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Phaser 6300
Xerox Phaser 6300 Service Manual
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4
Section
General
T
roubleshooting
In this
chapter
...
â–
P
owe
r On Sel
f T
est (POST
)
â–
Ser
vic
e Diagnostic
s
â–
Contro
l P
anel T
roubles
hooting
â–
Inoperable Pr
inter T
ro
ub
lesho
oting
â–
A
C P
ow
er S
upply T
r
oub
le
shooting
â–
DC P
o
wer Supp
ly T
roublesh
ooting
â–
Media
J
ams a
nd the P
a
per P
ath
â–
Operating
System
and Appli
cation Problem
s
â–
Network
Problems
185
187
Table of Contents
Default Chapter
3
Service Manual
3
Service Terms
4
Symbols Marked on the Product
5
Power Safety Precautions
6
Power Source
6
Electrostatic Discharge (ESD) Precautions
7
Service Safety Summary
8
General Guidelines
8
Warning Labels
8
Safety Interlocks
8
Servicing Mechanical Components
9
Regulatory Specifications
10
European Union
11
Manual Organization
12
Table of Contents
14
General Information
24
Printer Introduction and Overview
25
Printer Configurations
26
Metered Printing
27
Parts of the Printer
28
Control Panel
29
Rear Panel
30
Image Processor Board
30
Printer Options
31
Hard Drive
31
Additional Memory
31
Configuration Card
31
550-Sheet Feeder
32
Maintenance Items
33
Consumables
34
Consumable Life Counter Behavior
34
Specifications
35
Memory Specifications
35
Electrical Specifications
35
Physical Dimensions and Clearances
36
Functional Specifications
37
Image Specifications
38
Imaging Unit Cleaning Cycle Intervals
38
Environmental Specifications
39
First Print Output Time
39
Media and Tray Specifications
40
Theory of Operation
42
Phaser 6300/6350 Operational Overview
43
Summary of the Printing Process
44
Print Process Components
46
Print-Quality Modes
47
Printer Controls
48
Paper Size Control
48
Selective Control; Paper Pick
48
Laser Light Intensity Control
49
Process Control
50
Bias Control
50
Toner Density Control
51
LED Light Density CTD (ADC) Control Sensor
52
Color Registration Control
53
Transfer Roller Control
54
Toner Control
55
Fuser Control
56
Fuser Temperature Control
56
Paper Path of the Printer
57
Paper Path Route
58
Sensors
59
Sensor Types
59
Photo Sensors
59
Sensors in the Paper Path
60
Print Engine Assemblies
63
Drive Assemblies
63
Registration Roller Assembly
71
Chute Assembly in
74
Chute Assembly out
75
Transfer Roller and Fuser Assembly
78
Heater Lamp
79
Tray 1 (MPT)
80
Tray 2
81
Tray 2 Paper Pick Assembly
82
Xerographics
84
Toner Cartridge Holder Assembly
86
Electrical
89
1100-Sheet Feeder Assemblies
91
Paper Pick Assemblies
92
Electrical
93
Drive
94
Drive Gears
95
550-Sheet Feeder Assemblies
96
Tray 3 Feeder
97
Electrical
98
Drive
99
Drive Gears
100
Error Messages and Codes
102
Introduction
103
Accessing Fault History
103
Status Page
104
Service Usage Profile
104
Servicing Instructions
105
Messages, Codes, and Procedures
106
Error Message Abbreviations
106
Error Message Summary
107
Error Messages and Codes
108
Control Panel Message
108
Using the Troubleshooting Procedures
110
Measurement Techniques
110
Jam Error Procedures
112
Jam at Fuser: Jam F
112
Jam at Duplex: Jam D
114
Jam at Registration Roller: Jam RR
116
Misfeed at Tray 1 (MPT): Jam T1
118
Misfeed at Tray 2: Jam T2
121
Initial Actions
121
Misfeed at Tray 3: Jam T3
124
Misfeed at Tray 4: Jam T4
127
Misfeed at Tray 5: Jam T5
130
Door and Cover Error Procedures
132
Close Front Door
132
Consumable/Routine Maintenance Procedures
134
Install or Reseat Imaging Unit
134
Replace Imaging Unit or Imaging Unit Is Near End of Life
135
Install or Reseat Transfer Roller
136
Replace Transfer Roller or Transfer Roller Is at End of Life
138
Install or Reseat Fuser
139
Replace Fuser
140
Install or Lock [Y] [M] [C] [K] Toner Cartridge
142
Replace [Y] [M] [C] [K] Toner Cartridge or [Y] [M] [C] [K] Toner Is Low
143
Dusty Density Sensor
145
Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge
146
Tray 2 Paper Is Low
147
Tray [3] [4] [5] Paper Is Low
148
Replace [Y] [M] [C] [K] Toner Cartridge
149
Non-Phaser 6300/6350 Fuser
151
Replace Maintenance Kit
152
Non-Xerox Imaging Unit
153
Metered Toner Is Not Enabled
154
Tray and Media Errors
155
Insert Tray [2] or Tray [2] Missing
155
Insert Tray [3] [4] [5] or Tray [3] [4] [5] Missing
156
Out of Paper; Load Tray 1 (MPT) with [Size] [Type]
158
Out of Paper; Load Tray [2][3][4][5] with [Size][Type]
159
Output Tray Is Full, Unload Paper
161
Media Mismatch Errors
162
Wrong Paper Size; Load Tray 1 (MPT) with [Size][Type]
162
Wrong Paper Size; Load Tray 2 with [Size][Type]
163
Wrong Paper Size; Load Tray [3][4][5] with [Size][Type]
164
Configuration Errors
165
Invalid or Missing Configuration Card
165
Duplicate IP Address Detected
166
Unsupported Configuration
166
Fatal Error Procedures
167
Laser Failure
167
Density Sensor Failure
168
Fuser Failure
169
Fuser Failure
171
Fuser Fan Failure
172
Rear Fan Failure
173
Fan Failure
174
Fuser Firmware Failure
175
Engine Firmware Failure
176
Engine NVRAM Error
177
[Y] [M] [C] [K] Toner Cartridge Failure
178
Environmental Sensor Failure
179
Fuser Motor Failure
180
Developer Motor Failure
181
Main Motor Failure
182
Motor Failure
183
Disk Failure
184
Image Density Failure
185
General Troubleshooting
186
Introduction
187
System Startup
187
Power on Self Test (POST)
188
POST Soft Fault Messages
189
POST Hard Fault Messages
190
Fault Isolation
190
Service Diagnostics
191
Using Service Diagnostics
191
Service Diagnostics Controls
192
Hidden Service Menu
193
Control Panel Shortcuts
193
Service Diagnostics Utilities
193
Status
194
Test Prints
194
Diagnostic Fault History
194
Control Panel Troubleshooting
196
No Control Panel Display after Power Is Turned on
196
Control Panel LED Is On, Control Panel Display Is Blank
196
Inoperable Printer Troubleshooting
197
Engine Power-Up Sequence
197
Printer Continually Displays Warming up
197
Printer Continually Displays Install or Reseat Imaging Unit
197
Printer Displays Reseat Contoller Board
197
Printer Does Not Come to a Ready State
198
Paper Size Switch Assembly
198
Power Supply
198
AC Power Supply Troubleshooting
199
DC Power Supply Troubleshooting
199
RAM Memory Fault Isolation
201
Media Jams and the Paper Path
203
Skewed Image
204
Damaged Prints
204
Fuser Jams
204
Exit Jams
205
Operating System and Application Problems
205
Macintosh Printing Problems
205
Windows Printing Problems
207
Network Problems
208
Network Diagnostics
208
Network Logging
210
USB Port Testing
211
Print-Quality Troubleshooting
212
Print-Quality Problems Overview
213
Defects Associated with Specific Printer Components
214
Transfer Roller
214
Test Prints
215
Analyzing the Test Print
215
Test Print 1: CMYK Sample Page
215
Test Print 2: RGB Test Print
216
Test Print 3: Test Patterns
217
600 X 600 Test Print
219
Engine Test Print
220
Print-Quality Troubleshooting
221
Light Prints
221
Light Print in Only One Color
223
Blank Prints
225
Black Prints with White Margin Border
227
Solid Dark or Dirty Prints, no Border
228
Horizontal Bands, Voids or Streaks in any or All Colors
229
Vertical Bands, Voids or Streaks in any or All Colors
231
Repeating And/Or Random Spots
233
Background Contamination
235
Residual Image, Ghosting or Hot Offset
237
Incomplete Fusing or Cold Offset
239
Mis-Registration, Color Layers Not Correctly Registered
240
Dirty Vertical Streaks on the Edges of the Page
241
Adjustments and Calibrations
242
Color Calibration
243
Margin Calibration
243
Adjustments
244
Vertical and Horizontal Color Registration
244
Resetting NVRAM
245
Restore Factory Registration Settings
245
Restore Factory Color Settings
245
Restore Previous Color Settings
245
Restore Factory Margins Settings
246
Resetting Connection Setup Defaults
246
Resetting Paper Handling Defaults
246
Resetting Postscript Setup Defaults
247
Resetting PCL Setup Values to Default
247
Resetting Control Panel Setup Values to Default
247
Resetting Printer Controls Values to Default
247
Resetting All Printer Defaults (Postscript NVRAM)
248
Developer Assembly Life Count Resets
248
Maintenance Kit Life Count Resets
248
Service Diagnostics NVRAM Utilities
249
Postscript NVRAM Reset
249
Engine Control Board NVRAM Save/Restore
249
Toner Cartridge Install Date
249
Fuser Life
250
Toner Cartridge CRUM Check
250
CRU Life Reset
250
CRU Life Read
250
Cleaning and Maintenance
252
Service Maintenance Procedures
253
Cleaning
253
Recommended Tools
253
Cleaning the Developer Assemblies
254
Cleaning the Imaging Unit
254
Cleaning the Laser Windows
255
Maintenance
255
RIP (Repair, Inspect, and Prevent) Procedures
255
Long-Life Maintenance Kit Installation
255
Service Parts Disassembly
270
Overview
271
Standard Orientation of the Printer
271
Preparation
272
Notations in the Disassembly Text
272
Fastener Types
273
Maintenance Items and Consumables
274
Transfer Roller Removal
274
Imaging Unit Removal
274
Fuser Removal
274
Toner Cartridge Removal
275
Print Engine Disassembly
275
Covers
277
Top Main Cover (PL1.1.4)
277
Front Cover (PL1.1.6)
279
Control Panel (PL1.1.5)
280
Right Side Cover (PL1.1.20)
281
Left Side Cover (PL1.1.30)
282
Door C (PL1.1.8)
283
Rear Cover (PL1.1.17)
285
Right Front Cover (PL1.1.22)
286
Left Front Cover (PL1.1.28)
287
Front Feeder Frame Cover (PL3.1.1)
288
Universal Tray
289
Retard Assembly (PL2.1.12)
289
Paper Feeder
290
Feeder Chute (PL3.1.2)
290
Tray Rear Cover (PL3.1.3)
291
Printer Chassis
292
Paper Size Switch Assembly (PL3.2.24)
294
Option Feeder Harness (PL3.2.11)
295
Paper Pick Assembly (PL3.3.1)
296
No Paper Sensor (PL3.3.7)
297
Low Paper Sensor (PL3.3.7)
298
Upper Chute (PL3.3.15)
299
Low Paper Sensor Actuator (PL3.3.14)
300
Feed Roller (PL3.3.18)
301
No Paper Sensor Actuator (PL3.3.20)
302
Retard and Registration
303
Registration Chute (PL4.1.5)
303
Registration Sensor Actuator (PL4.1.1)
304
Registration Sensor (PL4.1.3)
305
Retard Holder Assembly (PL4.1.16)
306
Registration Roller Assembly (PL4.2.1)
307
Tray 1 (MPT)
308
Tray 1 (MPT) (PL1.1.23)
308
Tray 1 (MPT) Cover (PL1.1.27)
309
Tray 1 (MPT) Feed Solenoid (PL5.3.9)
310
Tray 1 (MPT) no Paper Sensor and Actuator (PL5.3.14)
314
Tray 1 (MPT) Feed Roller (PL5.3.20)
318
Chute Assemblies
321
Full Stack Sensor (PL5.4.1)
321
Full Stack Actuator (PL5.4.2)
322
Duplex Jam Sensor (PL5.4.1) and Actuator (PL5.4.13)
323
Duplex Motor Assembly (PL5.4.5)
326
Chute Assembly in (PL5.2.1)
327
Chute Assembly out (PL5.3.1)
330
Xerographics
335
Fuser Fan (PL5.3.31)
335
Fuser (PL5.1.1)
336
Fuser Exit Sensor Actuator (PL5.1.2)
337
Fuser Lock Lever (PL5.2.2)
338
Transfer Roller (PL5.1.4)
339
CTD (ADC) Sensor (PL5.2.19)
340
Toner Full Sensor (PL5.2.20)
341
Laser Unit (PL6.1.2)
345
Housing Assembly Bias (PL6.1.7)
346
Development
347
Developer Frame Assembly (PL7.1.1)
347
CRUM Connector (PL7.1.4)
349
Developer Assembly (PL7.1.17~20)
350
CRUM Reader (PL7.2.12)
352
Toner Cartridge Holder (PL7.2.1~4)
354
No Toner Sensor (Y), (M), and (C) (PL7.2.5)
356
No Toner Sensor (K) (PL7.2.5)
357
Toner CTG-IN Actuator and Switch Bracket (PL7.2.7)
358
Toner Cartridge Holder Assembly
359
Drive
362
Developer Drive Assembly (PL8.1.1)
362
Main Drive Assembly (PL8.1.2)
364
Fuser Drive Assembly (PL5.2.25)
365
Electrical
367
Image Processor Board (PL9.1.3)
367
Lvps (Pl9.1.4)
368
Interlock Switch (PL9.1.11)
370
Rear Fan (PL1.1.19)
371
EEPROM Board (PL9.1.12)
372
Engine Control Board (PL9.1.16)
373
Temperature/Humidity Sensor (PL9.1.20)
377
Hvps (Pl9.1.21)
378
Optional 1100-Sheet Feeder Disassembly
379
Docking (PL12.1.1)
379
Front Covers (PL12.1.6)
380
Left Cover (PL12.1.2)
381
Right Cover (PL12.1.3)
382
Foot (PL12.1.10)
383
Feeder Chute (PL12.2.7)
384
Left Feeder Assemblies (PL12.2.1)
385
Right Feeder Assemblies (PL12.2.4)
386
Paper Size Switch (PL12.2.6)
387
OPTFDR 2 Harness (PL12.3.1)
388
Circuit Board HCF (PL12.3.3)
389
Drive Assembly (PL12.3.9)
390
Paper Pick Assembly HCF T1 (PL12.4.1)
391
Paper Pick Assembly HCF T2 (PL12.5.1)
394
No Paper Sensor (PL12.5.7)
397
Low Paper Sensor (PL12.5.7)
398
Low Paper Sensor Actuator (PL12.5.14)
399
Feed Rollers (PL12.4.19)
400
No Paper Sensor Actuator (PL12.5.20)
401
Retard Roller Assembly (PL12.6.13)
402
Optional 550-Sheet Feeder Disassembly
403
Docking (PL11.1.1)
403
Right Cover (PL11.1.11)
404
Left Cover (PL11.1.7)
405
OPTFDR 1 Harness (PL11.1.6)
406
Circuit Board LTA (PL11.1.10)
407
OPTPLG 2 Harness (PL11.1.13)
408
Paper Size Switch (PL11.2.6)
409
Paper Pick Assembly (PL11.3.1)
410
No Paper Sensor (PL11.3.7)
412
Low Paper Sensor (PL11.3.7)
413
Drive Assembly (PL11.3.15)
415
Low Paper Sensor Actuator (PL11.3.16)
416
Feed Rollers (PL11.3.20)
417
No Paper Sensor Actuator (PL11.3.22)
418
Retard Roller Assembly (PL11.4.12)
420
Parts List
422
Serial Number Format
423
Using the Parts List
424
Print Engine Parts
425
Optional 550-Sheet Feeder
459
Optional 1100-Sheet Feeder
467
Xerox Supplies and Accessories
479
Service Kits
481
Feed Roller Kit
481
Spring Kit
482
Sensor Acutator Kit
483
Long-Life Maintenance Kit
483
Hardware Kit
484
Harness Kit
485
Wiring Diagrams
486
Plug/Jack Locator Diagrams
487
Print Engine Plug/Jack Designators
487
Print Engine Plug/Jack Locators
490
1100-Sheet Feeder Plug/Jack Designators
494
1100-Sheet Feeder Plug/Jack Locator
495
550-Sheet Feeder Plug/Jack Designators
496
550-Sheet Feeder Plug/Jack Locator
497
Wiring Diagrams
498
Notations Used in Wiring Diagrams
498
Print Engine Wiring Diagrams
500
Print Engine General Wiring (1/2)
500
Print Engine General Wiring (2/2)
501
Power
502
Tray 2
503
Drive Section
504
Developer (1/2)
505
Developer (2/2)
506
Fuser
507
Laser Unit
508
Xerographics (1/2)
509
Xerographics (2/2)
510
Paper Feed
511
Image Processor Board
512
Control Panel
513
1100-Sheet Feeder Wiring Diagrams
514
1100-Sheet Feeder General Wiring
514
Drive
515
Upper Tray
516
Lower Tray
517
550-Sheet Feeder Wiring Diagrams
518
550-Sheet Feeder General Wiring
518
Drive
519
Tray
520
Reference
522
Phaser 6300/6350 Menu Map
523
Printer Status Codes
525
Additional Information
525
Service Diagnostics Menu Map
531
Service Diagnostics Tests
532
Mode Select Port
539
Obtaining Serial Back Channel Traces
540
Preparing the Printer for Shipment
541
Index
542
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98 pages
Quick Reference Guide
6 pages
User Guide
112 pages
Supplementary Guide
2 pages
Setup Guide
2 pages
Competitive Comparison
2 pages
4
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Xerox Phaser 6300 Specifications
General
Brand
Xerox
Model
Phaser 6300
Category
Printer
Language
English
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