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Phaser 6128MFP
Service Manual
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606 pages
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8-72
Phase
r 6128
MFP Ser
vice
Manual
Service P
arts Disassem
bly
23.
R
emov
e 2 screws (silv
er, tap,
8mm) that secure the bottom and 1
screw (silver,
M4, 6mm) that se
cures the rea
r of the Dispense
Assembly .
s6128mfp-248
495
497
Table of Contents
Main Page
Default Chapter
5
Table of Contents
5
About this Service Manual
15
Manual Organization
16
Symbols Marked on the Product
17
Power Safety Precautions
18
Electrostatic Discharge (ESD) Precautions
19
Service Safety Summary
20
Regulatory Specifications
22
1 General Information
25
Printer Introduction and Overview
26
Technical Support Information
26
Printer Configurations
27
Parts of the Printer
28
Front and Side Views
28
Rear View
29
Internal View
30
Control Panel
31
Maintenance Items
33
Consumables
34
Specifications
35
Printer Specifications
35
Scanning Specifications
36
Copy Specifications
37
Fax Specifications
38
Memory Specifications
39
Electrical Specifications
39
Print Speed
40
Environmental Specifications
40
Operating Mode
41
First Print Output Time (FPOT)
42
First Copy Output Time
42
Image Specifications
43
Physical Dimensions and Clearances
44
Mounting Surface Specifications
45
Media and Tray Specifications
46
Controller Functions
47
Job Control
47
Non-Genuine Mode
49
Maintenance Function
50
Diagnostics
50
Information Pages
51
2 Theory of Operation
55
Phaser 6128MFP Operational Overview
56
Print Process Block Diagram
56
Printing Process
57
Charging
58
Exposure
59
Development
61
Transfer (Drum
62
Imaging Unit
63
Excess Toner Collection
64
Fusing
65
Media Path
66
Media Path Components
67
Major Assemblies and Functions
68
Tray
68
Feeder
70
Manual Feed & Registration
72
Transfer Belt and Fuser
76
Laser Unit
77
Toner Cartridge & Dispenser
79
Imaging Unit
80
Drive
81
Electrical
83
Printer Modes
87
Operational Modes
87
Printer Control
87
Paper Size Detection
87
Laser Unit Light Quantity Control
87
Process Control
88
Color Registration Control
89
Fuser Control
90
Drive Transmission
91
Main Drive
91
Sub-Drive Assembly
93
Scanner
102
CCD Image Sensor
105
Scanning on Document Glass
106
Automatic Document Feeder
107
ADF Components
107
ADF Media Path
108
ADF Drive
110
Fax
112
Fax Overview
112
Fax Scans
112
Protocol Monitor
115
Fax Standards (ITU-T Recommendations)
119
3 Error Messages and Codes
121
Introduction
122
Accessing Error History Report
122
Error History Report
122
Servicing Instructions
124
Messages, Codes, and Procedures
125
Error Messages Abbreviations
125
Error Message and Code Summary
126
Jam Errors
157
Jam at Tray or Jam at Exit
157
Jam at Front Cover
161
Jam at Front Cover Open Front Cover and Remove Paper
163
Jam at Exit
165
Jam at Manual Feed Slot
167
Jam at Registration Roller
170
Jam at Scanner
173
Consumable/Routine Maintenance Errors
174
Replace Fuser or Fuser Life Error
174
Fuser Error
175
Reseat Fuser Error
176
Toner Cartridge Errors
178
Low Density Yellow Cartridge Error
179
Low Density Magenta Cartridge Error
180
Low Density Cyan Cartridge Error
182
Low Density Black Cartridge Error
183
Non-Xerox Toner Cartridge Error
185
Insert Cartridge Error
186
Non-Xerox Toner
188
IU CRUM Error
189
Imaging Unit Life, Replace Imaging Unit Error
190
Check Imaging Unit Error
191
Insert Imaging Unit Error
192
Tray and Media Errors
193
Load Tray or Manual Feed
193
Load Tray or Illegal Settings
195
Insert Output to Tray
197
Check Manual Feed
198
Insert Output to Manual Feed
200
Load or Remove Paper from Manual Feed
201
Reseat Paper at Manual Feed
203
Registration Roller Actuator, PL3.3.8
204
Configuration, Memory, and Firmware Errors
206
Invalid User Error
206
Disabled Func Error
206
Limit Exceeded Error
207
Invalid Job Error
208
MCU Firmware Error
209
Download Mode Error
210
PAGEC Timer Error
211
RAM Disk Full Error
212
Collate Full Error
213
Firmware Errors
214
MCU Communication Error
215
MCU NVRAM Error
216
Electrical
218
Control Panel Error
218
K Mode Sol Error
219
Feed Drive Assembly, PL7.1.4
219
MCU Board, PL10.7.7
219
Registration (KSNR) Harness, PL10.8.9
219
Main Motor Error
220
Main Drive
221
Sub Motor Error
222
Fan Motor Error
223
Laser Error
224
Front Cover Open Close Front Cover
225
Side Door Open Close Side Door
226
Scanner ADF Cover R Open
228
CTD Sensor Error (CMYK)
229
Check Unit CTD Sensor Error
231
Transfer Life or DTB Life over Error
232
Env Sensor Error
233
Memory Errors
234
Out of Memory
235
RAM Errors
236
Controller Error
237
Email Errors
238
SMB Errors
240
SMB Login Error
240
SMB or DNS Error
241
SMB Login Error
242
SMB Error
243
SMB or FTP Errors
244
Scanner and Copier Errors
246
PC Scan Time out
246
Scanner Error
248
Scanner Error
250
Copier Error Last Sheet Not Copied
251
Controller Error
252
Fax Errors
253
Memory Full / Fax Communications
253
Fax Codec Error
254
MFD Controller Errors
255
Fax Communication Error
257
Target Fax Connect Errors
259
Fax Communication Error
260
Fax Codec Error
261
Fax Data Errors
262
Incorrect Password Error
264
Fax Communication Error
265
Fax Communication Error
266
Target Fax no Answer
267
Fax Communications Error
268
4 General Troubleshooting
271
Introduction
272
System Startup
272
Power on Self Test (POST)
273
Service Diagnostics
274
Entering Service Diagnostics Mode
274
Using Service Diagnostics
274
Exiting Service Diagnostics Mode
275
Service Diagnostics Menu Maps
276
Service Diagnostic Tests
279
IIT Diagnostic Tests
279
IIT I/O Diagnostic Testing Procedures
288
IOT Diagnostic Tests
295
IOT Sensor Testing Procedures
303
IOT Motor, Solenoid Testing Procedures
311
Feed Roller Rotation
315
Control Panel Troubleshooting
322
Printer Does Not Come to a "Ready" State
322
Control Panel LED Is On, Control Panel Display Is Blank
322
Fax Troubleshooting
322
Transmission Fault
322
Reception Fault
323
Other Fax Problems
324
Fax Failure after Installation/Relocation
325
Fax Failure after Continuous Normal Operation
328
Color Fax Troubleshooting
330
Engine Test Print
332
Inoperable Printer Troubleshooting
333
Engine Power-Up Sequence
333
Printer Continually Displays Warming up
333
AC Power Supply Troubleshooting
333
DC Power Supply Troubleshooting
334
LVPS Overcurrent Protection Circuit
334
LVPS Overvoltage Protection Circuit
334
Lvps
334
+24 VDC Interlock Switch
336
Abnormal Noise and Electrical Problems
337
Abnormal Noise When Power Is Turned on
337
Abnormal Noise During Standby
338
Abnormal Noise During Printing
339
Electrical Noise
342
AC Supply Problems
343
DC Short
344
Operating System and Application Problems
345
Windows 2000, Windows XP, Windows Server Troubleshooting
345
Verify Settings
345
Verify Driver Installation
345
Macintosh Troubleshooting (Mac os 10.2 and Higher)
346
5 Print-Quality Troubleshooting
347
Print-Quality Problems Overview
348
Defects Associated with Specific Printer Components
348
Checklist before Troubleshooting Print-Quality
350
Check Printer Condition
350
Symptom Checklist
350
Print-Quality Troubleshooting
353
Print-Quality Defect Definitions
353
Light or Undertone Print
354
Blank Print
356
Black Print
360
Vertical Blank Lines
362
Horizontal Band, Voids, or Streaks
364
Vertical Stripes
366
Horizontal Stripes
368
Partial Band
370
Random Spots
372
Repeating Bands, Lines, Marks, or Spots
374
Residual Image or Ghosting
375
Background Contamination
377
Skew
379
Damaged Media
381
Unfused Image
384
Color Registration
385
Wavy Lines
387
Incorrect Magnification
388
Lines or Streaks (from ADF)
389
Spots from ADF
390
Test Prints
391
No Image IOT Test Print
391
Pattern IOT Test Print
391
Grid 2 ESS Test Print
392
Cyan 20% ESS Test Print
392
Magenta 20% ESS Test Print
393
Yellow 20% ESS Test Print
393
Black 20% ESS Test Print
394
CMY 20% ESS Test Print
394
Gradation ESS Test Print
395
Toner Pallet Check Test Print
395
Contamination Check Test Prints
396
Pitch Chart Test Print
397
Imaging Unit Refresh Test Print
398
MQ Test Print
399
Alignment Test Print
400
Ghost Test Print
400
Print-Quality Specifications
401
Color Chart
401
Skew
402
Parallelism
402
Linearity
403
Perpendicularity
404
Magnification Error
404
Registration
405
Guaranteed and Maximum Print Areas
405
6 Adjustments and Calibrations
409
Adjustments
410
Color Registration
410
Printing the Color Registration Correction Chart
410
Enabling/Disabling Automatic Color Registration
411
Adjusting Color Registration
411
Resetting the Fuser
413
Calibrations
414
Initializing Print Meter
414
Initializing NVM (NVRAM)
414
Scanner Calibration
415
Parameter Settings
417
Print Parameter Setting
417
Fax/Scanner Parameter Setting
419
7 Cleaning and Maintenance
421
Service Maintenance Procedure
422
Recommended Tools
422
Cleaning
422
Maintenance
423
RIP (Repair, Inspect, and Prevent) Procedure
423
8 Service Parts Disassembly
425
Overview
426
Standard Orientation of the Printer
426
Preparation
427
Notations in the Disassembly Text
429
Fastener Types
430
Maintenance Items and Consumables
431
Separator Roller
431
Imaging Unit
432
Feed Roller
434
Fuser
435
Toner Cartridges
437
Covers
439
Front Cover
439
Left Side Cover
441
Outer Pole Cover
443
Inner Pole Cover
444
ESS Cover
445
Rear Cover
446
Right Side Cover
447
Right Side Door
448
Top Cover
449
Lower Scanner Cover
450
Feeder
451
Manual Feed no Paper Sensor
451
Manual Feed Sensor Actuator
452
Registration Sensor
453
Registration Roller
454
Registration Sensor Actuator
456
Tray no Paper Sensor
457
Tray no Paper Sensor Actuator
457
Feed Solenoid
458
Drive Clutch and Bearing Kit
459
Feed Drive Assembly
461
Gear P2
464
Electrical
465
Image Processor Board
465
Control Panel
467
Humidity Sensor
469
ESS Shield
470
FAX Board
471
Lvps
471
Fan
474
Right Side Door Switch
475
Interlock Harness
476
Hvps
478
Power Switch Harness
478
GFI Breaker
480
MCU Board
481
Main Drive Assembly
482
Sub-Drive Assembly
484
Chassis
486
Duct Plate
486
Breaker Chassis
488
LVPS Card Cage
490
Upper Frame Assembly
492
Feeder Assembly
499
IIT Procedures
501
ADF Feed Roll Assembly
501
ADF Seperator Pad
502
ADF Input Tray
502
ADF Assembly
503
IIT Sub-Assembly
506
Xerographics
510
Erase LED Assembly
510
Right Imaging Unit Restraint Block
511
Left Imaging Unit Restraint Block
512
Toner Cartridge Holders
514
Dispense Assembly
515
Toner Motor Frame Assembly
518
Laser Unit
522
Transfer Belt Pivot Kit
524
Transfer Belt
527
9 Parts List
529
Serial Number Format
530
Using the Parts List
531
Parts Lists
532
Parts List 3.2 Feeder
532
Parts List 4.1 Xerographics
534
Parts List 5.1 Dispenser
536
Parts List 6.1 Transfer & Fuser
538
Parts List 7.1 Drive
540
Parts List 10.1 Covers
542
Parts List 10.2 Front Cover
544
Parts List 10.3 Media Tray
546
Parts List 10.4 Feeder
548
Parts List 10.5 Frame
550
Parts List 10.6 Electrical (1/2)
552
Parts List 10.7 Electrical (2/2)
554
Parts List 10.8 Harnesses
556
Parts List 10.9 Scanner
558
Parts List 10.10 ADF
560
Xerox Supplies and Accessories
562
Service Kits
562
10 Wiring
563
Plug/Jack Designations and Locator Diagrams
564
Print Engine Plug/Jack Designators
564
System Connections
567
Plug/Jack Locators
568
Wiring Diagrams
572
Notations Used in the Wiring Diagrams
572
Wiring Diagram Descriptions
575
Lvps
576
Media Feed
577
Main Drive
578
Laser Unit
579
Xerographics
580
Hvps
581
Toner Dispense
582
Fuser
583
System Control
584
Adf
585
Imaging
586
Reference
587
Phaser 6128MFP Menu Map
588
Procedural Flow Diagrams
589
Removal Flow Diagrams
589
Replacement Flow Diagrams
591
Acronyms and Abbreviations
593
Firmware Update
596
Boot Controller Update
596
Firmware Controller Update
597
Firmware MPC Update
598
Index
599
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