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Xerox 6250N Service Manual - Page 162

General Troubleshooting

UPC - 095205770407

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General Troubleshooting In this chapter... ■ Introduction ■ System Start-Up and POST ■ Front Panel Troubleshooting ■ Fault Isolation ■ Inoperable Printer Troubleshooting ■ Paper Size Switch Assembly ■ AC Power Supply Troubleshooting ■ DC Power Supply Troubleshooting ■ Media Jams and the Paper Path ■ Operating System and Application Problems ■ Network Problems 4 Chapter

Section	Page
Cover Page	1
Frontis	5
Symbols Marked on the Product	6
Power Safety Precautions	7
Electrostatic Discharge (ESD) Precautions	8
Service Safety Summary	9
Regulatory Specifications	11
Contents	14
General Information	24
Printer Introduction and Overview	25
Printer Configurations	25
Printer Memory and RAM Capabilities	27
Parts of the Printer	28
Exterior	28
Phaser 6250 Front Panel Configuration	29
Rear View	30
Image Processor Board	31
Routine Maintenance Items	32
Consumables	32
Consumable Life Counter Behavior	33
Printer Specifications	34
Physical Dimensions and Clearances	34
Functional Specifications	35
Electrical Specifications	36
Environmental Specifications	36
Media and Tray Specifications	37
Theory of Operation	40
Overview of the Phaser 6250 Color Laser Printer Theory of Operation	41
Summary of the Printing Process	41
Print Modes	44
Printer Controls	44
Paper Size Control	44
Selective Control; Paper Pick	45
Laser Light Intensity Control	45
Process Control	45
LED Light Density CTD (ADC) Control of Sensor	47
Color Registration Control	48
Transfer Roller Assembly Control	50
Toner Control	51
Fuser Control	52
Paper Path of the Printer	53
Paper Path Route	54
Major Assemblies and Functions	55
Frame and Drive Assemblies	55
Main Drive Assembly - Transmission Route	56
Gear Layout - Print Engine and Tray 1	57
Paper Tray 2	58
Paper Feed - Tray 2	59
HCF Drive and Gears - Transmission Route	64
500-Sheet Feeder Drive and Gears - Transmission Route	65
Retard Housing Assembly	66
Chute Assembly In	67
Chute Assembly Out	68
Chute Assembly Exit	69
Duplex Motor Drive and Gear - Transmission Route	70
Chute Assembly Registration (REGI)	71
Transfer Roller and Fuser Assembly	72
Fuser Drive Assembly - Transmission Route	73
Xerographics	74
Imaging Unit Charge Voltage Contacts	75
Toner Cartridge Assembly	77
Toner Cartridge Assembly - cont’d	78
Toner Motor Drive Assembly - Transmission Route	79
Developer Assembly Transmission Route	79
Error Messages and Codes	82
Introduction	83
Servicing Instructions	84
Using the Troubleshooting Procedures	85
General Notes on Troubleshooting	85
Voltage Measurements	86
Service Diagnostics	87
Service Diagnostic Front Panel Button Descriptions	88
Diagnostic Menu Map	89
Service Diagnostic Tests	90
Jam History Error Codes Table	97
Error Messages and Codes Summary Table	98
Jam Errors	100
Jam at Fuser: Jam F	100
Jam at Duplex: Jam D	102
Jam at Registration Roller: Jam RR	104
Misfeed at Tray 1 (MPT): Jam T1	106
Misfeed at Tray 2: Jam T2	109
Misfeed at Tray 3: Jam T3	112
Misfeed at Tray 4: Jam T4	115
Door and Cover Errors	117
Close Front Door	117
Consumable Errors	118
Install or Reseat Imaging Unit	118
Replace Imaging Unit or Imaging Unit is Near End of Life	119
Install or Reseat Transfer Roller	120
Replace Transfer Roller or Transfer Roller is at End of Life	121
Install or Reseat Fuser	122
Replace Fuser or Fuser is Near End of Life	123
Install or Lock [Y] [M] [C] [K] Toner Cartridge	124
Replace [Y] [M] [C] [K]Toner Cartridge or [Y] [M] [C] [K] Toner Is Low	126
Dusty Density Sensor	128
Output Tray is Full, Unload Paper	129
Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge	130
Tray and Media Errors	131
Insert Tray [2] or Tray [2] Missing	131
Insert Tray [3] [4] or Tray [3] [4] Missing	133
Tray 2 Paper is Low	135
Tray [3] [4] Paper is Low	136
Out of Paper; Load Tray 1 (MPT) with [size] [type]	137
Out of Paper; Load Tray [2] [3] [4] with [size] [type]	138
Wrong Paper Size; Load Tray 2 with [size] [type]	139
Wrong Paper Size; Load Tray [3] [4] with [size] [type]	141
Wrong Paper Type; Load Tray [1 (MPT)] [2] [3] [4] with [size] [type]	143
Fatal Errors	144
Laser Failure	144
Density Sensor Failure	145
Fuser Failure	146
Fuser Failure (cont’d)	147
Fuser Failure (cont’d)	148
Fuser Fan Failure	149
Rear Fan Failure	150
Generic Fan Failure	151
Engine Firmware Failure	152
Imaging Unit Firmware Failure	153
Fuser Firmware Failure	154
Controller to Engine Communications Failure	155
Engine NVRAM Error	156
Replace [Y] [M] [C] [K] Toner Cartridge	157
[Y] [M] [C] [K] Toner Cartridge Failure	158
Non-Phaser 6250 Fuser	159
Non-Phaser 6250 Imaging Unit	160
Environmental Sensor Failure	161
General Troubleshooting	162
Introduction	163
Printer Status Page	163
Power-Up Modes	163
System Start-Up and POST	164
System Boot Sequence	164
Power On Self Test (POST)	165
POST Faults	167
LED Blink Patterns	167
POST Diagnostic Test Descriptions	168
Front Panel Troubleshooting	169
No Front Panel Display after Power is Turned ON	169
Front Panel LED is on, Front Panel Display is Blank	169
Front Panel Continually Displays “Warming Up...”	169
Front Panel Continually Displays \	169
Fault Isolation	170
Inoperable Printer Troubleshooting	170
Engine Power-Up Sequence	170
Printer Does Not Come to a \	170
Paper Size Switch Assembly	171
Power Supply	171
AC Power Supply Troubleshooting	172
DC Power Supply Troubleshooting	173
Media Jams and the Paper Path	175
Operating System and Application Problems	178
Macintosh printing problems	178
Windows printing problems	180
Network Problems	180
Print-Quality Troubleshooting	182
Print-Quality Problems Overview	183
Defects Associated with Specific Printer Components	184
Front Panel Test Prints	185
Test Print 1: CMYK Sample Page	185
Test Print 2: RGB Test Print	186
Service Test Prints	187
Test Print 3: Test Pattern Sample	187
600 x 600 Service Test Print	189
Print Engine Test Print	190
Print-Quality Troubleshooting	191
Light Prints	191
Light Print in Only One Color	192
Blank Prints	194
Black Prints with White Margin Border	195
Solid Dark or Dirty Prints, No Border	196
Missing Band, Voids Or Streaks In a Single Color or All Colors Parallel to the Leading Edge	197
Missing Band, Voids or Streaks in a Single Color or All Colors in Direction of Paper Travel	199
Repeating and/or Random Spots	200
Background Contamination	201
Residual Image, Ghosting or Hot Offset	203
Incomplete Fusing or Cold Offset	204
Mis-Registration, Color Layer not Correctly Registered in the Process Direction	205
Dirty Vertical Streaks on the Edges of the Page	206
Adjustments and Calibrations	208
Calibrations	209
Color Calibration	209
Margin Calibration	209
Adjustments	210
Horizontal and Vertical Color Registration	210
Resetting NVRAM	211
PostScript NVRAM Resets	211
Service Diagnostics PostScript NVRAM Resets	215
Cleaning and Maintenance	216
Service Preventive Maintenance Procedure	217
Cleaning	217
Service Parts Disassembly	220
Overview	221
Standard Orientation of the Printer	221
General Notes on Disassembly	222
Preparation	222
Notations in the Disassembly Text	222
Removing Routine Maintenance Items and Consumables	223
Transfer Roller Removal	223
Imaging Unit Removal	223
Fuser Removal	223
Toner Cartridge Removal	224
Print Engine Disassembly	225
Covers	225
Front Cover (PL 1.1.2)	225
Front Panel (PL 1.1.1)	226
Fuser Fan (PL 1.1.7)	227
Top Main Cover (PL1.1.9)	228
Image Unit Top Cover (Door C) (PL1.1.10)	229
Right and Left Side Covers (PL1.1.24), (PL1.1.30)	230
Rear Cover (PL 1.1.20)	231
Left and Right Links (PL 1.1.23)	232
Tray 1 (MPT) (PL1.1.99)	233
Front Right Cover (PL 1.1.25)	234
Front Left Cover Assembly (PL1.1.29)	235
Paper Feed	237
Paper Feed Roller (PL 2.1.2) (Routine Maintenance Item)	237
Turn Chute Assembly (PL3.1.2)	238
Printer Chassis/Feeder Assembly	239
Paper Pick Assembly (PL3.3.1)	241
Right and Left Housing (PL 3.2)	242
Temperature/Humidity Harness (PL3.2.1) and Sensor (PL3.2.2)	243
High-Capacity Feeder Harness (PL3.2.3)	244
Paper Size Switch Assembly (PL3.2.4)	245
Low Paper Lever (PL3.2.7), Indicator (PL3.2.8) and Indicator Guide (PL3.2.10)	246
Paper Pick Rollers (PL3.3.3)	248
No Paper Actuator (PL3.3.5), No/Low Paper Sensor (PL3.3.4)	249
Link Actuator (PL3.3.6)	251
Feed Solenoid (PL3.3.17)	252
Turn Clutch Assembly (PL3.3.18)	253
Roll Turn Assembly (PL3.3.20)	254
Paper Feed Roller (Routine Maintenance Item)	255
Retard Roller Housing Assembly (PL4.1.1)	256
Turn Roll (PL 4.1.2), Turn Clutch (PL 4.1.9), and Friction Clutch Assembly (PL 4.1.4)	257
Retard Roller Assembly (PL4.1.5)	258
Chute Assembly In	260
Chute Assembly In (PL 5.1.1)	260
CTD (ADC) Sensor (PL 5.1.11)	261
Toner Full Sensor (PL 5.1.13)	262
Fuser Drive Assembly (PL 5.1.18)	263
Right Latch (Door A) (PL 5.1.21)	264
Left Latch (PL 5.1.30)	265
Chute Assembly Out	266
Chute Assembly Out (PL6.1.1)	266
Output Tray Full Actuator (PL 6.1.5) and Full Stack Sensor (PL 6.1.4)	269
Duplex Actuator (PL 6.1.13) and Duplex Sensor (PL 6.1.4)	270
Tray 1 Actuator (PL 6.1.37) and Tray 1 Sensor (PL 6.1.4)	272
Static Eliminator Assembly (PL 6.1.9)	274
Duplex Roller (PL 6.1.12)	275
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)	276
Tray 1 Paper Pick Assembly (PL 6.1.27) (Roll Feed)	277
Tray 1 Feed Solenoid (PL 6.1.40)	278
Tray 1 Shaft (PL 6.1.28)	279
Tray 1 Bottom Plate (PL 6.1.42)	280
Chute Assembly Exit	281
Chute Assembly Exit (PL 7.1.1)	281
Exit Roller (PL 7.1.4)	282
Mid Roller (PL 7.1.5)	283
Duplex Motor Assembly (PL 7.1.8)	284
Exit Actuator (Fuser) (PL 8.1.7)	285
Strap (PL 8.1.13)	286
Xerographics	287
Laser Unit (PL 9.1.1)	287
Housing Assembly Bias (PL 9.1.4)	288
Chute Assembly Registration (PL 9.1.6) and Housing Assembly Electric (PL 9.1.11)	290
Registration Sensor Actuator (PL 9.1.9) and Registration Sensor (PL 9.1.8)	292
OHP Sensor and Harness (Kit) (PL 9.1.12)	294
Toner Cartridge Holder Assemblies	296
Toner Cartridge Holder Unit Assembly (PL 10.1)	296
Toner Cartridge Holder Assembly	299
Toner Present Switch Bracket and Actuator (PL 10.1.6 and 10.1.22)	301
Toner Low Sensor (PL 10.1.5)	303
CRUM Reader Box Assembly (PL 10.1.21)	304
EEPROM Board (PL 10.1.14)	305
Sub-High Voltage Power Supply Board (PL 10.1.15)	306
Frame and Drive Assemblies	307
Left Lever Plate (PL 11.1.1), Lever Bracket (PL 11.1.2), Lever Link (PL 11.1.3), Lever Drum (PL 11.1.4), and Lever Spring (PL 11.1.5)	307
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)	310
Main Drive Assembly (PL 11.1.14)	313
Developer Drive Assembly (PL 11.1.13)	314
Actuator, I/L (PL 11.1.8) and Spring, I/L (PL 11.1.9)	315
Earth Ground Circuit Board (PL 11.1.16)	316
Electrical	317
AC Switch Harness Assembly (PL 12.1.11)	317
Low-Voltage Power Supply (PL 12.1.10)	318
Motor Driver Board (PL 12.1.12)	320
Rear Fan (PL 12.1.2)	321
Card Cage	322
Housing Assembly Contact (PL 12.1.14)	325
Engine Control Circuit Board (PL12.1.1)	326
Image Processor Board (PL12.1.4)	329
Optional High Capacity Feeder Disassembly	330
Cover Front (PL14.2.4)	330
Cover, Right (PL14.2.1) and Cover, Left (PL14.2.3)	331
Turn Chute Assembly (PL14.3.7)	332
Tray 3 Harness Assembly (PL14.5.3), Tray 4 Harness Assembly (PL14.5.4), and HCF Plug Harness Assembly (PL14.5.2)	333
Circuit Board, HCF (PL14.5.1)	335
Drive Feeder Assembly (PL14.5.5)	336
Indicator Assembly (PL14.5.9)	337
Right Tray Guide (PL14.3.5)and Low Paper Lever (PL 14.5.8)	338
Left Tray Guide (PL14.3.3)	341
Link Actuator (PL 14.4.6)	343
HCF Paper Pick Assembly (PL14.4.1)	344
Idler Gear (PL14.5.6)	345
No Paper, Low Paper Sensor (PL14.5.7)	346
Paper Size Switch Assembly (PL14.3.6)	347
Casters, Locking (PL 14.2.5)/Non-Locking (PL 14.2.6)	348
Optional 500-sheet Feeder Disassembly	349
Cover Front (PL15.2.4)	349
Cover, Right (PL15.2.2) and Cover, Left (PL15.2.1)	350
Turn Chute Assembly (PL15.3.9)	351
Tray 3 Harness Assembly (PL15.5.3) and STF Plug Harness Assembly (PL15.5.2)	352
Circuit Board, STF (PL15.5.1)	354
Drive Feeder Assembly (PL15.5.5)	355
Indicator Assembly (PL15.5.8)	356
Right Tray Guide (PL15.3.5)and Low Paper Lever (PL 15.5.7)	357
Left Tray Guide (PL15.3.3)	360
Link Actuator (PL 15.4.6)	362
STF Paper Pick Assembly (PL15.4.1)	363
No Paper, Low Paper Sensor (PL15.5.6)	364
Paper Size Switch Assembly (PL15.3.6)	365
Parts List	366
Serial Number Format	367
Using the Parts List	368
Print Engine Parts	369
PL 1.1 Covers	369
PL 2.1 Universal Paper Tray	372
PL 3.1 Paper Feed I	373
PL 3.2 Paper Feed II	375
PL 3.3 Paper Feed III	377
PL 4.1 Housing Assembly Retard	379
PL 5.1 Chute Assembly In	381
PL 6.1 Chute Assembly Out	383
PL 7.1 Chute Assembly Exit	387
PL 8.1 Transfer Roller & Fuser Assembly (RMIs)	389
PL 9.1 Xerographics	391
PL 10.1 Holder Toner Cartridge Assembly	393
PL 11.1 Frame and Drive Assemblies	395
PL 12.1 Electrical	397
PL 13.1 Harness Assemblies	399
Optional High-Capacity Feeder	401
PL 14.1 Paper Trays 3 & 4	401
PL 14.2 High-Capacity Feeder Covers	402
PL 14.3 High-Capacity Feeder Guides and Turn Chute Assembly	403
PL 14.4 Paper Pick Assembly Trays 3 & 4	405
PL 14.5 High-Capacity Feeder Harness, Board and Motor	407
Optional 500-sheet Feeder	409
PL 15.1 Paper Tray 3	409
PL 15.2 500-sheet Feeder Covers	410
PL 15.3 500-sheet Feeder Guides and Turn Chute Assembly	411
PL 15.4 Paper Pick Assembly Tray 3	413
PL 15.5 500-sheet Feeder Harness, Board and Motor	415
Xerox Supplies and Accessories	416
Wiring Diagrams	422
Plug/Jack Locator Maps	423
Map 1	427
Map 2	428
Map 3	429
Map 4	430
High-Capacity Feeder Plug/Jack Locator Table	431
Map 5	432
500-sheet Feeder Plug/Jack Locator Table	433
Map 6	434
Print Engine Wiring Diagrams	435
Notations used in Wiring Diagrams	435
Main Wiring Diagram	436
Power Supplies	437
Paper Tray 2	438
Drive Section	439
Developer Section 1	440
Developer Section 2	441
Fuser Assembly	442
Laser Unit	443
Xerographics 1	444
Xerographics 2	445
Paper Feed	446
Image Processor Board	447
Printer Options Wiring Diagrams	448
High Capacity Feeder Main Wiring Diagram	448
Drive Section (HCF)	449
Paper Tray 3	450
Paper Tray 4	451
500-sheet Feeder Main Wiring Diagram	452
Drive Section (STF)	453
Paper Tray 3	454
Appendix	456
Printer Status Codes	457