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PHASER 6250
Service Manual
Page 359 (Tray 3 Harness Assembly (PL15.5.3) and STF Plug Harness Assembly (PL15.5.2))
Xerox PHASER 6250 - Tray 3 Harness Assembly (PL15.5.3) and STF Plug Harness Assembly (PL15.5.2)
474 pages
Manual
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Ser
vice P
art
s Disa
ssem
bly
8-
133
T
ray
3 Ha
rness A
ssem
bly (P
L15.
5.3) a
nd S
TF Plu
g
Harn
ess Asse
mbly
(PL15.5
.2)
1.
Remove the Paper
T
ray from the STF Assembly
.
2.
Remov
e the Fron
t Covers
(page
8-13
0).
3.
Remov
e the Cover
Right
(page
8-
131).
6250-413
358
360
Table of Contents
Main Page
Default Chapter
1
Phaser 6250
1
Service Manual
3
Service Terms
6
Manual Terms
6
Symbols Marked on the Product
7
Power Source
8
Power Safety Precautions
8
Electrostatic Discharge (ESD) Precautions
9
Service Safety Summary
10
General Guidelines
10
Warning Labels
10
Safety Interlocks
10
Servicing Electrical Components
11
Servicing Mechanical Components
11
Regulatory Specifications
12
Declaration of Conformity
13
In the European Union
13
Phaser 6250 Color Printer
14
Table of Contents
15
1 General Information
25
Printer Introduction and Overview
26
Printer Configurations
26
Printer Memory and RAM Capabilities
28
Parts of the Printer
29
Exterior
29
Phaser 6250 Front Panel Configuration
30
Front Panel Shortcuts
30
Led Indicators
30
Rear View
31
Image Processor Board
32
Routine Maintenance Items
33
Consumables
33
Consumable Life Counter Behavior
34
Printer Specifications
35
Physical Dimensions and Clearances
35
Functional Specifications
36
Electrical Specifications
37
Environmental Specifications
37
Media and Tray Specifications
38
2 Theory of Operation
41
Overview of the Phaser 6250 Color Laser Printer Theory of Operation
42
Summary of the Printing Process
42
Print Modes
45
Printer Controls
45
Paper Size Control
45
Selective Control; Paper Pick
46
Laser Light Intensity Control
46
Process Control
46
LED Light Density CTD (ADC) Control of Sensor
48
Color Registration Control
49
Transfer Roller Assembly Control
51
Toner Control
52
Toner Low Sensor
52
Fuser Control
53
Fuser Temperature Control
53
Paper Path of the Printer
54
Laser Beam
54
Paper Sensors
54
Optional Feeders
55
Paper Path Route
55
Major Assemblies and Functions
56
Frame and Drive Assemblies
56
Main Drive Assembly - Transmission Route
57
Gear Layout - Print Engine and Tray 1
58
Paper Tray 2
59
Paper Feed - Tray 2
60
HCF Drive and Gears - Transmission Route
65
500-Sheet Feeder Drive and Gears - Transmission Route
66
Retard Housing Assembly
67
Chute Assembly in
68
Chute Assembly out
69
Chute Assembly Exit
70
Duplex Motor Drive and Gear - Transmission Route
71
Chute Assembly Registration (REGI)
72
Transfer Roller and Fuser Assembly
73
Fuser Drive Assembly - Transmission Route
74
Xerographics
75
Imaging Unit Charge Voltage Contacts
76
Toner Cartridge Assembly
78
Toner Cartridge Assembly - Cont'D
79
Toner Motor Drive Assembly - Transmission Route
80
Developer Assembly Transmission Route
80
Ac Switch Harness Assembly
82
3 Error Messages and Codes
83
Introduction
84
Servicing Instructions
85
Using the Troubleshooting Procedures
86
General Notes on Troubleshooting
86
Voltage Measurements
87
Service Diagnostics
88
Service Diagnostic Front Panel Button Descriptions
89
Diagnostic Menu Map
90
Service Diagnostic Tests
91
Jam History Error Codes Table
98
Front Panel Message
98
Help Text/Code
98
Error Messages and Codes Summary Table
99
Jam Errors
101
Jam at Fuser: Jam F
101
Jam at Duplex: Jam D
103
Jam at Registration
105
Jam at Registration Roller: Jam RR
110
Misfeed at Tray 1 (MPT): Jam T1
112
Misfeed at Tray 2: Jam T2
115
Misfeed at Tray 3: Jam T3
118
Misfeed at Tray 4: Jam T4
121
Door and Cover Errors
123
Close Front Door
123
Consumable Errors
124
Install or Reseat Imaging Unit
124
Replace Imaging Unit or Imaging Unit Is Near End of Life
125
Install or Reseat Transfer Roller
126
Replace Transfer Roller or Transfer Roller Is at End of Life
127
Install or Reseat Fuser
128
Replace Fuser or Fuser Is Near End of Life
129
Install or Lock [Y] [M] [C] [K] Toner Cartridge
130
Replace [Y] [M] [C] [K]Toner Cartridge or [Y] [M] [C] [K] Toner Is Low
132
Dusty Density Sensor
134
Output Tray Is Full, Unload Paper
135
Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge
136
Tray and Media Errors
137
Insert Tray [2] or Tray [2] Missing
137
Insert Tray [3] [4] or Tray [3] [4] Missing
139
Tray 2 Paper Is Low
141
Tray [3] [4] Paper Is Low
142
Out of Paper; Load Tray 1 (MPT) with [Size] [Type]
143
Out of Paper; Load Tray [2] [3] [4] with [Size] [Type]
144
Wrong Paper Size; Load Tray 2 with [Size] [Type]
145
Wrong Paper Size; Load Tray [3] [4] with [Size] [Type]
147
Wrong Paper Type; Load Tray [1 (MPT)] [2] [3] [4] with [Size] [Type]
149
Fatal Errors
150
Laser Failure
150
Density Sensor Failure
151
Fuser Failure
152
Fuser Failure (Cont'D)
153
Fuser Fan Failure
155
Rear Fan Failure
156
Generic Fan Failure
157
Engine Firmware Failure
158
Imaging Unit Firmware Failure
159
Fuser Firmware Failure
160
Controller to Engine Communications Failure
161
Engine NVRAM Error
162
Replace [Y] [M] [C] [K] Toner Cartridge
163
[Y] [M] [C] [K] Toner Cartridge Failure
164
Non-Phaser 6250 Fuser
165
Non-Phaser 6250 Imaging Unit
166
Environmental Sensor Failure
167
4 General Troubleshooting
169
Introduction
170
Printer Status Page
170
Power-Up Modes
170
System Start-Up and POST
171
System Boot Sequence
171
Power on Self Test (POST)
172
POST Faults
174
Fault Reporting Devices
174
LED Blink Patterns
174
POST Diagnostic Test Descriptions
175
Front Panel Troubleshooting
176
No Front Panel Display after Power Is Turned on
176
Front Panel LED Is On, Front Panel Display Is Blank
176
Front Panel Continually Displays "Warming up
176
Front Panel Continually Displays "Install or Reseat Imaging Unit
176
Fault Isolation
177
Inoperable Printer Troubleshooting
177
Engine Power-Up Sequence
177
Printer Does Not Come to a "Ready" State
177
Printer Inoperable after Power Switch Is on
178
Paper Size Switch Assembly
179
Power Supply
180
AC Power Supply Troubleshooting
181
DC Power Supply Troubleshooting
181
Media Jams and the Paper Path
183
Skewed Image
184
Damaged Prints
184
Fuser Jams
184
Operating System and Application Problems
186
Macintosh Printing Problems
186
Windows Printing Problems
188
Network Problems
188
5 Print-Quality Troubleshooting
189
Print-Quality Problems Overview
190
Defects Associated with Specific Printer Components
191
Front Panel Test Prints
192
Test Print 1: CMYK Sample Page
192
Test Print 2: RGB Test Print
193
Service Test Prints
194
Test Print 3: Test Pattern Sample
194
600 X 600 Service Test Print
196
Print Engine Test Print
197
Print-Quality Troubleshooting
198
Light Prints
198
Front Panel
198
Light Print in Only One Color
199
Blank Prints
201
Black Prints with White Margin Border
202
Solid Dark or Dirty Prints, no Border
203
Missing Band, Voids or Streaks in a Single Color or All Colors Parallel to the Leading Edge
204
Missing Band, Voids or Streaks in a Single Color or All Colors in Direction of Paper Travel
206
Repeating And/Or Random Spots
207
Background Contamination
208
Residual Image, Ghosting or Hot Offset
210
Incomplete Fusing or Cold Offset
211
Mis-Registration, Color Layer Not Correctly Registered in the Process Direction
212
Dirty Vertical Streaks on the Edges of the Page
213
6 Adjustments and Calibrations
215
Color Calibration
216
Margin Calibration
216
Adjustments
217
Horizontal and Vertical Color Registration
217
Resetting NVRAM
218
Postscript NVRAM Resets
218
Service Diagnostics Postscript NVRAM Resets
222
7 Cleaning and Maintenance
223
Service Preventive Maintenance Procedure
224
Cleaning
224
8 Service Parts Disassembly
227
Overview
228
Standard Orientation of the Printer
228
General Notes on Disassembly
229
Preparation
229
Notations in the Disassembly Text
229
Removing Routine Maintenance Items and Consumables
230
Transfer Roller Removal
230
Imaging Unit Removal
230
Fuser Removal
231
Toner Cartridge Removal
231
Print Engine Disassembly
232
Covers
232
Front Cover (PL 1.1.2)
232
Front Panel (PL 1.1.1)
233
Fuser Fan (PL 1.1.7)
234
Top Main Cover (PL1.1.9)
235
Image Unit Top Cover (Door C) (PL1.1.10)
236
Right and Left Side Covers (PL1.1.24), (PL1.1.30)
237
Rear Cover (PL 1.1.20)
238
Left and Right Links (PL 1.1.23)
239
Tray 1 (MPT) (PL1.1.99)
240
Front Right Cover (PL 1.1.25)
241
Front Left Cover Assembly (PL1.1.29)
242
Paper Feed
244
Paper Feed Roller (PL 2.1.2) (Routine Maintenance Item)
244
Turn Chute Assembly (PL3.1.2)
245
Printer Chassis/Feeder Assembly
246
Replacement Notes
247
Paper Pick Assembly (PL3.3.1)
248
Right and Left Housing (PL 3.2)
249
Temperature/Humidity Harness (PL3.2.1) and Sensor (PL3.2.2)
250
High-Capacity Feeder Harness (PL3.2.3)
251
Paper Size Switch Assembly (PL3.2.4)
252
Low Paper Lever (PL3.2.7), Indicator (PL3.2.8) and Indicator Guide (PL3.2.10)
253
Indicator Guide (Pl)
253
Paper Pick Rollers (PL3.3.3)
255
No Paper Actuator (PL3.3.5), No/Low Paper Sensor (PL3.3.4)
256
Link Actuator (PL3.3.6)
258
Feed Solenoid (PL3.3.17)
259
Turn Clutch Assembly (PL3.3.18)
260
Roll Turn Assembly (PL3.3.20)
261
Paper Feed Roller (Routine Maintenance Item)
262
Retard Roller Housing Assembly (PL4.1.1)
263
Turn Roll (PL 4.1.2), Turn Clutch (PL 4.1.9), and Friction Clutch as
264
Retard Roller Assembly (PL4.1.5)
265
Chute Assembly in
267
Chute Assembly in (PL 5.1.1)
267
CTD (ADC) Sensor (PL 5.1.11)
268
Toner Full Sensor (PL 5.1.13)
269
Fuser Drive Assembly (PL 5.1.18)
270
Right Latch (Door A) (PL 5.1.21)
271
Left Latch (PL 5.1.30)
272
Chute Assembly out
273
Chute Assembly out (PL6.1.1)
273
Output Tray Full Actuator (PL 6.1.5) and Full Stack Sensor (PL 6.1.4)
276
Duplex Actuator (PL 6.1.13) and Duplex Sensor (PL 6.1.4)
277
Removing the Duplex Actuator
277
Tray 1 Actuator (PL 6.1.37) and Tray 1 Sensor (PL 6.1.4)
279
Static Eliminator Assembly (PL 6.1.9)
281
Duplex Roller (PL 6.1.12)
282
Latch Plate (PL 6.1.17), Latch out (PL 6.1.18), Latch Holder (PL 6.1.19), and Latch Spring out (PL 6.1.20)
283
Tray 1 Paper Pick Assembly (PL 6.1.27) (Roll Feed)
284
Tray 1 Feed Solenoid (PL 6.1.40)
285
Tray 1 Shaft (PL 6.1.28)
286
Tray 1 Bottom Plate (PL 6.1.42)
287
Chute Assembly Exit
288
Chute Assembly Exit (PL 7.1.1)
288
Exit Roller (PL 7.1.4)
289
MID Roller (PL 7.1.5)
290
Duplex Motor Assembly (PL 7.1.8)
291
Exit Actuator (Fuser) (PL 8.1.7)
292
Strap (PL 8.1.13)
293
Xerographics
294
Laser Unit (PL 9.1.1)
294
Housing Assembly Bias (PL 9.1.4)
295
Chute Assembly Registration (PL 9.1.6) and Housing Assembly Electric (PL 9.1.11)
297
Registration Sensor Actuator (PL 9.1.9) and Registration Sensor (PL 9.1.8)
299
OHP Sensor and Harness (Kit) (PL 9.1.12)
301
Toner Cartridge Holder Assemblies
303
Toner Cartridge Holder Unit Assembly (PL 10.1)
303
Toner Cartridge Holder Assembly
306
Toner Present Switch Bracket and Actuator (PL 10.1.6 and 10.1.22)
308
Toner Low Sensor (PL 10.1.5)
310
CRUM Reader Box Assembly (PL 10.1.21)
311
EEPROM Board (PL 10.1.14)
312
Sub-High Voltage Power Supply Board (PL 10.1.15)
313
Frame and Drive Assemblies
314
Lever Plate Right (PL 11.1.7), Lever Bracket (PL 11.1.2), Lever Link (PL 11.1.6), Lever Drum (PL 11.1.4), and Lever Spring (PL 11.1.5)
317
Main Drive Assembly (PL 11.1.14)
320
Developer Drive Assembly (PL 11.1.13)
321
Actuator, I/L (PL 11.1.8) and Spring, I/L (PL 11.1.9)
322
Earth Ground Circuit Board (PL 11.1.16)
323
Electrical
324
AC Switch Harness Assembly (PL 12.1.11)
324
Low-Voltage Power Supply (PL 12.1.10)
325
Motor Driver Board (PL 12.1.12)
327
Rear Fan (PL 12.1.2)
328
Card Cage
329
Housing Assembly Contact (PL 12.1.14)
332
Engine Control Circuit Board (PL12.1.1)
333
Image Processor Board (PL12.1.4)
336
Optional High Capacity Feeder Disassembly
337
Cover Front (PL14.2.4)
337
Cover, Right (PL14.2.1) and Cover, Left (PL14.2.3)
338
Turn Chute Assembly (PL14.3.7)
339
Circuit Board, HCF (PL14.5.1)
342
Drive Feeder Assembly (PL14.5.5)
343
Indicator Assembly (PL14.5.9)
344
Right Tray Guide (Pl14.3.5)And Low Paper Lever (PL 14.5.8)
345
Left Tray Guide (PL14.3.3)
348
Link Actuator (PL 14.4.6)
350
HCF Paper Pick Assembly (PL14.4.1)
351
Idler Gear (PL14.5.6)
352
No Paper, Low Paper Sensor (PL14.5.7)
353
Paper Size Switch Assembly (PL14.3.6)
354
Casters, Locking (PL 14.2.5)/Non-Locking (PL 14.2.6)
355
Optional 500-Sheet Feeder Disassembly
356
Cover Front (PL15.2.4)
356
Cover, Right (PL15.2.2) and Cover, Left (PL15.2.1)
357
Turn Chute Assembly (PL15.3.9)
358
Tray 3 Harness Assembly (PL15.5.3) and STF Plug Harness Assembly (PL15.5.2)
359
Circuit Board, STF (PL15.5.1)
361
Drive Feeder Assembly (PL15.5.5)
362
Indicator Assembly (PL15.5.8)
363
Right Tray Guide (Pl15.3.5)And Low Paper Lever (PL 15.5.7)
364
Left Tray Guide (PL15.3.3)
367
Link Actuator (PL 15.4.6)
369
STF Paper Pick Assembly (PL15.4.1)
370
No Paper, Low Paper Sensor (PL15.5.6)
371
Paper Size Switch Assembly (PL15.3.6)
372
9 Parts List
373
Serial Number Format
374
Using the Parts List
375
Print Engine Parts
376
PL 1.1 Covers
376
PL 2.1 Universal Paper Tray
379
PL 3.1 Paper Feed I
380
PL 3.2 Paper Feed II
382
PL 3.3 Paper Feed III
384
PL 4.1 Housing Assembly Retard
386
PL 5.1 Chute Assembly in
388
PL 6.1 Chute Assembly out
390
PL 7.1 Chute Assembly Exit
394
PL 8.1 Transfer Roller & Fuser Assembly (Rmis)
396
PL 9.1 Xerographics
398
PL 10.1 Holder Toner Cartridge Assembly
400
PL 11.1 Frame and Drive Assemblies
402
PL 12.1 Electrical
404
PL 13.1 Harness Assemblies
406
Optional High-Capacity Feeder
408
PL 14.1 Paper Trays 3 & 4
408
PL 14.2 High-Capacity Feeder Covers
409
PL 14.3 High-Capacity Feeder Guides and Turn Chute Assembly
410
PL 14.4 Paper Pick Assembly Trays 3 & 4
413
PL 14.5 High-Capacity Feeder Harness, Board and Motor
414
Optional 500-Sheet Feeder
416
PL 15.1 Paper Tray 3
416
PL 15.2 500-Sheet Feeder Covers
417
PL 15.3 500-Sheet Feeder Guides and Turn Chute Assembly
418
PL 15.4 Paper Pick Assembly Tray 3
420
PL 15.5 500-Sheet Feeder Harness, Board and Motor
422
Xerox Supplies and Accessories
423
10 Wiring Diagrams
429
Plug/Jack Locator Maps
430
Map 1
434
Map 2
435
Map 3
436
Map 4
437
High-Capacity Feeder Plug/Jack Locator Table
438
Map 5
439
500-Sheet Feeder Plug/Jack Locator Table
440
Map 6
441
Print Engine Wiring Diagrams
442
Notations Used in Wiring Diagrams
442
Main Wiring Diagram
443
Power Supplies
444
Paper Tray 2
445
Drive Section
446
Developer Section 1
447
Developer Section 2
448
Fuser Assembly
449
Laser Unit
450
Xerographics 1
451
Xerographics 2
452
Paper Feed
453
Image Processor Board
454
Printer Options Wiring Diagrams
455
High Capacity Feeder Main Wiring Diagram
455
Drive Section (HCF)
456
Paper Tray 3
457
Paper Tray 4
458
500-Sheet Feeder Main Wiring Diagram
459
Drive Section (STF)
460
Paper Tray 3
461
Reference
463
Printer Status Codes
463
Index
467
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Network Guide
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Software Guide
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Setting Instructions
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Competitive Comparison
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Settings Guide
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