Xerox Phaser 6125

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2-48 Phaser 6125/6130 Color Laser Printer Service Manual

Theory of Operation

s6130-037

Front

Sub Drive

Fuser

Heat Roller Idler Gear

Heat Roller Gear

[ Heat Roller ]

Exit Idler Gear

Exit Gear

[ Exit Roller ]

Fuser Drive

: Indicates The Engagement Of Gears

[ Name Of Moving Parts ]

Main Page

Service Terms5
Symbols Marked on the Product6
Power Safety Precautions7
Electrostatic Discharge (ESD) Precautions8
Service Safety Summary9
Regulatory Specifications11
Manual Organization13
Table of Contents15
General Information23
Printer Introduction and Overview24
Technical Support Information24
Printer Configurations25
Parts of the Printer26
Front and Side Views26
Rear View27
Control Panel28
Printer Options30
Additional Memory30
Multi-Protocol Network Card30
Maintenance Items31
Consumables32
Printer Specifications33
Memory Specifications34
Electrical Specifications34
Print Speed35
Environmental Specifications35
Operating Mode36
First Print Output Time (FPOT)37
Image Specifications38
Physical Dimensions and Clearances39
Mounting Surface Specifications40
Media and Tray Specifications41
Controller Functions42
Job Control42
Non-Genuine Mode44
Toner Remaining Amount45
Maintenance Function45
Diagnostics46
Information Pages46
Theory of Operation51
Phaser 6125/6130 Operational Overview52
Print Process Block Diagram52
Printing Process53
Charging54
Exposure55
Development57
Transfer (Drum59
Cleaning (Imaging Unit)60
Excess Toner Collection61
Fusing62
Paper Path of the Printer63
Paper Path Route63
Paper Path Components64
Major Assemblies and Functions65
Paper Tray65
Paper Feeder67
Manual Feed & Registration69
Transfer Unit and Fuser73
Laser Unit74
Toner Cartridge & Dispenser76
Imaging Unit77
Drive Assembly78
Electrical80
Printer Modes84
Operational Modes84
Printer Control84
Paper Size Detection84
Laser Unit Light Quantity Control84
Process Control85
Color Registration Control86
Fuser Control87
Drive Transmission88
Main Drive88
Sub Drive Assemblies90
Error Messages and Codes99
Introduction100
Accessing Error History Report100
Error History Report100
Servicing Instructions102
Messages, Chain Link Codes, and Procedures103
Error Messages Abbreviations103
Error Message and Chain Link Code Summary104
Image Processor Board Errors119
Flash Memory Errors119
Out of Memory120
PDL Error121
Network/Fontrom/Macaddress/Ram/Controller/Nvram/Asic Error122
PAGEC Time Error123
RAM Error124
Toner Cartridge Errors125
Insert Yellow/Cyan/Magenta/Black Cartridge125
Non-Xerox Toner, Invalid Yellow/Magenta/Cyan/Black125
Replace Yellow/Magenta/Cyan/Black125
Yellow/Magenta/Cyan/Black Low125
Waste Full, Yellow/Magenta/Cyan/Black Cartridge126
Jam Errors127
Jam at Tray127
Jam at Front Cover132
Jam at Manual Feed Slot135
Jam at Front Cover140
Jam at Exit142
Jam at Registration Roll144
MPC Errors148
MPC Error148
Transfer Unit Errors149
CTD Sensor Error/Ctd Sensor/Check Unit149
DTB Life Over/Transfer Life150
Insert Imaging Unit151
Low Density Yellow/Magenta/Cyan/Black Cartridge152
Paper Setting Errors154
Insert Output to Tray/Manual Feed154
Load Manual Feed154
Load Tray157
Load Tray/Tray Empty158
Fuser Errors160
Insert Fuser160
Replace Fuser / Fuser Life161
Fuser Error162
Motor Errors164
Fan Motor Error164
Motor Error165
Sub Motor Error167
Imaging Unit Errors169
Replace Imaging Unit/Phd CRUM Error169
Cover Open Errors170
Front Cover Open170
Side Door Open171
MCU Errors172
MCU Firmware Error172
MCU NVRAM Error173
Laser Unit Errors174
Laser Error174
System Error175
MCU Communication Error175
Other Errors176
Invalid Job176
Download Mode177
K Mode Sol Error178
Env Sensor Error180
General Troubleshooting181
Introduction182
System Startup182
Power on Self Test (POST)183
Service Diagnostics185
Entering Service Mode185
Using Service Diagnostics185
Service Mode Control Panel Button Descriptions185
Service Mode Menu Map186
Menu Map186
Printer Components188
Motors, Clutches, Solenoids, Lamps188
Sensors188
Service Mode Diagnostic Tests189
Diagnostic Tests and Utilities189
Sensor Tests200
Motor Tests207
Tray Feed Solenoid (Half/Init)210
Control Panel Troubleshooting217
Printer Does Not Come to a "Ready" State217
Control Panel LED Is On, Control Panel Display Is Blank217
Engine Test Print218
Inoperable Printer Troubleshooting219
Engine Power-Up Sequence219
Printer Continually Displays Warming up219
AC Power Supply Troubleshooting220
DC Power Supply Troubleshooting221
LVPS Overcurrent Protection Circuit221
LVPS Overvoltage Protection Circuit221
Lvps221
+24 VDC Interlock Switch223
Abnormal Noise and Electrical Problems224
Abnormal Noise When Power Is Turned on224
Abnormal Noise During Standby225
Abnormal Noise During Printing226
Electrical Noise229
AC Supply Problems230
DC Short231
Operating System and Application Problems232
Windows 2000, Windows XP, Windows Server Troubleshooting232
Verify Settings232
Verify Driver Installation232
Macintosh Troubleshooting (Mac os 10.2 and Higher)233
UNIX / Linux234
Print-Quality Troubleshooting237
Print-Quality Problems Overview238
Defects Associated with Specific Printer Components238
Checklist before Troubleshooting Print-Quality240
Checking the Printer Condition240
Checklist241
Test Prints244
No Image IOT244
Pattern IOT245
Grid 2 ESS245
Cyan 20% ESS246
Magenta 20% ESS246
Yellow 20% ESS247
Black 20% ESS247
Cmy 20% Ess248
Gradation ESS248
Toner Pallet Check249
Contamination Check250
Print-Quality Specifications251
Environmental Condition251
Quality Paper251
Paper Condition251
Printer Condition251
Specifications252
Print-Quality Troubleshooting256
Print-Quality Defect Definitions256
Repeating Defect Measurement257
Light or Undertone Print258
Blank Print (no Print)261
Black Print264
Vertical Blank Lines266
Horizontal Band, Voids, or Streaks268
Vertical Stripes271
Horizontal Stripes273
Partial Band275
Random Spots278
Repeating Bands, Lines, Marks, or Spots281
Residual Image or Ghosting282
Background Contamination284
Skew287
Damaged Paper290
Unfused Image293
Color Registration295
Adjustments and Calibrations297
Adjustments298
Color Registration298
Printing the Color Registration Correction Chart298
Enabling/Disabling Automatic Color Registration299
Adjusting Color Registration299
Resetting the Fuser301
Calibrations302
Initializing Print Meter302
Initializing NVM (NVRAM)302
Parameter Setting303
Cleaning and Maintenance307
Service Maintenance Procedure308
Recommended Tools308
Cleaning308
Maintenance309
RIP (Repair, Inspect, and Prevent) Procedure309
Service Parts Disassembly311
Overview312
Standard Orientation of the Printer313
Preparation314
Notations in the Disassembly Text315
Fastener Types316
Maintenance Items and Consumables317
Separator Roller317
Imaging Unit318
Fuser319
Toner Cartridges (C, M, Y, K)320
Covers321
Toner Access Door321
Rear Tray Cover322
Cassette Stopper322
Control Panel323
Top Cover324
Output Tray Extension325
Right Side Cover326
Left Side Cover327
Rear Cover328
Front Cover329
Paper Feeder331
Drive Clutch Kit331
Feed Drive Assembly332
Feed Solenoid334
Feeder Assembly335
Left Harness Assembly336
Manual Feed no Paper Sensor338
Feed Roller340
Xerographics341
Laser Unit341
Dispenser Assembly344
Erase LED Assembly347
Right Imaging Unit Restraint Block348
Left Imaging Unit Restraint Block349
Toner Cartridge Holder (K), (C), (M), (Y)350
Transfer Unit351
HVPS Board353
Frame354
I/P Board Cage354
Transfer Unit Pivot Kit355
Separate Upper and Lower Assemblies357
Drive362
Main Drive Assembly362
Sub-Drive363
Electrical364
Control Panel Harness364
Interlock Harness364
Lvps365
Fan366
GFI Breaker367
Humidity Sensor368
MCU Board369
Image Processor Board370
Toner Access Door Switch373
Parts List375
Serial Number Format376
Using the Parts List377
Print Engine Parts378
Parts List 1.1 Covers378
Parts List 2.1 Paper Tray380
Parts List 3.1 Paper Feeder (1 of 2)382
Parts List 3.2 Paper Feeder (2 of 2)384
Parts List 4.1 Xerographics386
Parts List 5.1 Dispenser388
Parts List 6.1 Transfer & Fuser390
Parts List 7.1 Drive392
Parts List 8.1 Electrical (1/2)394
Parts List 8.2 Electrical (2/2)396
Parts List 9.1 Wiring Harness398
Xerox Supplies and Accessories400
Service Kits401
Plug/Jack and Wiring Diagrams403
Plug/Jack Diagrams and Designators404
Print Engine Plug/Jack Designators404
Plug/Jack Locators408
General Diagram - Plug/Jack Locations408
Map 1 - Transfer Unit, Control Panel, Imaging Unit, Dispenser, Fuser410
Map 2 - Laser Unit, Feeder Assembly411
Map 3 - LVPS, Drive Motors, I/P Board, AC Power412
Map 4 - Toner Dispenser Motors, HVPS, MCU413
Notations Used in the Wiring Diagrams414
Print Engine Wiring Diagrams417
Wiring Diagrams Configurations417
DC Power Supply417
Feeder, Manual Feed, & Registration417
Drive422
Laser Unit424
Xerographic426
High Voltage Power Supply428
Developer429
Fuser431
Controller433
Phaser 6130 Menu Map436
Firmware Update437
Boot Controller Update437
Firmware Controller Update438
Firmware MPC Update439
Acronyms and Abbreviations440

Xerox Phaser 6125

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