicing this assembly Remove the rear cover. (6.4.3) Remove the main board. (6.4.7b) Remove the main board shield.
  • Page 88 Disassembly Disconnect 8 harnesses from the DEVE drive board: CN1, CN10, CN5, CN9, CN4, CN8, and supply. Remove 6 screws (3*10 silver) and then take out the DEVE drive Board Caution CN5, CN9, CN4, and CN8 are keyed the same and can be plugged in incorrectly. Start with CN8 which corresponds to the bottom clutch assembly, then work up to CN4, CN9, and CN5..

  • Page 89: Deve Drive Motor (Pl 9.7.16) And Clutch Cam Solenoid (Pl9.1.33) (T1 Clean)

    Disassembly 6.4.13 DEVE Drive Motor (PL 9.7.16) and Clutch Cam Solenoid (PL9.1.33) (T1 Clean) Remove the rear cover. (6.4.3) Remove the main board shield. (6.4.7b) Remove 4 screws (3*6 gold) and then remove the DEVE drive motor. Unplug 1 harness from the DEVE drive board. Screw Screw Screw...

  • Page 90: Erase Lamp (Pl 9.13.12)

    Disassembly 6.4.14 Erase Lamp (PL 9.13.12) Remove all the consumables (6.3.3) Remove the front cover and top cover (6.4.1) Remove the waster toner cartridge (o 6.4.18) Open the DEVE cover (Door A) and the exit cover (Door B). Remove 2 screws (4*10 silver) from the laser unit cover and 2 clips located next to the DEVE cover hinge. Remove the laser unit cover.

  • Page 91: Laser Brush (Pl 9.1.49)

    Disassembly 6.4.15a Laser Brush (PL 9.1.49) Remove all consumables (toner cartridges, transfer unit, and imaging unit (protect from light)) (6.3.3) Remove the front cover and top cover. (6.4.1) Remove the laser unit cover. (Steps 1-3 of 6.4.14) Remove 3 screws (4-15 silver) from the hinge bracket on the right of the DEVE cover Release the brush arms from the laser housing and pull the brush out of the printer..

  • Page 92: Deve Cover - Door A (Pl 9.1.18)

    Disassembly 6.4.15 DEVE Cover - Door A (PL 9.1.18) Remove the Laser Brush (6.4.15a). Remove the DEVE cover by pulling it in the direction of the arrows. LSU Cleaner Deve Cover 6-36...

  • Page 93: Laser Unit (Pl 9.1.21)

    Disassembly 6.4.16 Laser Unit (PL 9.1.21) Remove the transfer unit and imaging unit (protect from light and damage). (6.3.3) Remove the DEVE cover (Door A). (6.4.15) Remove the Laser Unit Brush. (6.4.15.1) Remove 4 screws (4*10 silver). Screw Screw Screw Screw Remove 1 screw (3*8 yellow).
  • Page 94 Disassembly Disconnect 2 harnesses and remove the laser unit. Harness Harness 6-38...

  • Page 95: Deve Oem Key Board - Crum Reader Board (Pl 9.14.36)

    Disassembly 6.4.17 DEVE OEM Key Board - CRUM Reader Board (PL 9.14.36) Remove the Front Cover and the Top Cover. (6.4.1) Disconnect the harness (CN1) from the HVPS and free it from the channel. Disconnect the harness (CN2) from the DEVE OEM board. 2) Remove the 6 screws (3*8 black) and remove the Board Harness Screw...

  • Page 96: Waste Toner Auger Assembly (Pl 9.13.1)

    Disassembly 6.4.18 Waste Toner Auger Assembly (PL 9.13.1) Remove the Front Cover and the Top Cover. (6.4.1) Caution It is very likely that waste toner will be spilled when removing the waste toner assemby. Have a toner vacuum when servicing this part. NEVER use a standard vacuum cleaner to clean up spilled toner.

  • Page 97: Waste Toner Cartridge Full Sensor (Pl 9.14.1)

    Disassembly 6.4.18a Waste Toner Cartridge Full Sensor (PL 9.14.1) Remove the Front Cover and the Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the Fuser and Fuser Cover Base. (6.4.5 and 6.4.5.1) Remove the LVPS. (6.4.7) Remove the Main Drive Assembly. (6.4.9) Disconnect the harness CN17 from the main board.

  • Page 98: Mpt (Multi-Purpose Tray) Feed Assembly And Roller (Pl 9.17.0)

    Disassembly 6.4.19 MPT (Multi-Purpose Tray) Feed Assembly and Roller (PL 9.17.0) Remove all consumables (Toner cartridges, Transfer unit, and Imaging Unit (protect from light)) (6.3.3) Remove the Front Cover and Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the Duplex Cover. (6.4.4) Remove the LVPS and LVPS Cover.
  • Page 99 Disassembly 6.4.19 cont’d >> MPT Feed Roller Place the MPT assembly on a flat surface and remove the e-ring and washer securing the pick roller shaft to the assembly. Slide the shaft to the right to free the roller and remove it. Service Manual 6-43...
  • Page 100 Disassembly >> On re-assembly: Note The roller has 3 pieces; 2 collars and the roller. When re-assembling the roller, the collars fit with the long ends facing out. The hole through the roller is round on one end and D shaped on the other. The D shaped end needs to face the left.

  • Page 101: Main Frame (Pl 9.13) And Base Frame (Pl 9.16)

    Disassembly 6.4.20 Main Frame (PL 9.13) and Base Frame (PL 9.16) Remove the Front Cover and Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the Duplex Cover. (6.4.4) Remove the LVPS and LVPS Cover. (6.4.7a) Remove the Main Board Shield. (Steps 1 and 2 of 6.4.11) Remove the DEVE Cover (Door A).

  • Page 102: Pick Roller Assembly, Tray1 (Pl 9.18.0)

    Disassembly 6.4.21 Pick Roller Assembly, Tray1 (PL 9.18.0) Remove the Main Frame and Base Frame. (6.4.20) Remove the split ring from the white gear. Remove the gear by rotating it to the no tooth portion. Gently pull out on the outer bushing’s locking tab, where the gear was, to free it from the chassis. Align the tab in the bushing with the slot in the base and slide it toward the back of the printer to free it.

  • Page 103: Pick Roller (Pl 9.18.12)

    Disassembly 6.4.22 Pick Roller (PL 9.18.12) Remove all consumables (Toner cartridges, Transfer unit, and Imaging Unit (protect from light)) (6.3.3) Remove the Rear Cover. (6.4.3) Remove the Duplex Cover. (6.4.4) Remove the LVPS Cover. (6.4.7a) Gently and slowly, rotate the printer onto its front. Do not spill waste toner into the printer. Remove the split ring from the white gear.

  • Page 104: Paper Pickup Solenoid (Pl 9.16.22)

    Disassembly 6.4.23 Paper Pickup Solenoid (PL 9.16.22) Remove all consumables (Toner cartridges, Transfer unit, and Imaging Unit (protect from light)) (6.3.3) Remove the Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the LVPS and LVPS Cover. (6.4.7a) Remove the LVPS inner cover by lifting it out of the printer, it is not held by screws. Remove the 1 screw securing the solenoid to the base.

  • Page 105: Temperature Sensor (Pl 9.16.23)

    Disassembly 6.4.24 Temperature Sensor (PL 9.16.23) Remove the Front Cover and Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the Duplex Cover. (6.4.4) Remove the LVPS and LVPS Cover. (6.4.7a) Remove the Main Board Shield. (Steps 1 and 2 of 6.4.11) Remove the DEVE Cover (Door A).

  • Page 106: Paper Feed Roller (Pl 9.19.13)

    Disassembly 6.4.25 Paper Feed Roller (PL 9.19.13) Open Door C and protect the transfer roller. Remove the e-ring and slide the large black feed roller off the shaft. This roller is a press-fit roller, so gently work the roller off the shaft using a small flat-blade screwdriver. >>...

  • Page 107: Paper Feed Roller Mid (Pl 9.19.9)

    Disassembly 6.4.26 Paper Feed Roller Mid (PL 9.19.9) Open Door C and protect the transfer roller. Remove the e-ring from the shaft. Remove the 2 screws from the bracket. Caution Being careful not to lose the white bushing and black plastic washer, when removing the bracket. This roller is a press-fit roller, so gently work the roller off the shaft using a small flat-blade screwdriver.

  • Page 108: Feed Sensor (Pl 9.20.2)

    Disassembly 6.4.27 Feed Sensor (PL 9.20.2) Remove the Waste Toner Assembly. (6.4.18) Open Door C and protect the transfer roller. Unscrew the links from the door and lay the door down flat for more clearance. Remove 3 screws (type) from the inner paper path cover and remove it. Remove the 2 screws (type) securing the sensor housing to the printer and remoe the housing.

  • Page 109: Fuser Exit Sensor (Pl 9.14.5)

    Disassembly 6.4.28 Fuser Exit Sensor (PL 9.14.5) Remove the Front Cover and Top Cover. (6.4.1) Remove the Rear Cover. (6.4.3) Remove the Duplex Cover (Door C). (6.4.4) Remove the Fuser and Fuser Cover Base. (6.4.5 and 6.4.5.1) Remove the LVPS and LVPS Cover. (6.4.7) Remove the Main Drive Assembly.

  • Page 110: 500-Sheet Feeder (Pl 9.1.44)

    Disassembly 6.4.29 500-Sheet Feeder (PL 9.1.44) Turn the printer off and remove all cables. Using 2 people, lift the printer off the 500 Sheet Feeder. Front Door D Tray 2 Contacts Sensor 6-54...

  • Page 111: Maintenance And Diagnostics

    Maintenance and Diagnostics Maintenance and Diagnostics This chapter describes some of the main service procedures including: Using the Engine Diagnostic Contol mode (EDC) Clearing paper jams Test patterns. Much of this chapter is also included in the user’s guide. 7.1 Paper path and Paper jam 7.1.1 Paper path Exit Sensor EXIT Ass'y...

  • Page 112: Jams

    Maintenance and Diagnostics 7.1.2 Jams 1) Jam at Tray 1/Tray 2 (Jam in feed area) After paper pick, paper was not fed any further. Paper did not reach the feed sensor in time. Feed sensor is faulty and does not detect paper. Tray 1 paper pick error: When paper is not picked from Tray 1.
  • Page 113 Maintenance and Diagnostics 4) Jam at C (Jam in duplex area) Jams in the duplex area occur while printing the reverse Exit Sensor side of the paper. After printing the front side, the duplex solenoid must operate in order to feed the paper back into the duplex path.

  • Page 114: Jam Removal

    Maintenance and Diagnostics 7.2 Jam Removal When a jam occurs while printing, a jam message is displayed on the control panel. * Jam at Tray 1: Paper jam in Tray 1. * Jam at MPT: Paper jam in the MPT. * Jam at Tray 2: Paper jam in Tray 2.

  • Page 115: Sample Prints

    Maintenance and Diagnostics 7.3 Sample Prints This product has the several sample patterns for maintenance. With the sample patterns, check the existence of the abnormality. The patterns help to regularly maintain the product. 7.3.1 Printing a Demo Page Print a demo page to make sure that the printer is operating correctly. Press the Menu button on the control panel until you see Information on the display.

  • Page 116: Checking Consumable Life

    Maintenance and Diagnostics 7.3.4 Checking Consumable Life Checking the Remaining Toner You can check the level of toner left in each cartridge. Maintenance, In Ready mode, press the Menu button on the control panel until you see then press OK. Press the Scroll button to access the Check Toner menu, then press OK.

  • Page 117: Control Panel Functions

    Maintenance and Diagnostics 7.4 Control Panel Functions The control panel on the front of your printer has a display and seven buttons. 7.4.1 The Display Buttons Status Map Display : displays the printer status and job in progress. Message Description Ready The printer is on-line and ready to print.

  • Page 118: Control Panel Buttons

    Maintenance and Diagnostics 7.4.2 Control Panel Buttons Item Description When an error occurs, a lamp turns on at the corresponding location on the Status Map. The status map is located on the control panel. The color of the On-line/continue button indicates the status of the printer. Press to switch between on-line and off-line.

  • Page 119: Control Panel Menu Map

    Maintenance and Diagnostics 7.4.3 Control Panel Menu Map Phaser 6100 Color Laser Printer Menu Map Information Config Page Menu Map Demo Page Connection Pg* Top Margin Long Edge Page Layout Short Edge Left Margin Short Binding Duplex Long Binding Duplex Margin Color Auto CMYK...

  • Page 120: Repeating Defects

    Maintenance and Diagnostics 7.5 Repeating Defects If an image defects appears at regular intervals on the printed-paper, it may be due to a faulty or damaged maintenance item or part. To identify which maintenance item is responsible for the defect, refer to the table below and check the condition of the appropriate roller.

  • Page 121: How To Use Engine Diagnostic Control Mode (Edc)

    Maintenance and Diagnostics 7.6 How to use Engine Diagnostic Control Mode (EDC) 7.6.1 What is EDC Mode EDC Mode is a feature that allows the service technician to check the condition of the print engine. It can check the operating condition of the motors, sensors, solenoids and clutches, measure the high voltage from the HVPS and check the operation of the fuser and laser units.

  • Page 122: Edc Menu Map

    Maintenance and Diagnostics 7.6.2 EDC Menu Map MOTOR TEST SOLENOID TEST SENSOR TEST LSU & FUSER TEST Main Motor Y Clutch Feed Sensor LSU Test Dev Motor M Clutch Exit Sensor Laser Diode Fan Motor C Clutch Waste Box Sensor Fuser Waste Motor K Clutch...

  • Page 123: Motor Tests

    Maintenance and Diagnostics 7.6.2.1 Motor Tests This function allows the operation of the various motors to be checked. <How to operate> Press the Scroll button until “Motor Test” is displayed. Press the OK button to select this function. Press the Scroll button until you see the name of the motor you wish to test. Press the OK button to run the test.

  • Page 124: Solenoid Tests

    Maintenance and Diagnostics 7.6.2.2 Solenoid Tests This function allows the operation of the various solenoids and clutches to be checked. <How to operate> Press the Scroll button until “Solenoid” is displayed. Press the OK button to select this function. Press the Scroll button until you see the name of the solenoid or clutch you wish to test. Press the OK button to run the test.

  • Page 125: Sensor Tests

    Maintenance and Diagnostics 7.6.2.3 Sensor Tests This function allows the operation of the various sensors to be checked. <How to operate> Press the Scroll button until “Sensor Test” is displayed. Press the OK button to select this function. Press the Scroll button until you see the name of the sensor you wish to test. Press the OK button to run the test.

  • Page 126: Test Prints

    Maintenance and Diagnostics 7.6.2.5 Test Prints This function allows the printer to be checked by printing various test prints. <How to operate> Press the Scroll button until “Test Print” is displayed. Press the OK button to select this function. Press the Scroll button until you see “Select Tray”...

  • Page 127: Hvps Tests

    Maintenance and Diagnostics 7.6.2.6 HVPS Tests This function provides an “acceptable range” specification for the HVPS outputs. Note These are not actual readings. <How to operate> “HVPS” Press the Scroll button until is displayed. Press the OK button to select this function. Press the Scroll button until you see the name of the voltage you wish to test.

  • Page 128: Regi.set Test

    Maintenance and Diagnostics 7.6.2.7 Regi.Set Test This function adjusts the vertical color registration for the printer. <How to operate> From the main menu, in customer mode go to “Maintenance”, then “Registration”. Press the OK button to select this function, a page will automatically print. Identify and mark the Lead Edge of the page.

  • Page 129: Color Calibration

    Maintenance and Diagnostics 7.6.2.8 Color Calibration This feature controls the setting of the TRC (Tone Reproduction Curve). Note Color Calibration can be found on the control panel’s main menu, in normal customer mode, and is not part of the EDC diagnostic tests. <How to operate>...
  • Page 130 Maintenance and Diagnostics 7-20...

  • Page 131: Troubleshooting

    Troubleshooting Troubleshooting 8.1 Verifying Symptoms Before attempting to repair a problem with the printer, obtain a detailed description of the problem from the customer. Power On "8.1.1 Basic Check List" Control Panel - No Power - Control Panel - Main Board Ready Indicate "Error Message"...

  • Page 132: Basic Check List

    Troubleshooting 8.1.1 Basic Check List 1. Check power. Does “Warming Up” appear on the display ? If not, check the power cable, switch or LVPS. (see section 8.1.2 below) Verify the wall socket outputs the correct voltage. Do the Motors or other components initialize (listen for the main motor and fan)? If not, or there is no sounds, check the power cord, switch or LVPS.

  • Page 133: Initial Inspection

    Troubleshooting 8.1.2 Initial Inspection 1. Check printer power. The printer does not work at power on. Is the power switch (printer and wall socket) turned on? Is the power cord connected to the printer correctly? Is the power cord connected to the wall socket correctly? Is the wall socket outputting the correct voltage? Is the printer rated as the same voltage as the supply? The fan doesn’t work when power is turned on?

  • Page 134: Check The Consumable Life

    Troubleshooting 8.1.3 Check the Consumable Life The length of life for consumables is indicated by the quantity of printed images and percent of life used, some consumables will continue to operate even at their end of life, but should be replaced as soon as possible to avoid print-quality issues.

  • Page 135: Print-Quality Problems

    Troubleshooting 8.2 Print-Quality Problems Blank Page Example Possible Cause Sequence of Repair Actions Driver installation problem. Try printing a Demo Page. Check that the printer driver is installed correctly. Toner cartridge contacts are dirty or Check and clean the toner cartridge contacts. not making good contact.
  • Page 136 Troubleshooting White Spots / Black Spots / Colored Spots Example Possible Cause Sequence of Repair Actions Contamination of the internal Replace the toner cartridge. mechanism of the toner cartridge. Imaging unit surface contaminated or Replace the imaging unit. damaged. Transfer belt is contaminated or Replace the transfer belt.
  • Page 137 Troubleshooting Low Image Density, Light in ALL Colors Example Possible Cause Sequence of Repair Actions The image on the drum is light. Replace the toner cartridge. Poor toner transfer to the transfer belt. Check and clean the transfer belt contacts. Re-install or replace the transfer belt.
  • Page 138 Troubleshooting Deterioration of Print Quality In ALL Colors Example Possible Cause Sequence of Repair Actions Problem transferring the intermediate Check and clean the transfer belt contacts. images to the transfer belt. Re-install or replace the transfer belt. Contamination of the paper path. Check and clean the printers internal paper path.
  • Page 139 Troubleshooting Voids or White Areas Example Possible Cause Sequence of Repair Actions The paper is wet or moist. Use a fresh ream of dry paper and inspect the storage area for the media. Some parts of the image are blank Replace the fuser.

  • Page 140: Paper Feed Problems And Troubleshooting

    Troubleshooting 8.3 Paper Feed Problems and Troubleshooting 8.3.1 Trouble with the Top Margin Symptom: Printing begins at the wrong position on the paper (mis-registration?) Possible Cause Repair Actions Wrong sensor timing caused by a Replace the defective actuator. defective feed sensor actuator. 8.3.2 Jam at Tray 1 / Tray 2 Symptoms: Paper has not exited from the tray.

  • Page 141: Jam At B, C

    Troubleshooting 8.3.4 Jam at B, C Symptoms: Paper is jammed inside the fuser. Paper is caught in the exit actuator. Paper is caught in the exit roller and fuser, but has not passed through the feed actuator. Possible Cause Repair Actions The exit sensor is defective if a Jam Check the exit sensor actuator for at B, C occurs after the paper is...

  • Page 142: Jam At Mpt

    Troubleshooting 8.3.6 Jam at MPT Symptoms: Indicated Jam at MPT on the control panel. Possible Cause Repair Actions Check the surface of the pick roller. Clean or replace the pick roller. Is it dirty or damaged? Check the MPT clutch (pick Replace the solenoid if defective.

  • Page 143: Printer Symptoms And General Troubleshooting

    Troubleshooting 8.4 Printer Symptoms and General Troubleshooting 8.4.1 Fuser Error Warning THE FUSER IS HOT! Use caution and allow the fuser cool down before handling. Symptoms: “Fuser Error Low/High Temperature” is displayed on the control panel. Checks and Causes Repair Actions Check the continuity of the thermostat, AC wire and Replace the fuser if any of these circuits are open.

  • Page 144: Paper Empty

    Troubleshooting 8.4.4 Paper Empty Symptoms: “Tray1/MPT/Tray2 [Size] Empty” is displayed on the control panel, even though paper is loaded. Checks and Causes Repair Actions Check for a broken or distorted paper empty sensor Replace the paper empty sensor actuator. actuator. Check that the actuator is not stuck. Test the tray empty sensor and actuator in EDC Replace any defective part as necessary.

  • Page 145: Cover Open Not Detected

    Troubleshooting 8.4.7 Cover Open Not Detected Symptoms: “Ready” is displayed on the control panel when a cover is open. Checks and Causes Repair Actions Check the switch actuators on the inside of the Replace the duplex cover (Door C) or developer cover (Door duplex (Door C) and developer (Door A) covers to see if they are broken or damaged.

  • Page 146: Curved Or Distorted Vertical Lines

    Troubleshooting 8.4.10 Curved or Distorted Vertical Lines Symptoms: Curved, wavy or distorted vertical lines on prints. Checks and Causes Repair Actions Use EDC mode to test the laser. Replace the laser Check the +24V signal between the main board Replace the main board. (CN12) and the laser.

  • Page 147: Error Message Handling

    Troubleshooting 8.5 Error Message Handling ADC Not Confirm Error: The ADC is defective. Turn the printer OFF, wait 30 seconds then turn the printer back ON. Replace the main board if the error recurs. Cover Open Door A or Door C is not properly closed. DEVE Cover (Door A) or the duplex cover (Door C) is open.
  • Page 148 Troubleshooting Fuser Error Low Temperature The temperature of the fuser is lower than the Verify the fuser is installed correctly. Printing temperature. If not, re-install. The Fuser harness is not connected properly. Check the AC power to the fuser (copper contact.) If bad, go to step 3, otherwise, go to step 4.
  • Page 149 Troubleshooting Main Motor Error The main motor that drives the imaging unit, the Open the DEVE cover and top cover, then check the transfer belt and the pickup assembly is faulty. imaging unit and transfer unit. Reseat or replace if defective. Open the rear cover and check (CN1) main motor harness to (CN27) main board harness.
  • Page 150 Troubleshooting Invalid Imaging Unit Error Cannot communicate with the imaging unit. Verify a Xerox imaging unit is installed. This is caused by an incorrect value of the OEM If not replace the imaging unit. resistor in the imaging unit. Clean the imaging unit contact points.
  • Page 151 Troubleshooting CTD Calibration Error Turn the printer off, wait 30 seconds, then turn it back on. Clean the CTD sensor, located on the underside of the transfer belt. Power cycle the printer to clear the error. If the error recurs, reseat the imaging unit and transfer belt and power cycle the printer again.
  • Page 152 Not enough memory capacity. The printer has insufficient memory to build the page image. The print process will be cancelled automatically and the printer will return to ready. Add more memory. Note Note Note Xerox does not currently support adding memory 8-22...
  • Page 153 Note Note Note Xerox does not currently support adding memory Replace Transfer Roller Soon The transfer roller is nearing it’s end of life. Replace the transfer roller when the image quality becomes unacceptable.
  • Page 154 Troubleshooting Install [Color] Toner Occurs when the toner cartridge of the indicated Verify the toner cartridge is installed. color is not installed. Check the contact point for contamination. If the toner cartridge is not installed. Replace the toner cartridge. The resistor cannot be read due to the Replace the DEVE_OEM board, the HVPS or the main contamination of the contact points.

  • Page 155: Parts List

    9.14 Front Frame Assembly 9.15 Rear Frame Assembly 9.16 Base Frame Assembly 9.17 MPT Assembly 9.18 Pickup Assembly 9.19 Feeder Assembly 9.20 Paper Guide Assembly 9.21 Transfer Belt Cam Assembly 9.22 Fuser Base Assembly 9.23 Xerox Kits and Accessories Service Manual 9-1...

  • Page 156: Consumables, Routine Maintenance Items And Options

    Parts List 9.0 Consumables, Routine Maintenance Items and Options Toner Cartridge (C,M,Y,K) Transfer Belt Imaging Unit Tray 2 (SCF) Waste Toner Cartridge Item Life based on 5% coverage Part No. Replaceable by Black Standard Toner Cartridge 3,000 106R00679 User replaceable Black High capacity 7,000 106R00684...

  • Page 157: Parts List

    Parts List Screws Used in the Printer (Hardware Kit) DESCRIPTION SPEC DESCRIPTION SPEC SCREW-MACHINE 2.6*4, GOLD SCREW-TAPTITE 3*6, GOLD SCREW-TAPPING 4*15, GOLD SCREW-TAPTITE 3*8, BLACK S13 SCREW-MACHINE 3*8, SILVER SCREW-TAPPING 3*8, GOLD SCREW-TAPTITE 4*10 SILVER SCREW-TAPTITE 2.6*6, GOLD SCREW-TAPTITE 3*6, GOLD SCREW-TAPTITE 3*8, BLACK S16 SCREW-MACHINE...

  • Page 158: Main Exploded View

    Parts List 9.1 Main Exploded View...
  • Page 159 Parts List Main Assembly Parts List 9.1 Part number Part Name and (part description) Set_Xerox 108R00594 Transfer Belt 108R00593 Imaging Unit 106R00679 Standard Capacity Black Toner Cartridge 106R00684 High Capacity Black Toner Cartridge 106R00676 Standard Capacity Cyan Toner Cartridge 106R00680 High Capacity Cyan Toner Cartridge 106R00677 Standard Capacity MagentaToner Cartridge...
  • Page 160 Parts List Part number Part Name and (part description) 116-1933-00 Harness-Main LVPS (SMPS) 116-1934-00 Clutch Cam Solenoid Bushing 8/5 116-1864-00 Sheet Cover Front OPE (Control Panel Cover) HVPS Shield LVPS (SMPS) Cover OPC Drive Gear 2_Z40 Cam-T2 Engage Shaft Cover Exit Hinge Bracket Guide Bracket Upper Bracket Lower...

  • Page 161: Front Cover

    Parts List 9.2 Front Cover Front Cover 9.2 Part number Part Name and (part description) Xerox Front Cover Cover-Front Hinge F Cover Front Hinge R 116-1917-00 Waste Cartridge Lock 116-1937-00 Front Cover Lock 116-1918-00 Waste Cartridge Lock Spring Strap 116-1938-00...

  • Page 162: Top Cover

    Parts List 9.3 Top Cover Top Cover 9.3 Part number Part Name and (part description) 116-1856-00 Top Cover ASM Cover Top Spring-CS Cover Top Button Cover Top Opener Cover Top Stacker Stopper-Stacker F Stopper-Stacker R Lavel(P)-Top P/O Screw Kit Screw-Taptite...

  • Page 163: Deve Cover (Door A)

    Parts List 9.4 DEVE Cover (Door A) 11 8 DEVE Cover (Door A) 9.4 Part number Part Name and (part description) 116-1857-00 DEVE Cover ASM (Door A) Spring TS Cover DEV Lock Bar Label(P) DEVE Cover Cover Dup Locker F Cover Dup Locker R Cover DEVE Cover DEVE Inner...

  • Page 164: Exit Assembly

    Parts List 9.5 Exit Assembly 11-6 11-3 11-7 11-2 11-2-1 11-22 11-5 11-9 11-10 11-21 11-8 11-S8 11-1 11-4 11-S8 11-13 11-14 11-15 11-16 11-18 11-12 11-17 11-19 11-20-1 11-20 11-20-2 11-11 11-S8 Exit Assembly 9.5 Part number Part Name and (part description) 116-1853-00 Exit ASM Cover Exit...
  • Page 165 Parts List Part number Part Name and (part description) Cover Exit R Cap Cover Exit Hinge 116-1939-00 Exit Frame ASM 11-1 Guide Exit Upper 11-2 Roller Exit Drive 11-2-1 Roller Exit Drive Idle 11-3 Bearing Large DP 11-4 Ground Exit 11-5 Bearing Large DP 11-6...

  • Page 166: Duplex Assembly

    Parts List 9.6 Duplex Assembly 2-29 2-10 2-9 2-28 2-16 2-11 2-14 2-22 2-15 2-10 2-20 2-16 2-21 2-14 2-19 2-26 2-15 2-16 2-12 2-23 2-13 2-12-6 2-24 2-25 2-12-1 2-12-8 2-12-2 2-27 2-12-4 2-17 2-12-3 2-30 2-12-4 2-18 2-12-7 2-12-5 2-17 2-30...
  • Page 167 Parts List Duplex Assembly 9.6 Part number Part Name and (part description) 116-1928-00 Duplex ASM Cover Right Cover Duplex Cover Dup Lock Shaft Cover Duplex Handle Spring TS Cover Dup Locker F Cover Dup Locker R Cover Duplex Link Cover Duplex Link R Cover Duplex Rail 1-10 Cover Duplex Rail R...
  • Page 168 Parts List Part number Part Name and (part description) 2-18 Fuser Exit Spring 2-19 Bracket Guide B 2-20 Bracket Guide Duplex 2-21 Bracket Ground B 2-22 Bracket Ground A 2-23 Bracket Ground D 2-24 Bracket Ground C 2-25 CBF-Harness Control Panel Ground (OPE) 2-26 Bushing Feed 2-27...

  • Page 169: Deve Drive Assembly

    Parts List 9.7 DEVE Drive Assembly DEVE Drive Assembly 9.7 Part number Part Name and (part description) 116-1851-00 DEVE Drive ASM Bracket DEVE Front Clutch Spring DEVE Shaft DEVE Clutch Bushing D6/L4 P/O Hardware Kit E-ring Shaft DEVE Drive Washer plain Gear DEVE DRive 2_Z20 Gear Idle Z51 Harness Guide...
  • Page 170 Parts List Part number Part Name and (part description) Gear DEVE Idle_Z41 Gear DEVE Idle_Z53 Bracket DEVE Rear 116-1880-00 Motor BLDC-DEVE (DEVE Motor) Washer Plain PIN ADF Gear DEVE Drive 1_Z25 Gear DEVE Clutch 2_Z33 Screw-Taptite Screw-Taptite 9-16...

  • Page 171: Main Drive Assembly

    Parts List 9.8 Main Drive Assembly Main Drive Assembly 9.8 Part number Part Name and (part description) 116-1850-00 Main Drive ASM 116-1880-00 Motor BLDC-Main Drive (Main Motor) Duplex Solenoid 116-1934-00 Clutch Cam Solenoid Clutch Electric Feed Busing 8/5 Bushing D6/L4 P/O Hardware Kit Spring ETC Solenoid DP Gear Feed Drive_Z37...
  • Page 172 Parts List Part number Part Name and (part description) Gear Idle Z51 Gear Idle Z53 Gear ITB (Transfer Belt) Drive 1_Z90 Gear ITB Drive 2_Z30 Gear OPC Drive 1_Z120 Gear OPC RDCN_Z120/Z60 Gear RDCN Z110/Z37 Gear RDCN Z120/Z60 Gear Swing Drive Gear T2 Drive Z_25 Shaft Feed Drive Shaft Fuser Drive...

  • Page 173: Fuser Assembly

    Parts List 9.9 Fuser Assembly Fuser Assembly 9.9 Part number Part Name and (part description) 119-1579-00 230V Fuser Assembly 116-1567-00 110V Fuser Assembly Roller-Heat Bearing Fuser F Bearing Fuser Gear Gear Fuser Z35 Spring-ETC-PR Fuser Upper Fuser Lower Ground Fuser NPR Electrode AC Wire Thermostat NPR Electrode F...
  • Page 174 Parts List Part number Part Name and (part description) Cover Thermostat Cover Cleaning Roller Exit Idle Roller Exit F_Up Guide DP Side NPR Electrode Connector Halogen Lamp 300w (110V/220V) Halogen Lamp 500W (110V/220V) Actuator Exit Spring ETC Actuator Guide Output Thermistor NTC Nut Hexagon Guide Input...

  • Page 175: Paper Tray, Tray 1 (Fct)

    Paper Tray, Tray 1 (FCT) Frame Cassette Cover Cassette Guide Side CST Guide Front CST Guide Rear Plate K/UP Finger Spring Plate Guide Guide Plate Paper Spring Spring Locker Locker Plate RPR Pad CST Label(R)-Height Xerox Label(P)-Instruction P/O Screw Kit Screw_Taptite Service Manual 9-21...

  • Page 176: Paper Tray, Tray 2 (Sct)

    Parts List 9.11 Paper Tray, Tray 2 (SCT) Paper Tray, Tray 2 (SCF) Assembly 9.11 Part number Part Name and (part description) 116-1940-00 Paper Tray, Tray 2 (SCT) Frame Cassette Cover Cassette Guide Side CST Guide Front CST Guide Rear Plate K/UP Finger Spring Plate Guide...

  • Page 177: Optional 500-Sheet Feeder (Scf)

    Parts List 9.12 Optional 500-Sheet Feeder (SCF) 3-10 3-12 3-13 3-11 1-S9 2-S9 (SCF) Optional 500-Sheet Feeder Assembly 9.12 Part number Part Name and (part description) 119-6506-00 500-Sheet Feeder HOU-Motor Ground_Roller P/O Hardware Kit E-ring Service Manual 9-23...
  • Page 178 Parts List Part number Part Name and (part description) Motor Step Pick-up Solenoid Gear P/UP DRV SCF Gear idler Option Gear idle Z30 Gear Idle SCF Bracket Gear Screw_Taptite Hou-Guide Lower SCF Guide Lower Rail Spring CS Bushing Idle Roll-SCF-16 Holder Idle Roll-16 Cover Guide Lower Guide Lower...
  • Page 179 Parts List Part number Part Name and (part description) Harness Driver Ground Harness SCF_8P Board SUB-SCF P/O Screw Kit Screw-Taptite P/O Screw Kit Screw-Taptite Service Manual 9-25...

  • Page 180: Main Frame

    Parts List 9.13 Main Frame 1-17 1-1-2 1-10 1-14 1-1-5 1-1-3 1-15 1-1-1 1-1-4 1-20 1-11 1-18 17-2 17-1 17-5 17-6 1-16 17-4 1-12 17-9 17-8 17-7 1-19 17-3 1-13 9-26...
  • Page 181 Parts List Main Frame 9.13 Part number Part Name and (part description) 116-1872-00 OPC Waste Toner Duct 116-1956-00 Waste Toner Motor ASM 1-1-S1 Screw-Machine 1-1-1 116-1957-00 E-ring (also in hardware kit) 1-1-2 116-1958-00 Waste Toner Motor-DC 1-1-3 Bracket Waste Toner Motor 1-1-4 Gear Worm Wheel Idle 1-1-5...
  • Page 182 Parts List Part number Part Name and (part description) Frame Base Frame Rear Frame Front 116-1874-00 Erase Lamp ShutterTension P/O Hardware Kit Ring CS Cable Clamp 116-1919-00 Dust Cover OPC 116-1920-00 OPC Toner Housing 17-1 Vibration Plate Outlet 17-2 Bushing Waste Cam M 17-3 Cap Shutter Transfer Belt 17-4...

  • Page 183: Front Frame Assembly

    Parts List 9.14 Front Frame Assembly Front Frame Assembly 9.14 Part number Part Name and (part description) Frame Front 116-1879-00 Waste Toner Sensor P/O Hardware Kit Ring CS Holder M Waste Toner Sensor Service Manual 9-29...
  • Page 184 Parts List Part number Part Name and (part description) 116-1881-00 Waste Toner Sensor Actuator Sub Waste Sensor Transfer Belt Lifter Sponge Duct Toner Transfer Belt Lift Duct Toner Transfer Belt Lifter Sponge Transfer Belt Duct 116-1883-00 Transfer Belt Waste Toner Housing Housing M Waste Toner Transfer Belt Sponge Duct Toner OPC Cap Shutter Transfer Belt...
  • Page 185 Parts List Part number Part Name and (part description) Spring Transfer Belt Lock (ITB) Spring Toner Duct Housing P/O Screw Kit Screw-Taptite P/O Screw Kit Screw-Taptite P/O Screw Kit Screw-Taptite Service Manual 9-31...

  • Page 186: Rear Frame Assembly

    Parts List 9.15 Rear Frame Assembly 9-32...
  • Page 187 Parts List Rear Frame Assembly 9.15 Part number Part Name and (part description) Frame Rear P/O Hardware Kit Ring CS 116-1942-00 CBF Harness HVPS Charge 116-1943-00 CBF Harness HVPS T1 116-1944-00 CBF Harness HVPS T2 Feed Unit Plate Switch Duplex Plate Guide T2 Rear Ground Main Transfer Belt Drive Ground Laser DEVE Drive...

  • Page 188: Base Frame Assembly

    Parts List 9.16 Base Frame Assembly 9-34...
  • Page 189 Parts List Base Frame Assembly 9.16 Part number Part Name and (part description) 116-1925-00 Base Frame 116-1889-00 MPT Pickup ASM 116-1890-00 Tray 1 Pickup ASM 116-1891-00 Harness SCF 116-1926-00 Assembly, AC Switch Guide Rail Foot ML80 Ground Tray 2 (SCF) Screw Cover Locking Cap Cover M Base Bar Cam Catch...

  • Page 190: Mpt Assembly

    Parts List 9.17 MPT Assembly 9-36...
  • Page 191 Parts List MPT Assembly 9.17 Part number Part Name and (part description) 116-1889-00 MPT Pickup ASM P/O Hardware Kit E Ring 116-1894-00 MPT Solenoid Spring Cam MPT Spring Pickup MPT Spring MPT Bracket Solenoid Holer Cam MPT Roller Cam MPT 116-1895-00 Actuator, MPT Empty MPT Adjuster...

  • Page 192: Pickup Assembly

    Parts List 9.18 Pickup Assembly Pickup Assembly 9.18 Part number Part Name and (part description) 116-1890-00 Tray 1 Pickup ASM Pickup Spring Ground Feed Guide Input Cap Connector L Cap Connector U 116-1897-00 Actuator Tray 1 Empty Pickup Shaft Guide Paper 116-1898-00 Tray 1 Empty Sensor Bearing Shaft...

  • Page 193: Feeder Assembly

    Parts List 9.19 Feeder Assembly Feeder Assembly 9.19 Part number Part Name and (part description) Feed Unit Holder Pinch C3 Holder Pinch C3 Roller Feed L Feed Idler Shaft Service Manual 9-39...
  • Page 194 Parts List Part number Part Name and (part description) Holder Pinch C5 Holder Pinch C5 Roller Feed L Feed Idler Shaft Holder Pinch M Holder Pinch M Roller Feed L Holder Feed Roller Feed S Feed Idler Shaft Frame Feed P/O Hardware Kit E Ring Bushing Feed Mid...

  • Page 195: Paper Guide Assembly

    Parts List 9.20 Paper Guide Assembly Paper Guide Assembly 9.20 Part number Part Name and (part description) Paper Guide 116-1901-00 Feed Sensor Cover 116-1902-00 Feed Sensor 116-1903-00 Feed Sensor Actuator Paper Guide Bracket 116-1952-00 Sheet - Paper Guide 116-1953-00 Guide Paper Path Actuator Spring P/O Screw Kit Screw-Taptite...

  • Page 196: Transfer Belt Cam Assembly

    Parts List 9.21 Transfer Belt Cam Assembly 9-42...
  • Page 197 Parts List Transfer Belt Cam Assembly 9.21 Part number Part Name and (part description) 116-1873-00 ITB Cam ASM (Transfer Belt Cam) Transfer Belt Cam Lower 116-1904-00 PTL SensorUpper Erase Lamp (PTL) 116-1905-00 PTL Path Shaft Transfer Belt Cleaning Cam Transfer Belt Cleaning Cam Bushing D6/L4 P/O Hardware Kit E Ring...

  • Page 198: Fuser Base Assembly

    Parts List 9.22 Fuser Base Assembly Fuser Base Assembly 9.22 Part number Part Name and (part description) Fuser Base Fuser Base 116-1907-00 Housing Switch AC 116-1906-00 Switch AC P/O Screw Kit Screw 9-44...

  • Page 199: Xerox Kits And Accessories

    Parts List 9.23 Xerox Kits and Accessories Kits Description Part Number Screw/Washer Kit (See page 9-3) 116-1908-00 Hardware Kit 116-1909-00 Main Drive Hardware Kit 116-1910-00 LVPS Fuse Kit 116-1960-00 Miscellaneous Items Description Part Number Network Interface Board (DN Model Only) 116-1916-00 128 Mbytes, 16M x 64, PC133;...
  • Page 200 Parts List 9-46...

  • Page 201: Block Diagram

    Block Diagram Block Diagram 10. Block Diagram Service Manual 10-1...

  • Page 202: Controller Block Diagram

    Block Diagram 10.1 Controller Block Diagram 10-2...

  • Page 203: Connection Diagram

    Connection Diagram Connection Diagram Service Manual 11-1...
  • Page 204 Connection Diagram 11-2...
  • Page 205 Connection Diagram Service Manual 11-3...
  • Page 206 Connection Diagram 11-4...
  • Page 207 Connection Diagram Service Manual 11-5...
  • Page 208 Connection Diagram 11-6...
  • Page 209 Connection Diagram Service Manual 11-7...
  • Page 210 Connection Diagram 11-8...

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