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Phaser 6200 Color Laser Printer

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2. ENGINE MOTOR DRIVER CONTROL BOARD PL12 1 12 Se P J12 P J42 P J51 S P J431 ll Dk K 4 pA C 2 E 12 gt gt 1 mo TONER PRESENT SWITCH Y PL10 1 18 P J12 P J42 P J51 OND sabe P J432 9 m De Fy s s fe NESE e fs 6 mbes TONER PRESENT SWITCH M PL10 1 18 P J12 P J42 P J51 ie ee P J433 25 D 6 29 De oe lt 2 Em 30 gt lt 1 mo TONER PRESENT SWITCH C PL10 1 18 P J12 P J42 P J51 Sn ee P J434 28 De lt 3 31 D1 lt 2 jm 32 gt lt 4 37 TONER PRESENT SWITCH K PL10 1 18 P J441 P J51 K 4 NOTNR_Y 16 gt lt C C 2 m 15 gt lt 3 j LOW TONER SENSOR Y pisao PL10 1 18 P J12 P J42 P J51 K m 21 J NOTNRCHK C r 1 18 le NORM 5 1 NOTNR_CHK_M A SG 22 5 gt C 9 17 5 lt 3 NOTNR_CHK_Y 23 OT NOTNR CHK TS LOW TONER 24 gt tc 7 Toner SENSOR M NOTNR Sensor PL10 1 18 3 gt lt 28 Control P J443 a 1 P J51 Fe 4 NOTNR_C 34 gt lt sa C 2 m 33 Di 3 m LOW TONER SENSOR C pigga PL10 1 18 P J51 K 4 36 gt lt a 2 m 35 gt lt 3 j LOW TONER SENSOR K PL10 1 18 S6200 252 356 Phaser 6200 Color Laser Printer Service Manual Developer 2 ENGINE CONTROL BOARD PL12
3. ENGINE MOTOR DRIVER PAPER CONTROL BOARD SIZE SW BOARD P J12 pyyag PL12 1 12 P J47 pazi PL24 PL12 1 1 i5 ie 5 TRAY1 SIZEO SWITCH ON L 3 3VDC i i i7 Se TPAY1 SIZE1 SWITCH ON L 3 8VDC 3 ia ia S PA SIZE2 a ON L 3 3VDC i a 3 3VDC i P J47 PUEDE ADE P J472 a ta jji PUA 2 TRAVI NO PAPER SENSED H 3 3VDC 2 m 12 DK 19 5k as lt 1 j 43 3VDC No PAPER SENSOR PL3 3 4 i P J47 P J473 i PULL UP 3 3VDC 3 i i i i SG Pie ai TRAY1 LOW PAPER SENSED H 3 3VDC C 2 m 3 1 DK 20 1 m Wend LOW PAPER i SENSOR i i 24VDC HEN i H P JA7 P474 J474 VL 24VDC Pig PUE 21 TRAVI FEED SOLON L 24VD0 nae 10 D gt of 21 ye gt m i 2 i i FEED SOLENOID H H Interlock Tray1 i 24VDC PL3 3 17 J47 PA P475 J475 g PU 2na TON CLOU avc a 1 2 9 Dt gt 2 gt Ch gt m i 2 5 TURN CLUTCH Tray1 PL3 3 18 S6200 250 354 Phaser 6200 Color Laser Printer Service Manual Drive Section
4. ie a k i Charged i Charged Charged Charged 1 with oy 1 with toy 1 with oy 1 with I electricit oy electricity Poj electricity oy electricity I l l v Y i Y l 2 Exposure 2 Exposure 2 Exposure I 2 Exposure I l l l meet E a pe l a i eae ot 1 fee ot 1 peer L akeri i I l l Wa 4 ts 4 SsSsS a Primary transfer f Z 4 Primary transfer p gt m Drum fi IDT1 paom i i Drum fi IDT1 eas l i i i Intermediate 6 Cleaning Intermediate 6 Cleaning transfer unit IDT1 transfer unit IDT1 IDT1 a IDT1 i Yy l l Yy Nios 5 Secondary transfer a ss 7 IDT1 fi IDT2 pai i l Intermediate H i l transfer unit 8 Cleaning IDT2 l IDT2 4 l S 7 Tertiary transfer 4 11 Cleaning i ee IDT2 fi Paper j 74 general Fx I 1 l l v jl eT ere Transfer Paper 9 Static elimination v l l I 1 igi foe tee eee a ZY 10 Fixing l l N 6200 009 1 Charai ith el mes Refresher Drum Y 1 Charging with electricity Refresher ne RIC IDT1 1 Charging with electricity 4 Primary transfer 5 Secondary transfer IDT1 Cleaner 6 Cleaning Dev
5. ID No Part Number Qty Name Description 1 Chute Assembly In with 2 30 1a 116 1379 00 1 120 V 1b 116 1380 00 1 220 V 2 116 1381 00 1 Assembly Wiring 2nd BTR J5020 Transfer Roller 3 116 1382 00 1 Spring 2nd BTR 4 116 1383 00 1 Shaft BTR IN 5 116 1384 00 1 Assembly Wire Disk J5030 6 116 1385 00 1 Spring DTC 7 116 1386 00 1 Stud 2nd BTR 8 116 1387 00 1 Spring Holder BTR 9 9a 116 1388 00 1 Assembly Harness Fuser 100 V 120 V FSR 2 9b 116 1389 00 1 Assembly Harness Fuser 220 V FSR 22 10 116 1390 00 1 Assembly Harness CTD ADC 11 116 1391 00 1 Assembly Sensor CTD ADC 12 116 1392 00 1 Spring ADC 13 116 1393 00 1 Sensor Toner Full 14 116 1394 00 1 Assembly Harness Toner Full SNS 15 116 1395 00 1 Spring IDT 16 116 1396 00 1 Stud IDT 17 116 1397 00 1 Holder IDT 18 116 1398 00 1 Assembly Drive Fuser 19 116 1399 00 1 Spring BTR 20 116 1400 00 1 Wire Assembly FSR Earth GRND 21 116 1401 00 1 Right Latch 22 116 1402 00 1 Spring Latch 23 1 Shaft Latch NS 24 116 1403 00 1 Plate In T R 25 116 1404 00 2 Roll Pinch Turn 1 per order 26 116 1405 00 2 Spring Pinch Turn 1 per order 27 116 1406 00 2 Roll Pinch Dup Duplex 1 per order 28 116 1407 00 1 Spring Pinch Dup Duplex 29 116 1408 00 1 Chute In Duplex 30 116 1409 00 1 Left Latch FRU Parts List 269 PL 6 1 Chute Assembly Out J134 P132 41 J13
6. BOARD PL12 1 1 5VDC P J140 ise P14 J141 P J142 19 TONER FUSES 3 3VDC poa g 12 D lt 2 2 Die 2 E 11 ms 1 lt 3 a SENSOR TONER FULL PL5 1 13 CTD SENSOR ADC ASSY P J13 aneviour P1361 J1361 pie PEN 12 Je AG 5 1 e KX 5 13 Jm 4 2h si 4 i ADC MONITOR 3 32 gt i 15 D 2 4 D gt 2 GLED 16 gt m 5 gt gt K 1 P J24 svo P2361 J2361 J231 ENUN Am 4 gt C 1 3 gt a me 3 DeK 2 2 3 2 K 3 ENV TEMP a 1 De m4 1 DHe 4 HUM TEMP SENSOR PL3 2 2 6200 256 360 Phaser 6200 Color Laser Printer Service Manual Xerographics 2 ENGINE CONTRO NOTE BTR Transfer Roller BOARD PL12 1 1 S HVPS Interlock 24VDC PL10 1 17 A P J13 TEEN P J5011 22 gt TSN fC 11 23 gt 3 0V_REF 9 24 gt aa gt lt 9 25 gt HV_REF_BTR_P E 26 gt rc 7 HV_REF_BTR_M 27 gt gt K 6 HV_REF_DTS 28 gt gt 5 oa BTR_P ON L 24VDC ate 4 30 gt BTR_M ON L 24VDC var at gt DTS ON L 24VDC 2 HV_MONI_BTR_V C 32 H4 1 P J702 IDT2 12 1 P J5030 1 P J5020 pa IDT2 CLEANER 1 gt P J701 ri 1 gt P J801 1 IDT1 CLEANER gt P J805 F t2 P J804 HTC 1 w g D TRANSFER ROLLER P J601 ASSY PL8 1 12 Detack
7. MOTOR DRIVER BOARD PL12 1 12 Interlock DEVELOPER DRIVE ASSY P J49 15 VL 24VDC Eolas 1 L 24VDC P J11 beveg PMA 2 X EER 1 Y LC 40 3 gt 2 SPEVE TDB TF 39 4 DEVE_B a S 2EVEA EE 3 5 5 DEVE_XA c o af DEVE TDA a7 6 5 DEVE_XB paa DA_DEVEMOT 5 D K 3 Interlock MAIN DRIVE ASSY P J48 15 VL 24VDC Petita VL 24VDC P J11 nine P J4 2 AR 7 X C 34 3 gt 2 a 5 MAN TDB 4 4 st MAIN_B MAINA MAIN_XA 9 gt I 32 Motor 5 gt MAIN TDA Control MAIN_XB 10 gt _ gt 31 6 gt DA_MAINMOT 1 DK 30 Interlock FUSER DRIVE 24VDC ASSY P J52 15 VL 24VDC Pte 1 18 VL 24VDC P J11 ERE P J41 2 FSRA 12 X C 29 3 gt y HH FSRTDB PH SI FSR_B 13 gt K_ 28 4 gt FSRA FSR_XA 14 Or Fea TDA E A 5 2 FSR_XB 15 gt DA_FSRMOT A e 2 16 DK 25 Interlock DUPLEX MOTOR ASSY PISO wn oye Y3 1p as 6 vL 24v0c PH P J12 ON P J42 2 gt BUPA 5 5 2 DUP B C 28 3 2 DUP_B C 4 e 2 gt DUP TDA i 4 gt DUP XA C 3 7 J KC 24 Motor 5 J rc 2 P DUP TOB TF 03 Control e SL DUP XBT DA_DUPMOT 29 i 2 P2 a erop Pa 1 LC 30 P J50 J137 P137 go fS _FANLOW 1 75 FAN ON H 24VDC 3a K at rae 8 S FAIL H 3 3VDG os 91 gt t3 FUSER FAN PL1 1 7 NOTE FSR Fuser W L Interlock S6200 251 Wiring Diagrams 355 Developer Section 1
8. IMAGING UNIT PL9 1 3 6200 257 Wiring Diagrams 361 Paper Feed ENGINE CONTROL BOARD NOTE REGI Registration PL12 1 1 3 3VDC P J13 BULLORE P139 J139 P J133 wa 3 E DUP JAM SENSED L 3 3VDC 2 D 2 jm gt lt 8 mo s E 3 3VDC Dup Jam Sensor PL6 1 4 P J13 suit UpAsavbe P139 J139 P J134 4 poms 419 3 j FULL STACK SENSED H 3 3VDC 7 2 2 6 gt Hja 6 6 1 Full Stack Sensor PL6 1 4 P J13 Suni UeSs ane P139 J139 P J135 3 gt t Jm 5 7 32 m 8j 2 m MPT NO PAPER SENSED H 3 3VDC pr ms o 1 m MPT No Paper Sensor Interlock PL6 1 4 24VDC P J13 iabe P139 J139 P132 J132 2 MPT FEED Sag L 24VDC m 2 10 2 12 is gt m l5 1 2 5 MPT FEED SOLENOID P J18 put uBseavee P J181 PLG 1 40 3 SG gt 3 jm Regi Sensor gt 2 PL9 1 8 REGI PAPER SENSED L 3 3VDC gt lt 1m Interlock 24VDC REGI CHU P J18 PL9 1 7 VL 24VDC B REGI CLUTCH ON L 24VDC Regi Clutch Interlock 24VDC P J19 gt VERANDE gt yyy CLUTCH TURN MPT TURN CLUTCH ON L 24VDC MPT gt ps i9 P J32 P J321 5VDC sc 1 OHP PAPER SENSED L 3 3VDG OHP SENSOR ASSY gt 2 SG PL9 1 12 3 jm S6200 258 362 Phaser 6200 Color Laser Printer
9. Step Check Yes No 1 Run the 600 x 600 test print from Replace the Image Go to step 2 service diagnostics Processor Board Examine the print see Resetting RBar Tee NVRAM on page 114 for evaluating the print 2 Check for an obstruction in the laser Remove the Go to step 3 beam path between the Laser Unit obstruction and the Imaging Unit 3 Does the image quality improve if Replace the Go to step 4 the Imaging Unit is replaced Imaging Unit CRC PL 9 1 3 4 Does the imaging quality improve if Replace the Go to step 5 the Transfer Roller is replaced Transfer Roller CRC PL 8 1 12 5 Does the image quality improve if Replace the Laser Replace the Engine the Laser Unit is replaced Unit RRP 9 1 Control Board RRP 12 7 Troubleshooting 99 Black Prints with White Margin Border 6200 289 The entire image area except the margins are black Step Check Yes No 1 Run the 600 x 600 test print from Replace the Image Go to step 2 service diagnostics Processor Board Examine the print see Resetting RRP 12 8 NVRAM on page 114 for evaluating the print 2 Does the image improve if the laser Replace the Engine Go to step 3 beam path between the Laser Unit Control Board and the Imaging unit is blocked with RRP 12 7 a sheet of paper 3 Does the image quality improve if Replace the Go to step 4 the Imaging Unit is replaced Imaging Unit CRC PL
10. Steps Actions and Questions Yes No 1 Ensure the correct Fuser 110v 220v is Replace the parts Go to step 2 installed in the printer verify against the concerned label on the Fuser Assembly Check the Fuser Assembly for evidence of fault or damage 2 Remove the Fuser Assembly and check Replace the parts Go to step 3 for broken or bent pins concerned 3 Does the error recur after the Fuser Go to step 4 Complete Assembly has been replaced with a new one 4 Replace the Low Voltage Power Supply Go to step 5 Complete Does the error recur after the LVPS has been replaced 5 Check the Fuser Harness for continuity Go to step 6 Replace the Fuser ij Harness pa diagram Fuser Assembly FSR2 110V FSR 22 22 0 V PL 5 1 9 6 Check the Front 1A Harness for Replace the Replace Front 1A continuity Engine Control Harness See the wiring diagram Fuser Assembly Board RRP 12 7 ail on page 358 oe 70 Phaser 6200 Color Laser Printer Service Manual Fuser Failure cont d Code 44 Indicates a failure in the Fuser Lamp circuit Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Low Voltage Power Supply PL 12 1 10 Fuser Assembly on page 358 Fuser Harness Assembly PL 5 1 9 Troubleshooting Procedure Table Engine Control Board is 2 8 VDC Engine Control Board RRP 12 7 Steps Actions and
11. Does this solve the problem Step Check Yes No 1 Clean the CTD Sensor and cycle Complete Go to step 2 power to the printer Is the problem resolved 2 Replace the CTD Sensor Go to step 3 Complete Is the problem resolved 3 Print the 600 x 600 Service Test Replace the Image Go to step 4 Print Processor Board Are all the colors aligned both RRP 12 8 vertically and horizontally 4 If only one color is affected replace Complete Go to step 5 the Imaging Unit Does this solve the problem 5 Replace the Laser Unit Complete Replace the Engine Control Board RRP 12 7 108 Phaser 6200 Color Laser Printer Service Manual Test Prints Adjustments and NVRAM Test Prints pg 110 A variety of test prints are available to aid in determining the quality of output from the printer and to assist in troubleshooting problems This section shows how to select and analyze all test prints available Adjustments pg 113 Adjustments for print quality and margin issues are explained in this section The main adjustments are Color Registration Color Calibration and Margin Calibration Reseting NVRAM pg 114 Resetting NVRAM returns all the Image Processor Board NVRAM stored parameters to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset The details and parameters for resetting NVRAM are detailed in this section Test Prints Adju
12. ID No Part Number Qty Name Description 1 116 1487 00 1 Circuit Board Engine Control 2 116 1488 00 1 Rear Fan 3 116 1489 00 2 Harness Clamp Guide 1 per order 4 671 5290 81 1 Image Processor Board no configuration chip no memory no NVRAM no Hard Drive 4a 163 1459 00 IC Memory NVRAM 4b Configuration Chip i button eee IC Base Configuration Chip 163 1475 00 IC Network Configuration Upgrade Chip a 7 IC DP DX Configuration Upgrade Chip 4c 650 4237 00 Internal Hard Drive FRU Memory 4q 156 4838 00 64 MB 8M x 64 PC133 Memory DIMM 156 4837 00 128 MB 16M x 64 PC133 Memory DIMM 156 4663 00 256 MB 32M x 64 PC133 Memory DIMM 5 1 Plate Rear Image Processor Board NS 6 2 Spring Ground Image Processor Board NS 7 1 Guide Right Engine Control Board NS 8 1 Guide Left Engine Control Board NS 10 10a 116 1494 00 1 Low Voltage Power Supply 110 V 10b 116 1495 00 1 Low Voltage Power Supply 220 V 11 116 1496 00 1 Assembly Harness AC Switch 12 116 1497 00 1 Circuit Board Motor Driver 14 116 1498 00 1 Housing Assembly Contact FRU Parts List 283 PL 13 1 Harness Assemblies vo99 P13 P140 P26 15 P311 P32 PL12 1 12 J11 J42 8 3 Pa 321 12 3164 9 4 P 3311 J151 10 5 JI oD o9 37 J60 12 6 wo DA J163 284 PL12 1 9 P163 P166 P165 P167 P164 P162 P139 P1361 p138 J501 1 P210 Z
13. Troubleshooting Procedure Table Steps Action and Questions Yes No 3 Disconnect the connectors J163 J164 Go to step 4 Replace the and J165 from the LVPS turn the AC Low Voltage power switch on and verify the DC Power Supply voltages between the following pins on Board RRP 12 2 the Low Voltage Power Supply board P163 1 lt gt P163 2 24VDC P164 1 lt gt P164 2 3 3VDC P165 1 lt gt P165 2 5VDC P165 3 lt gt P165 4 3 3VDC Caution Be careful not to touch any other pins during these measurements or you may blow the fuse F001 on the LVPS 4 Turn the AC power switch OFF Go to step 6 Go to step 5 Connect J164 to the LVPS then turn the AC power switch ON P J164 1 lt gt P J164 2 3 3 VDC 5 Check the following parts for fault or Replace if Go to step 6 damage damaged or LVRPG Harness Assembly for damage or defective if it is shorted to the frame Engine Control Board 6 Turn the AC power switch OFF Go to step 8 Go to step 7 Connect J165 to the LVPS then turn the AC power switch ON Verify P J165 1 lt gt P J165 2 5 VDC P J165 3 lt gt P J165 4 3 3 VDC 7 Check the following parts for fault or Replace if Go to step 8 damage damaged or LVNC Harness Assembly defective Motor Driver Board 8 Turn the AC power Switch OFF Complete Go to step 9 Connect J163 to the LVPS then turn the AC power switch ON P J163 1 lt gt P J16
14. 3 TONER LOW SENSOR Y f PIWA pL10 1 8 TONER LOW SENSOR M PL10 1 8 TONER LOW SENSOR C PL10 1 8 TONER LOW SENSOR K PL10 1 8 Toner Motor Y PLIO 1 1 Toner Motor M PL10 1 1 Toner Motor C PL10 1 1 Toner Motor K PL10 1 1 S6200 248 Phaser 6200 Color Laser Printer Service Manual Power Supply NOTE I L Interlock MOTOR DRIVER BOARD PL12 1 12 Interlock 24VDC LVPS PL12 1 10 F VL Switch P J163 P J60 1 2BINPOSET 1 P J165 P J61 5VDC 8 j P J61 3 3VDC SG 1 Supply 2 ew 3 3VDC P J165 4 P J165 P J61 8 1 6 gt 3 7 gt 2 P J166 2 REAR FAN FAIL H 3 3VDC 1 REAR FAN ON H RTN 3 P J164 GND_ESS 3 5VDC_ESS 2 GND_ESS 1 3 3VDC_ESS Heater Control P J162 pe 2 gt 1 gt P J161 1 2 VYIV AC SW aa Wiring Diagrams P J41 P J41 P J42 s P J12 14 gt I 17 SG 15 Y 16 PIAR aow P 13 18 12 19 29 2 P J11 V L 24VDC V L 24VDC I L_OPEN P J11 P J11 24 DI 5VDC ral 17 P J11 REAR FAN PL12 1 2 P J311 24 23 ENGINE CONTROL BOARD PL12 1 1 Interlock 24VDC 3 3VDC sop OR 6200 249 353 Paper Tray 1
15. FRU Parts List 287 PL 14 2 High Capacity Feeder Covers S S 4 5 4 4 as Ae ll sA 7 A 3 Y s A 6200 242 288 Phaser 6200 Color Laser Printer Service Manual PL 14 2 High Capacity Feeder Covers FRU Parts List Table ID No Part Number Qty Name Description 1 116 1510 00 1 Cover Left 2 116 1337 00 2 Cover Rear 1 per order 3 116 1511 00 1 Cover Right 4 116 1512 00 3 Cover Front 1 per order 5 116 0009 00 2 Casters Locking 1 per order 6 116 0008 00 2 Casters Non Locking 1 per order 7 116 1514 00 2 Indicator Paper 1per order FRU Parts List 289 PL 14 3 High Capacity Feeder Guides and Turn Chute Assembly VY 1 with 3 and 8 V 2 with 5 and 6 P821 6 S P831 N S6200 243 290 Phaser 6200 Color Laser Printer Service Manual PL 14 3 High Capacity Feeder Guides and Chute FRU Parts List Table ID No Part Number Qty Name Description 1 Guide Assembly with 3 and 8 NS 2 Guide Assembly with 5 and 6 NS 3 116 1515 00 2 Guide Tray Left 1 per Tray 5 116 1516 00 2 Guide Tray Right 1 per Tray 6 116 1343 00 2 Assembly Paper Size Switch 1 per Tray 7 116 1336 00 2 Assembly Turn Chute 1 per Tray 8 116 1351
16. TURN CLUTCH ASSY MPT GEAR GEAR IDLER FEED RETARD HOUSING ASSY TURN CLUTCH GEAR IDLER IN GEAR FEED1 GEAR IDLER GEAR FEED H1 PAPER PICK ASSY TRAY 6200 037 318 Phaser 6200 Color Laser Printer Service Manual Paper Tray 1 6200 040 1 Paper Retard Feed Roller The paper retard feed roller prevents more than 1 sheet at a time from printing The paper feed retard roller and the paper feed nudge roller are interchangeable parts in all trays 2 Side Guides Right and Left The side guides move against media to align or register the width of print media in the paper feed direction 3 Rear Guide The rear guide moves to determine the length of print media in the paper feed direction The paper size switch uses this rear guide to detect the paper size Theory of Operation 319 Paper Feed Tray 1 6200 041 1 Temperature Humidity Sensor Detects temperature and humidity inside the printer to adjust the charge voltage the voltage supplied to the transfer roller and the developing bias 2 No Paper Sensor Detects print media in the tray based on the position of the Actuator 3 Paper Pick Rollers When the feed solenoid energizes the spring feed force engages the gear feed and the gear idler feed to turn and feed the paper from the paper tray This activates the pick up assembly After completion of one turn determined by a cutout in the gear feed the gear f
17. Sample Pack Repackaging Kit Phaser 6200 065 0610 00 Repackaging Kit High Capacity Feeder 065 0620 00 Phaser 6200 Cleaning Kit 5 Texwipes 016 1845 00 Power Cords Description Part Number Cable Assy 3 18AWG 115 V 98 OL 161 0066 00 Cable PWR EURO 220V 99L 161 0066 09 Cable PWR U K 240 V 96L 161 0066 10 Cable PWR AUST 240 V 96L 161 0066 11 Cable Assy SWISS 220 240 V 50Hz 161 0154 00 Cable Assy PWR DANISH 250 V 161 0240 00 Cable Assy PWR PRC 161 0304 00 Power 240V ARGENTINA 161 0307 00 296 Phaser 6200 Color Laser Printer Service Manual Upgrade Kits and Options Description Part Number Internal Hard Drive FRU 650 4237 00 Memory 64 MB 8M x 64 PC133 Memory DIMM 156 4838 00 128 MB 16M x 64 PC133 Memory DIMM 156 4837 00 256 MB 32M x 64 PC133 Memory DIMM 156 4663 00 High Capacity Feeder w Trays 119 6415 00 Casters Non Locking 116 0008 00 Casters Locking 116 0009 00 IC Base Configuration Chip 163 1458 00 IC Network Configuration Upgrade Chip 163 1474 00 IC DP DX Configuration Upgrade Chip 163 1475 00 IC Memory NVRAM 163 1459 00 Customer Replaceable Consumables CRCs Description Part Number Toner Cartridges Phaser 6200 all Yellow Toner Cartridge Standard Capacity 016 2003 00 Yellow Toner Cartridge High Capacity 016 2007 00 Magenta Toner Cartridge Standard Capacity
18. Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Transfer Roller PL 8 1 12 Toner Full Sensor PL 5 1 13 2 Use service diagnostics to test the Replace the Go to step 3 Transfer Roller Toner Full Sensor Engine Control Does the Transfer Roller Toner Full Board RRP 12 7 Sensor function correctly 3 Remove the Transfer Roller Assembly Go to step 5 Go to step 4 Verify the voltage between P J141 2 lt gt P J141 1 on the Transfer Roller Toner Full Sensor Harness is 0 VDC 4 Verify the voltage between P J141 3 lt gt Go to step 5 Replace P J141 1 on the Transfer Roller Toner Full Assembly Sensor Harness is 5 VDC Harness EEPROM PL 13 1 5 Check theTransfer Roller Toner Full Replace the Toner Replace the Toner Sensor Harness for continuity Full Sensor Full Sensor See Xerographics 1 on page 360 RRP 5 3 Harness RRP 5 3 Error Messages and Codes 51 Install or Reseat Fuser The printer s front panel displays Install or Reseat Fuser The Fuser is correctly installed and locked into position Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Fuser Harness FSR 2 PL 5 1 9 Fuser Assembly on page 358 Troubleshooting Procedure Table Steps Actions and Questions Yes
19. Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Paper Size Switch Assembly PL 3 2 4 Tray 1 PL 2 1 1 2 Use service diagnostics to test the paper Replace Engine Go to step 3 size switches using the table below Control Board Do the switches function normally RRP 12 7 3 Troublshoot using the wiring diagram Complete Replace Engine Paper Tray 1 on page 354 Control Board Replace any defective parts RRP 12 7 Paper Size Switches are indicated as SW1 SW2 and SW3 Paper Size Paper Size Switch Swi Sw2 SW3 LEGAL14 ON ON ON LEGAL13 ON ON OFF EXECUTIVE ON OFF ON B5 ON OFF OFF A4 OFF ON ON A OFF OFF ON A5 OFF ON ON Used for reference only Supported by MPT only No Tray OFF OFF OFF Error Messages and Codes 59 Insert Tray 2 3 orTray 2 3 Missing The printer s front panel displays Insert Tray 2 or 3 or Tray 2 or 3 is Missing The corresponding tray cavity is free of debris and obstructions The paper tray is free of defects and properly inserted into the printer Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Paper Size Switch Assembly PL 14 3 6 Paper Tray 2 on page 366 Pap
20. A hard fault is any fault discovered by POST that prevents the operating system from initializing successfully A hard fault prevents the system from further execution and is halted with blinking LEDs front panel and health LED The test name of the test that failed is displayed on the front panel Fault Reporting Devices There are four fault presentation devices m All soft faults are printed on the StartPage For hard faults m The health LED flashes according to the fault code E The front panel LED flashes in unison with the health LED E The last posted message to the graphic front panel is present LED Blink Patterns For faults identified as hard faults the POST firmware causes the PS health LED to blink in a particular pattern to identify the fault There are short and long blinks A long blink is worth 5 and a short blink is worth 1 If a fault blink pattern is flashed as long long short short this is fault code 5 5 1 1 12 which indicates a failure in the CPU interupt test See POST Diagnostics Test Descriptions on page 85 The exception to the above pattern is a RAM test error The RAM tests have a special blink pattern and the front panel displays RAM Error During power up the front panel LED is on If the RAM tests fail the Image Processor Board health LED is turned off and the front panel LED is red At 1 2 second intervals the health LED and the front panel LED toggle continuously 84 Phaser 6200 C
21. Toner Motor Yellow Toner Motor Magenta Toner Motor Cyan Toner Motor Black Normal Speed Audible verification of motor functionality Caution Only run the Toner Motor tests once per power cycle to avoid toner spillage inside the Imaging Unit cavity and packing the auger tubes with toner Rear Fan High Speed Low Speed High Speed Continuous Low Speed Continuous Audible verification of motor functionality Check for airflow Error Messages and Codes 25 Service Diagnostics Tests and Functions Table cont d High Speed Continuous Low Speed Continuous Test Front Panel Display and Test Definition Fuser Fan High Speed Audible verification of motor Low Speed functionality Check for airflow Sensor Switch Tests Tests the functionality of the sensors and switches by giving service personnel the ability to input actuation and state changes of all sensors and switches Interlock Switch Sensor is ON Sensor is OFF Front Door OPEN Front Door CLOSED Registration Sensor is OFF This test continuously cycles paper Toner M Low Yellow Toner Y Low Sensor Sensor is ON through the printer The sensor state changes from off to on as the paper passes through the Registration Chute Note This test can also be used as a paper path transport test when troubleshooting Jam conditions Exit Sensor Sensor is OFF Actuate de actuate the Exit
22. Y Parea P J473 EEPROM PL10 1 16 PIAS PIT PAA P J474 P J231 P J136 P J5030 P 35011 P J5020 IMAGING UNIT PL9 1 IDT2 CLEANER maA 1 AC SW HARNESS PL12 1 11 REAR FAN PL12 1 2 MOTOR DRIVER BOARD PL12 1 12 P J166 P J702 P J802 j P J801 j P J805 P J601 P J603 P J604 P J139 PISS P J132 Regi Sensor PL9 1 8 Pita Regi Clutch CLUTCH TURN MPT PL4 1 9 OHP SENSOR PL9 1 12 Poget BOARD IMAGING PROCESSOR P J475 P J131 P J137 P J432 P J433 P J434 P J442 P J511 P J512 P J513 PL12 1 4 P J514 FRONT PANEL P1220 aia i 4 TONER PRESENT SW Y PRAS pLi0 1 18 PAPER SIZE SW 2 PL3 2 4 No Paper Sensor PL3 3 4 Low Paper Sensor PL3 3 4 FEED SOLENOID PL3 3 17 CLUTCH TURN ASSY PL3 3 18 MAIN DRIVE ASSY PL11 1 14 DEVE DRIVE ASSY PL11 1 13 FUSER DRIVE ASSY PL5 1 18 DUPLEX MOTOR PL7 1 8 FUSER FAN TONER PRESENT SW M PL10 1 18 TONER PRESENT SW C PL10 1 18 TONER PRESENT SW K PL10
23. 3 4 Release the tabs securing the harness cable guide located on top of the power Disconnect P J151 from the Laser Unit switch and move out of the way Unhook the springs from the left and right ends of the shaft Remove 1 screw securing the Laser Unit to the printer and remove the assembly Replacement 1 2 3 4 Align the Laser Unit with the printer Secure the right and left shafts of the Laser Unit with the tabs on the top of the Spring Laser Install the screw Connect P J151 Note Perform the Color Registration procedure after replacing the Laser Unit FRU Disassembly Removal and Replacement Procedures 193 RRP 9 2 Bias Housing Assembly PL 9 1 4 6200 143 194 Phaser 6200 Color Laser Printer Service Manual Removal Note The Imaging Unit must be removed to prevent loss of the biasing buttons Remove the Imaging Unit Remove the Left Side Cover RRP 1 6 Disconnect all the wires and remove from the channel Remove the Link Left RRP 1 8 Remove the 5 screws securing the Bias Housing Assembly akon Caution The biasing buttons fall out easily 6 Remove the Housing Assembly Replacement 1 Replace in reverse order Note Move all wiring harness out of the way when replacing Note Ensure all 8 biasing buttons are in place Note Verify the proper alignment of the biasing springs FRU Disassembly Removal and Replacement Procedures 195 RRP
24. The toner low sensor is attached to the Toner Cartridge Holder Assembly and detects the presence of toner dispensed by the toner motor from the toner cartridge into the auger tube The toner low sensor can make a false detection if toner has stuck to the sensors surface To prevent this a film attached near the auger in the toner cartridge holder assembly cleans the sensor surface whenever toner is dispensed This film rotates with the auger as toner dispenses scraping toner off the toner low sensor surface The toner low sensor may detect toner even if toner is not present or may not detect the toner even if toner is present depending on the film position when the toner motor stops This is avoided by the printer s internal toner presence control Toner Presence Control 1 Checks toner presence when the power is turned on or after the front cover is opened and closed Every 14 seconds 2 The Toner Empty warning is displayed when the toner low sensor detects the toner is empty two or more times consecutively and if toner is dispensed during the time of detection 3 The Replace Toner Cartridge error is displayed when the toner dispense time count exceeds the specified value 4 Reseat or Replace Toner Cartridge C Y M K error or warning displays when the toner is dispensed for 1 5 seconds after toner cartridge installation is detected At the next toner control timing if the toner low sensor detects toner present
25. 6 092 meters 20 000 ft Acoustic Noise Idle Printing 35 0db or less 53 0db or less Full Speed 5 3 B 70 0db or less Half Speed 7 0 B General Information 13 Media and Tray Specifications Media and Tray Specifications Specification Trays Printable Minimum margins 5 mm 0 2 in on all sides All Trays Area Maximum paper size 215 9 mm x 355 6 mm 8 5 in x 14 in Minimum paper size 88 9 mm x 139 7 mm 3 5 in x 5 5 in Usable Paper Type Size paper sizes Letter 8 5x 11 in All Trays Legal 8 5 x 14 in All Trays Executive 7 25 x 10 5 in All Trays Statement 5 5 x 8 5 in MPT Only US Folio 8 5 x 13 in All Trays A4 210 x 297 mm All Trays A5 148 x 210 mm MPT Only A6 105 x 148 mm MPT Only B5 JIS 182 x 257 mm All Trays ISO B5 176 x 250 mm MPT Only Custom Size MPT Only Supported Type Weight ae g Plain Paper 64 90 g m 17 24 Ib Bond All Trays ati Heavy Plain Paper 85 105 g m 22 28 lb Bond All Trays weignts Phaser 6200 Transparency ONLY MPT amp Tray 1 Thin Card Stock 100 163 g m 26 60 Ib Cover MPT Only Thick Card Stock 160 216 g m 59 80 Ib Cover MPT Only Labels N A MPT Only Letterhead 85 105 g m 22 28 Ib Bond All Trays Glossy Coated Paper 120 163 g m 81 110 Ib Book MPT Only Business and Greeting Card N A MPT Only CD DVD Labels and Inserts N A MPT Only Digital Photo Paper 120 163 g m 81 110 Ib MPT Only
26. CRUM Harness in Assembly See Laser Unit on page 359 PL 10 1 15 4 Check CRUM Harness Assembly for Go to step 5 Replace the continuity CRUM Harness van Assembly See Laser Unit on page 359 PL 10 1 15 5 Check the EEPROM Harness for Replace the Replace EEPROM continuity Engine Control Harness n Board RRP 12 7 Assembly See Fuser Assembly on page 358 PL 13 1 10 Error Messages and Codes 49 Install or Reseat Transfer Roller The printer s front panel displays Install or Reseat Transfer Roller The CTD ADC Sensor is clean and the transfer roller is correctly installed in the printer Printer power has been cycled and the error still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References CTD ADC Sensor Assembly PL 5 1 11 Xerographics 1 on page 360 Transfer Roller Assembly CRU PL 8 1 12 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following parts for damage and Complete Go to step 2 replace if defective Transfer Roller CRC PL 8 1 12 CTD ADC Sensor PL 5 1 11 2 Clean the CTD ADC Sensor to remove Complete Go to step 3 any toner build up Does this fix the problem 3 Use service diagnostics to test the ADC Go to step 4 Go to step 5 Sensor Does the sensor function correctly 4 Replace the Transfer Roller Go to step 5 Complete Does
27. FRU Disassembly Removal and Replacement Procedures 133 RRP 1 8 Left and Right Links PL 1 1 23 6200 070 Removal Remove the Right and Left Side Covers RRP 1 6 Remove the upper end eye of the spring from the printer Open Door A From inside the printer push out the Link Pin securing the Link to the printer With a flat blade screwdriver spread apart both sides of the metal retaining clip holding the Link to the Front Cover Assembly and remove the Link and Spring together akhonDd Note To disengage the links from the printer without removing the link only perform Steps 1 through 4 134 Phaser 6200 Color Laser Printer Service Manual RRP 1 9 Multi Purpose Tray MPT PL1 1 99 6200 074 Removal 1 Open the Multi Purpose Tray 2 Flex the right and left side of the MPT slide PL 1 1 27 to seperate the base from the slide 3 With the MPT Slide at a 90 degree angle pull the slide out of the printer 4 To remove the Mult Purpose Tray Base PL 1 1 28 from the printer press in lift up and pull out from the printer Replacement Note The base must be re installed at a 90 degree angle to align the tabs properly 1 With the base at a 90 degree angle with the printer ensure the tabs are on the outside push down and then pull forward to re install FRU Disassembly Removal and Replacement Procedures 135 RRP 1 10 Front Right Cover PL 1 1 25 6200 07
28. Fuser Firmware Failure Code 76 The CRUM firmware has failed Troubleshooting Reference Table Applicable Parts EEPROM Board PL 10 1 16 Wiring and Plug Jack Map References Fuser Assembly on page 358 FSR 2 Harness Assembly PL 5 1 9 Laser Unit on page 359 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the Fuser Assembly for evidence Replace the parts Go to step 2 of fault or damage concerned 2 Remove the Fuser Assembly and check Replace the parts Go to step 3 for broken or bent pins concerned 3 Does the error recur after the Fuser Go to step 4 Complete Assembly has been replaced with a new one 4 Troubleshoot using the wiring diagram Go to step 5 Replace the Fuser Assembly on page 358 Assembly Does the printer function correctly after oe Fuser PL replacing any defective parts n 5 Troubleshoot using the wiring diagrams Replace the Replace Laser Unit on page 359 and Fuser Engine Control EEPROM Assembly on page 358 for the EEPROM Board RRP 12 7 Harness Harness Assembly PL 13 1 10 72 Phaser 6200 Color Laser Printer Service Manual Fuser Fan Failure Code 50 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Fuser Fan PL 1 1 7 Drive Section on page 355 Motor Driver Board PL 12 1 12 Troubleshooting Procedure Table Board RRP 12 7 Steps Acti
29. P71 J144 P141 J2361 S6200 241 Phaser 6200 Color Laser Printer Service Manual PL 13 1 Harness Assemblies FRU Parts List Table ID No Part Number Qty Name Description 1 116 1499 00 1 Assembly Harness LVNC J165 61 2 116 1500 00 1 Assembly Harness DRV 1 J11 J41 3 116 1501 00 1 Assembly Harness DRV 2 J12 J42 4 116 1502 00 1 Assembly Harness LVRPG J164 311 5 116 1503 00 1 Assembly Harness ROSKA J15 J151 6 116 1504 00 1 Assembly Harness 24 V J60 J163 7 116 1505 00 1 Assembly Harness FRONT 1A J13 P139 P1361 P1381 P5011 8 116 1506 00 1 Assembly Harness OPF MAIN J121 P210 9 116 1507 00 1 Assembly Harness OPEPANE OPA J22 P221 10 116 1508 00 1 Assembly Harness EEPROM J140 P71 J144 P141 12 116 1509 00 1 Assembly Harness TMPB J24 2361 FRU Parts List 285 High Capacity Feeder FRU Parts List PL 14 1 High Capacity Feeder Paper Trays 2 amp 3 V 1 with 2 6 6200 246 286 Phaser 6200 Color Laser Printer Service Manual PL 14 1 Tray 2 amp 3 Univeral Paper FRU Parts List Table ID No Part Number Qty Name Description 1 116 1330 00 1 Universal Paper Tray with 2 5 2 116 1331 00 2 Paper Feed Roller Kit 2 interchangeable rollers per order 3 116 1332 00 1 Assembly Friction Clutch 4 1 Holder Retard NS 5 116 1334 00 1 Spring Retard 6 1 Cover Front Tray NS
30. Phaser 6200 Color Laser Printer Service Manual 366 sky pl d e Aes ASSY HOLT NYNL k et OGAve C NO 10 NHNL EAVHL Me e Die ov ov im fC oa sa fale fC 9 z Wj el t8f d oLsr Ol8d ober Obed b d OaAve Vi seer Seed E8f d Lb yld oaAvet e kes yoopau GION310s 0334 jt M Lz OdAVZ T NO 10S 0334 AVHL ct e Det ov ev mile fC sa oa fp C 8 z Wj tk t8f d oLsr led oler Old b d OGAve V I vesr veed E8f d ghd gi oanve e1 sosuag yooueul Jaded MO gt l a gt K sv mK gt K o t 2 gt OQAE E H AISNIS H3dYd MOT EAVHL C ow sv jm ora va fm C oF Co z gt 58 KC 6 led ogr 018d Ober Od Zd lt D Oane s dN TINd C 8 eeerld E8f d veld e1 s0sueg Jaded ON gt seans aa onena M HSK 4 St gt K ziv ev K za 19 mp ok z z zz gt 9 L8f d OLer Obed ORZI Ol d bed e Di 28 Le DJL s oane s dN TINd zeet d oz 8d ozzsr 8f d Yy oane s d 5s e l gt K v oL va ol ov ovim k z E OGAE E H NO HOLIMS 23ZIS EAVEL aS z 6 gt i a 7 7 R et OGAE E NO HOLIMS IZIS SAYHL SI a gt ee d ov ov i FE ot OGAE E 1 NO HOLIMS OAZIS EAVEL LeBtid E8f d L8f d oLBr Ol8d ober Ol d Zid beelnd auvog
31. RRP 3 12 RRP 3 13 RRP 3 14 RRP 3 15 RRP 4 1 RRP 4 2 Turn Roll PL 4 1 2 Turn Clutch PL 4 1 9 Friction Clutch Assembly No Paper Actuator PL3 3 5 No Low Paper Sensor PL3 3 4 Link Actuator PL3 3 6 Feed Solenoid PL3 3 17 Turn Clutch Assembly PL3 3 18 Roll Turn Assembly PL3 3 20 Paper Feed Roller CRC Roller Kit RRP 4 Housing Assembly Retard Retard Roller Housing Assembly PL4 1 1 PL 4 1 4 RRP 4 3 Retard Roll Assembly PL4 1 5 RRP 5 Chute Assembly In RRP 5 1 RRP 5 2 RRP 5 3 RRP 5 4 RRP 5 5 RRP 5 6 RRP 6 1 RRP 6 2 RRP 6 3 RRP 6 4 RRP 6 5 RRP 6 6 RRP 6 7 RRP 6 8 120 Chute Assembly In PL 5 1 1 CTD ADC Sensor PL 5 1 11 Toner Full Sensor PL 5 1 14 Fuser Drive Assembly PL 5 1 18 Latch R Door A PL 5 1 21 Latch L PL 5 1 30 RRP 6 Chute Assembly Out Chute Assembly Out Duplex PL6 1 1 Output Tray Full Actuator PL 6 1 5 Full Stack Sensor PL 6 1 4 Duplex Actuator PL 6 1 13 Duplex Sensor PL 6 1 4 Multi Purpose Tray Actuator PL 6 1 37 Multi Purpose Tray Sensor PL 6 1 4 Static Eliminator Assembly PL 6 1 9 Duplex Roller PL 6 1 12 Latch Plate PL 6 1 17 Latch Out PL 6 1 18 Latch Holder PL 6 1 19 Latch Spring Out PL 6 1 20 MPT Paper Pick Assembly PL 6 1 27 Roll Feed RRP Page 149 150 152 154 156 157 158 159 160 161 162 164 166 167 168 169 170 172 175 176 178 180 181 182 183 Phas
32. Service Manual Image Processor Board ENGINE CONTROL BOARD PL12 1 1 TEST PRINT SG Wiring Diagrams IMAGE PROCESSOR BOARD PL12 1 4 P J14 gt ON L 3 3VDC P J221 OAN DOAK WD VIV wo 14 15 e gt SONIDO 17 gt ml 18 E i9 E 20 J2211 FRONT PANEL PL1 1 1 P220 FP RXD FP TXD FP STS Si G FP RST OMAN DOAK ON 3 3 VDC 3 3 VDC 3 3 VDC S S SG S 3 3 VDC S 3 3 VDC S6200 259 363 High Capacity Feeder Wiring Diagrams ENGINE CONTROL BOARD 2 PAPER SIZE SW T2 f P821 114 36 P J210 P J810 No Paper Sensor T2 ees PL14 4 4 Low Paper Sensor T2 od ro PL14 5 7 P J84 7 FEED SOLENOID T2 PL14 4 17 TURN CLUTCH ASSY T2 P825 1 14 4 18 Pigagi_ PAPER SIZE SW T3 3 PL14 3 6 No Paper Sensor T3 FEEDER DRIVE ASSY PL14 5 5 PHS a E eee ee P J824 Biles PL14 4 4 pras FEED SOLENOID T3 Pr m5 TURN CLUTCH ASSY T8 S6200 260 36
33. Service Manual Troubleshooting This section is for troubleshooting electrical system power up print quality media jams and paper path problems For information on troubleshooting error codes hard stop and fatal errors refer to the section Error Messages and Codes on page 17 Troubleshooting is ordered as follows Contents Page System power up and POST 83 System Boot Sequence 83 Power On Self Test POST 83 Power Supply and Printer Malfunctions 86 Printer does not come to Ready 87 Front Panel Troubleshooting 87 AC Power Supply Troubleshooting 88 DC Power Supply Troubleshooting 88 Media Jams and the Paper Path 90 Media based problems 90 Multiple sheet pick 90 Mis pick 90 Skewed Image 90 Damaged prints 91 Fuser Jams 91 Exit Jams 91 Operating System and Application Problems 92 Networking Problems 93 Print Quality Problems 94 Isolating Print Quality Problems Repeating Defect Identification Chart 95 Using the Print Engine only test print 96 Light Prints 97 Light Print in only one color 98 Blank Prints 99 Solid Black Prints 100 Dirty Prints 101 Troubleshooting 8l Contents cont d Page Missing Band Voids Or Streaks in a Single Color or All Colors Parallel 102 to Leading Edge Missing Band Voids Or Streaks in a Single Color or All Colors in 103 direction of paper travel Repeating and Random Spots 104
34. a N KYIYYYYYY Interlock 24VDC ji 3 3VDC PLATE DISPENSER L PL10 1 9 IMAGING UNIT PL9 1 3 P J15 AS P J151 20 gt K 1 XPDATA_B_M 19 gt lt 2 XPDATA_C_C 18 gt lt 3 XPDATA_D_K 17 gt K 4 MO_A_Y 16 gt lt 5 MO_B_M 15 ri 6 MO_C_C 14 oD gt 7 S VAY 1c 8 1 VBM 1c 9 11 a gt K 10 10 gt et vi 9 gt lt 12 5 5VDC 8 7 as gt lt 14 LD 5VDC 6 gt K 15 SOS SENSED L 3 3VDC 5 De 16 VL 24VDC 4 akc 17 3S RTN ig 5 SCANNER LOTOR ON Lsvoc SFE 4g 1 lt 20 PIO me P7 J74 PIJ710 12 gt ST DATA a C 2 12 gt cRum clock ae KI 5 s 2 gt 3 3VDC ae C 4 4 ki a 34 Ic 3 5 Se 25 2 6 gt mi 6 Lo 4 EEPROM BOARD PL10 1 16 Wiring Diagrams P J140 EEPROMDATA P J144 7 i gt L 4 EEPROM CLOCK 8 gt 3 3 3VDC 9 a gt lt 2 10 lt 4 See fuser assembly 6200 255 359 Xerographics 1 ENGINE CONTROL
35. both the front panel and health LED blink the error code pattern see LED Blink Patterns on page 84 POST Startup indications m At power on the hardware default is to turn on the IP board health LED m The Image Processor Board health LED is turned off E The front panel display is reset addressable area becomes gray E The Green LED turns on for 1 3 second m The Yellow LED turns on for 1 3 second m The Red LED turns on for 1 3 second E The front panel LED is turned off m The backlight is turned on high intensity with nominal contrast display m The front panel display area is turned on dark black for 1 second E The front panel display is cleared E The backlight is turned on with nominal intensity m The POST Vn nn message appears and tests are quickly executed E If any tests fail the front panel screen freezes with the name of the test displayed and the line posted is Call Customer Service E After the POST tests have finished running the Xerox splash screen is posted to the front panel and PostScript begins initialization Troubleshooting 83 POST Faults There are two kinds of faults soft and hard A soft fault is any fault that is discovered by POST but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting These POST faults do not stop execution and are reported on the StartPage in a red box after the system is running
36. design with an image processor supporting PostScript 3 and PCLSc The Phaser 6200 is a high performance A4 16 ppm desktop color laser printer with a resolution up to 2400 x 600 dpi The Phaser 6200 has four configurations The main difference is optional networking standard memory optional High Capacity Feeder HCF duplexing and optional internal hard drive A replaceable Configuration Upgrade Chip holds configuration information that enables or disables built in features as described below Phaser 6200B The Phaser 6200B is a base configuration entry level single pass color laser printer The printer comes standard with 64 Mbytes of memory resolution of 600 x 600 dpi USB and Parallel support a built in Multi Purpose Tray and a 500 sheet universal paper tray Phaser 6200N The Phaser 6200N is the networking configuration This configuration includes all the features of the 6200B but comes with 128 Mbytes of memory built in 10 100 Ethernet networking capabilities job pipelining enhanced print mode and a resolution up to 2400 x 600 dpi Phaser 6200DP The Phaser 6200DP is the plus configuration The printer includes all the features of the 6200N but comes standard with 128 Mbytes of memory built in auto duplexing PDF and Photo Mode support Phaser 6200DX The Phaser 6200DX is the marketing configuration The printer includes all the features of the 6200DP but comes standard with 256 Mbytes of memory a 1000 sheet High Cap
37. the Toner Empty Warning and Toner Empty Error are reset When toner is dispensed and the toner low sensor detects toner present three or more times consecutively the controller regards this status as toner presenct 312 Phaser 6200 Color Laser Printer Service Manual Fuser Control Fuser temperature control During fuser temperature control the printer s target temperature is set The heat roller surface temperature is controlled to match the target temperature by turning the heater lamp on off The heat roller surface temperature is detected by the thermistor sensor The logic detects the resistance value alternately at 40ms cycles The temperature is detected at 80ms cycles and if the detection result is high the heater lamp is turned off If the detection result is low the heater lamp is turned on For the target temperature different temperatures are set for standby printing and process control The target temperature is also changed according to the inside temperature detected with the temperature humidity sensor print count print mode input power supply voltage and paper type Cool down During printing the temperature distribution of the heat roller becomes uneven between paper and non paper To make the heat roller temperature as even as possible a wait time is provided and the heater lamp is kept off This is called the cool down A cool down is executed according to the number of sheets continuously printed
38. 00 2 Paper Tray Stopper 1 per Tray FRU Parts List 291 PL 14 4 Paper Pick Assembly Trays 2 amp 3 V 1 with 2 23 V 99 with 8 11 15 and 19 3 6200 244 292 Phaser 6200 Color Laser Printer Service Manual PL 14 4 Paper Pick Assembly Trays 2 amp 3 FRU Parts List Table ID No Part Number Qty Name Description 1 116 1517 00 1 Paper Pick Assembly LTA with 2 24 2 1 Shaft Feed 1 NS 3 116 1353 01 2 Paper Pick Roller Kit 2 per order 4 116 1354 00 1 Sensor No Paper Low Paper 5 116 1355 00 1 Actuator No Paper 6 116 1356 00 1 Actuator Link 7 3 Bearing Metal NS 8 1 Gear Feed 1 NS 9 1 Spring Feed 1 NS 10 1 Spring Feed H NS 11 1 Gear Feed H2 NS part of 99 12 1 Gear Feed H1 NS part of 99 13 1 Gear Feed 2 NS part of 99 14 1 Gear Idler Feed NS part of 99 15 1 Gear Idler NS part of 99 16 1 Clutch Stopper NS 17 116 1361 00 1 Feed Solenoid 18 116 1362 00 1 Assembly Turn Clutch 19 1 Gear Idler In NS part of 99 20 116 1363 00 1 Assembly Roll Turn 21 2 Bearing Black NS 22 1 Shaft Feed 2 NS 23 116 1331 00 2 Paper Feed Roller Kit 2 interchangeable rollers per order 99 116 1367 00 1 Paper Feed Gear Kit with 8 11 15 and 19 FRU Parts List 293 PL 14 5 High Capacity Feeder Harness Board and Motor J810 6200 245 294
39. 1 Sensor Temperature Humidity 3 116 1342 00 1 Asssembly Harness LTA HCF J210 P810 4 116 1343 00 1 Assembly Paper Size Switch 5 116 1344 00 4 Printer Feet 4 per order 7 116 1345 00 1 Lever Low Paper 8 116 1346 00 1 Indicator Paper Level 9 116 1347 00 1 Indicator Holder Shaft 10 116 1348 00 1 Indicator Guide 11 116 1349 00 1 Indicator Spring 12 116 1350 00 1 Indicator Shaft 13 116 1351 00 1 Paper Tray Stopper FRU Parts List 263 PL 3 3 Paper Feed Ill Y i with 2 24 V 99 with 8 11 15 and 19 22 f J471 21 J472 J473 P474 24 P475 J47 6200 247 264 Phaser 6200 Color Laser Printer Service Manual PL 3 3 Paper Feeder Ill FRU Parts List Table ID No Part Number Qty Name Description 1 116 1352 00 1 Assembly Paper Pick with 2 24 2 1 Shaft Feed 1 NS 3 116 1353 01 2 Paper Pick Roller Kit 2 per order 4 116 1354 00 1 Sensor No Paper Low Paper 5 116 1355 00 1 Actuator No Paper 6 116 1356 00 1 Actuator Link 7 3 Bearing Metal NS 8 1 Gear Feed 1 NS 9 1 Spring Feed 1 NS 10 1 Spring Feed H NS 11 1 Gear Feed H2 NS part of 99 12 1 Gear Feed H1 NS part of 99 13 1 Gear Feed 2 NS part of 99 14 1 Gear Idler Feed NS part of 99 15 1 Gear Idler NS part of 99 16 1 Clutch Stopper NS 17 116 1361 00 1 Feed Solenoid 18 116 1362 00 1 Assembly Clutch Turn 19 1 Gear Idler In NS
40. 2 3 PL 14 3 6 Paper Tray 2 on page 366 and Paper Tray 3 on page 367 Troublshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the Go to step 2 damage parts concerned Paper Size Switch Tray 2 3 PL 14 3 6 Tray 2 3 PL 14 1 1 2 Use service diagnostics to test the Tray 2 Replace the Go to step 3 3 switches using the table below for Engine Control reference Board RRP Does the sensor and actuator function 12 properly 3 Does the printer function correctly after Complete Go to step 4 replacing the HCF Circuit Board 4 Troubleshoot using the Paper Tray 2 3 Complete Replace the wiring diagrams Engine Control Board Does the printer function correctly after replacing any defective parts RRP 12 7 Paper Size Switches are indicated as SW1 SW2 and SW3 Paper Size Paper Size Switch sw sw2 sSw3 LEGAL14 ON ON ON LEGAL13 ON ON OFF EXECUTIVE ON OFF ON B5 ON OFF OFF A4 OFF ON ON A OFF OFF ON A5 Supported by MPT only OFF ON ON No Tray OFF OFF OFF 66 Phaser 6200 Color Laser Printer Service Manual Load Tray MPT 1 2 3 with size type The printer s front panel displays Load with a specific size and or type of paper The tray cavity is free from debris and obstructions The paper tray is free from defects Printer power has been cycled an
41. 3 Remove the Motor Driver Board akhoND FRU Disassembly Removal and Replacement Procedures 215 27 MII 7 Y PN S6200 181 6 Remove the 4 screws securing the Right Plate Assembly 7 Press on the aligning post from inside the cavity of the printer to remove the Plate Assembly Phaser 6200 Color Laser Printer Service Manual 216 6200 179 8 Carefully remove the Right Link lever item 3 from the printer chassis together with the springs and the drum levers item 4 Note Lay the asssembly on a flat surface pressing down on the assembly prior to removing the springs and the drum levers 9 Remove the spring levers Note For reassembly ensure the drum levers are seated properly on the aligning posts FRU Disassembly Removal and Replacement Procedures 217 RRP 11 3 Main Drive Assembly PL 11 1 14 6200 164 al Printer Service Manu 6200 Color Laser Phaser 218 Removal Remove the Cover Top Main RRP 1 4 Remove the Cover Front Right RRP 1 10 Remove the Cover Right RRP 1 6 Remove the Link Right RRP 1 8 Disconnect the P J48 from the Motor Driver Board Free the harness from the clamp on the Main Drive Assembly Remo
42. 354 Low Paper Lever PL 3 2 7 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Fill the paper tray with paper to the fill Go to step 2 Complete line Does the error still appear 2 Check the following for evidence of fault Replace the parts Go to step 3 or damage concerned Low Paper No Paper Sensor PL 3 3 4 No Paper Actuator PL 3 3 5 3 Use service diagnostics to test the Tray 1 Replace the Go to step 4 Low Paper Sensor Engine Control Do the sensor and actuator function Board RRP 12 7 properly 4 Does the printer function correctly after Complete Go to step 5 replacing the Motor Driver Board 5 Troubleshoot using the Paper Tray wiring Complete Replace the diagrams Engine Control Does the printer function correctly after Board RRP 12 7 replacing any defective parts Error Messages and Codes 61 Tray 2 3 Paper is Low The printers front panel displays Tray 2 or 3 Paper is Low when the paper tray is full of paper The tray has been inspected for defects Printer power has been cycled and the error still appears In the following procedures diagnose the part that correlates directly to the Tray receiving the error Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Low Paper Sensor PL 14 5 7 Paper Tray 2 on page 366 Low Paper Lever PL 14 5 8 Paper Tray 3 on pa
43. 5 Verify the voltage between P J81 2 lt gt Replace the Go to step 6 P J81 1 on the Lower Feeder Circuit Board Lower Feeder HCF is 24 VDC Circuit Board PL 14 5 1 6 Verify the connector between the HCF and Replace the Go to step 7 the printer is connected properly and not damaged part damaged 7 Does the error recur after the HCF Motor has Go to step 8 Complete been replaced with a new one 8 Perform steps 1 through 3 in RRP 14 3 Open Go to step 13 Go to step 9 Error Messages and Codes 43 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 9 Use service diagnostics to test the Tray 2 Check the Go to step 10 Turn Clutch Clutch for During the test close the Interlock Switch slipping or the gear for Does the Tray 2 Turn Clutch function damage correctly 10 Verify the voltage between P J82 13 lt gt Go to step 11 Replace the P J81 1 on the Lower Feeder Circuit Board is Lower Feeder 24 VDC Circuit Board PL 14 5 1 11 Check the Tray 2 Harness Assembly for Go to step 12 Replace the continuity Tray 2 Harness n Assembly Paper Tray 2 on page 366 PL 14 5 3 12 Remove the clutch connector J825 Go to step 13 Replace the Tray 2 Turn Is J825 1 lt gt J825 2 of the Tray 2 Turn Clutch Clutch Assembly less than 200 ohms ug Assembly PL 14 4 18 13 Does the Feed Gear in the Tray 2 Feeder turn
44. Background contamination 105 Residual Imaging or Ghosting 106 Incomplete Fusing Hot Offset or Cold Offset 107 Mis registration or Color Layer not Correctly Registered 108 82 Phaser 6200 Color Laser Printer Service Manual System Boot Sequence 1 When the main power switch is turned on the health LED on the Image Processor Board turns on immediately 2 The boot loader checks for RAM present and functional If not it posts a very large RAM ERROR on the front panel and blinks the LED 1 2 second on off continuously The boot Loader then runs POST diagnostics POST turns off the health LED Post checks the front panel If keys have been pushed the front panel displays Processing Input The front panel LED cycles Green Yellow Red and then off The front panel turns on the LED turns Green and the POST tests are run ONO oR O Power On Self Test POST The following tests are performed when the printer is powered on after the boot loader runs and before the operating system is loaded and initialized POST diagnostics are intended to provide a quick means of isolating a defective subsystem associated with the Image Processor Board and SDRAM POST returns control to the boot loader and the operating system is loaded The operating system then loads the imaging processing software If POST detected any soft errors a message is printed in a red box on the start page If POST detects any hard errors
45. Board 200000 e eee eee Printer Specifications 0 000 20 e eee eae Functional Specifications 0 00 Electrical Specifications 0 0 0 cee Environmental Specifications Media and Tray Specifications 20 21 23 24 31 81 83 83 85 86 87 xiii Engine Power Up Sequence 2 0202000 eee 87 AC Power Supply Troubleshooting 88 DC Power Supply Troubleshooting 0 88 Media Jams and the Paper Path 0055 90 Operating System and Application Problems 92 Macintosh printing problems 2 2 200000 92 Windows printing problems 20000000eeee 92 Network Problems 2000 0c cece eee ee eens 93 Print Quality Problems 0 0 000 ccc eee 94 Test Prints Adjustments and NVRAM 109 Service Test Prints 000 00 cece eee ee eee 110 Analyizing the CMYK Sample Page 244 110 Analyizing the RGB Sample 0 2000 e eee eae 110 Analyizing the Test Pattern Sample 4 111 Analyizing the 600 x 600 Service Test Print 112 Color Calibration 000000 eee 112 Color Registration eces ereraa raadde iaa 113 Margin Calibration sse akere rs gadan ra nr RE ee 113 Resetting NVRAM 0 000 eee eae 114 PostScript NVRAM Resets 000002
46. Cartridge AC Power Cord Plug Image Processor Board oa AeA N Paper Tray Rear Cover General Information 6200 008b No Description 1 Transfer Roller 2 Imaging Unit 3 Door C 4 Fuser Assembly Phaser 6200 Color Laser Printer Service Manual CRC Life Counter Behavior Internal counters track Customer Replaceable Consumables CRCs life usage and store the values in NVRAM The image processor board monitors these counters in order to display the near end of life and end of use messages Life ratings are based on 5 coverage Imaging Unit average 4 page job length Customer Replaceable Consumable CRC Print Life Toner Cartridges High Capacity 8 000 B50 Black Toner Cartridge Standard Capacity is 4 000 Standard Capacity 3 000 Imaging Unit 30 000 B50 Fuser Assembly 60 000 B10 Transfer Roller and Waste Box 15 000 B50 Customer Replaceable Unit CRU Feed Roller Kit up to 100 000 General Information 7 Front Panel Configuration The Front Panel consists of one tricolor LED a display window and six functional keys These keys navigate the menu system perform functions and select modes of operation for the printer LED indicators E Green Ready to Print or Printing E Flashing Green Receiving Processing Data Printing or Power Saver Mode m Flashing Yellow Warning E
47. Check the Tray Go to step 14 when printing one sheet of paper 2 Feed Solenoid for damage 14 Use service diagnostics to test the Tray 2 Check the Go to stop 15 Clutch Solenoid stopper on the Does the solenoid function correctly feed solenoid and replace if necessary 15 Verify the voltage between P J82 11 lt gt Go to step 16 Replace the P J81 1 on the Lower Feeder Circuit Board is Lower Feeder 24 VDC Circuit Board PL 14 5 1 16 Remove the Tray 2 Feed Solenoid connector Go to step 17 Replace the J824 Tray 2 Feed Solenoid A Is J824 1 lt gt J824 2 less than 100 ohms PL 14 417 17 Verify the voltage between P J83 11 lt gt Go to step 18 Replace the P J81 1 on the Circuit Board HCF is 24 Lower Feeder VDC Circuit Board PL 14 5 1 18 Check the OPT Feeder Plug Assembly to the Replace the Replace the HCF Main Assembly to the Tray 2 Harness Engine Control open Harness Assembly for continuity Board Assembly Paper Tray 2 on page 366 Bane 44 Phaser 6200 Color Laser Printer Service Manual Misfeed at Tray 3 The printers front panel displays Misfeed at Tray 3 indicating a paper misfeed has occurred in the printer Tray 3 is free of defects and correctly installed in the printer Any obstruction media and debris has been removed from the paper path and there is adequate paper in the paper tray Printer power has been cycled and the error still displays Troubleshooting
48. Check the following for evidence of fault Replace the parts Go to step 3 or damage concerned No Paper Sensor PL 3 3 4 No Paper Actuator PL 3 3 5 3 Use service diagnostics to test the Tray 1 Replace Engine Go to step 4 No Paper Sensor Control Board Does the sensor function correctly RRP 12 7 4 Does the printer function correctly after Complete Go to step 5 replacing the Motor Driver Board 5 Troubleshoot using the wiring diagram Complete Replace the Paper Tray 1 on page 354 Engine Control Does the printer function correctly after Board RRP 12 7 replacing any defective parts 64 Phaser 6200 Color Laser Printer Service Manual Load Tray 1 with size type The printer s front panel displays Load Tray 1 with a specific size and or type of paper The tray 1 cavity is free from debris and obstructions The paper tray is free from defects fully loaded with paper and all paper guides are seated securely against the paper Printer power has been cycled and the message still appears Note This is a media SIZE mismatch error Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Paper Size Switch Assembly PL 3 2 4 Paper Tray 1 on page 354 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Pap
49. Flashing Red Error Phaser 6200 S9 D e 1 2 4 6 7 8 56200 004 Phaser 6200 Front Panel Configuration Front Panel Key Descriptions 1 LED Power Status 5 Up Arrow Key scrolls up the menu system 2 Graphic front panel display 6 Down Arrow Key scrolls down the menu system 3 Cancel Key 7 OK select Key 4 Back Key 8 Information Key for additional explanation or help Front Panel Shortcuts Mode Press this selection at Power On Skip execution of POST diagnostics OK Print Service Diagnostics Map INFO Reset PostScript NVRAM BACK OK Password Bypass UP DOWN Enter Service Diagnostics BACK INFO 8 Phaser 6200 Color Laser Printer Service Manual Image Processor Board The following components need to be transferred from the old board when installing a new Image Processor Board in the printer See RRP 12 8 for information on replacing the Image Processor Board _ Q ht TN I 1 2 3 4 6200 270 Top View No Description 1 Hard Drive optional Configuration Upgrade Chip i Button NVRAM A wl N Memory RAM DIMM 1 and DIMM 2 Rear Panel Configuration Interfaces Em IEEE 1284 Parallel E Ethernet 10BaseT and 100BaseTx E USB General Inform
50. Gear In item 3 from the Paper Pick Assembly Remove the right and left E rings securing the shaft of the Roll Turn Assembly to the Paper Pick Assembly Remove the metal bearing item 6 securing the right shaft of the Turn Roll Assembly Remove the black bearing item 4 securing the left shaft of the Roll Turn Assembly Remove the shaft item 5 from the Paper Pick Assembly FRU Disassembly Removal and Replacement Procedures 159 RRP 3 15 Paper Feed Roller CRC Roller Kit 6200 176 Removal 1 Pull paper tray out of the printer 2 Release 1 tab securing the Paper Feed Assembly to the shaft 3 Slide the Paper Feed Roller off the left side of the shaft Note The Paper Feed Roller Kit contains two rollers One roller for the Paper Tray and one Roller for the Paper Feeder PL 3 3 23 The Paper Feed Rollers are interchangeable 160 Phaser 6200 Color Laser Printer Service Manual RRP 4 1 Retard Roller Housing Assembly PL4 1 1 NI MIN Ae A j E E SATI S6200 099 Removal 1 Remove the Registration Chute Assembly RRP 9 3 2 Disconnect the blue wire from the Turn Clutch 3 Remove the 3 screws securing the Retard Roller Housing Assembly to the printer and remove the assembly FRU Disassembly Removal and Replacement Procedures 161 RRP 4 2 Turn Roll PL 4
51. Harness Assembly 23 3 Engine Control Board Low Voltage Power Supply 24 3 Engine Control Board Temperature Humidity Harness 26 3 30 3 Flash Write 31 3 Test Print 32 3 Engine Control Board OHP Sensor 41 2 Motor Driver Board Engine Control Board 42 2 Motor Driver Board Engine Control Board Plug Jack Locator Maps 341 Plug Jack Locator Table cont d P J Map Connected to Other end connected to No 47 2 Connects Motor Driver Board Paper Pick Assembly No Paper Sensor Low Paper Sensor Solenoid Feed Clutch Turn and Paper Size Switch 48 2 Motor Driver Board Main Drive Assembly 49 2 Motor Driver Board Developer Drive Assembly 50 2 Connects Motor Driver Board Chute Assembly Exit Duplex Motor Assembly and Front Cover Assembly Fan Fuser 51 2 Motor Driver Board Toner Cartridge Holder Assembly Toner Present Sensor Low Toner Sensor Toner Motor 52 2 Motor Driver Board Chute Assembly In Fuser Drive 60 2 Motor Driver Board LVPS Assembly 61 2 Motor Driver Board LVPS Assembly 71 3 EEPROM Harness Assembly Plate Dispenser L Assembly 131 1 Chute Assembly Exit Engine Control Board Duplex Motor Assembly 132 1 Chute Assembly Out FRONT 1A Harness Assembly MPT Feed Solenoid 133 1 Chute Assembly Out FRONT 1A Harness Assembly Duplex Jam Sensor 134 1 Chute Assembly Out FRONT 1A Harness Assembly Full Stack Sensor 135 1 Chute Assembly Out FRON
52. Insert Sheet 016 2011 00 Letter 8 5 x 11 in 20 Sheets 2 Labels per Sheet 10 Sheets CD DVD Labels and Inserts A4 016 2026 00 210 x 297mm 1 Insert Sheet 20 Sheets 2 Labels per Sheet 10 Sheets Premium Business Card Media A 10 per 016 1898 00 25 Sheets Premium Business Card Media A4 10 per 016 1899 00 25 Sheets Phaser 6200 Premium Transparency Letter 016 1948 00 8 5 x 11 in 50 Sheets Phaser 6200 Premium Transparency A4 016 1949 00 210 x 297mm 50 Sheets Premium Greeting Card Media w Envelopes 016 1987 00 A 50 sheets 298 Phaser 6200 Color Laser Printer Service Manual Print Media cont d Description Part Number Premium Greeting Card Media w Envelopes 016 1988 00 A4 50 sheets Digital Photo Paper A 50 Sheets 016 2009 00 Digital Photo Paper A4 50 Sheets 016 2010 00 FRU Parts List 299 Blank Page 300 Phaser 6200 Color Laser Printer Service Manual Theory of Operation Contents Desctiption Page Summary of the Printing Process 302 Print Modes 304 Printer Controls 305 Printer Paper Path 314 Major Assemblies and Functions Paper Tray 1 319 Paper Feed 320 HCF Trays 2 amp 3 321 HCF Drive and Gears 323 Printer Frame and Drive 316 Print Engine Gears 318 Print Engine Main Drive 317 Retard Housing Assembly 324 Chute Assembly In 325 Chute Assemb
53. P511 Y P512 M P513 C P441 Y D P514 K P432 M P442 M P433 C P443 C P434 K P444 K 6200 238 278 Phaser 6200 Color Laser Printer Service Manual PL 10 1 Toner Cartridge Holder Unit Assemblies FRU Parts List ID No Part Number Qty Name Description 1 016 2003 00 1 Yellow Toner Cartridge Standard Capacity 016 2007 00 1 Yellow Toner Cartridge High Capacity 2 016 2002 00 1 Magenta Toner Cartridge Standard Capacity 016 2006 00 1 Magenta Toner Cartridge High Capacity 3 016 2001 00 1 Cyan Toner Cartridge Standard Capacity 016 2005 00 1 Cyan Toner Cartridge High Capacity 4 016 2004 00 1 Black Toner Cartridge Standard Capacity 016 2008 00 1 Black Toner Cartridge High Capacity 8 116 1464 00 1 Sensor Toner Low 9 116 1465 00 1 Assembly Plate Dispenser Left 10 116 1460 00 1 Holder Toner Cartridge Assembly Yellow 11 116 1461 00 1 Holder Toner Cartridge Assembly Magenta 12 116 1462 00 1 Holder Toner Cartridge Assembly Cyan 13 116 1463 00 1 Holder Toner Cartridge Assembly Black 14 116 1466 00 1 Assembly Harness Toner J51 J431 J432 J433 5S434 544 1 J442 J443 J444 J511 J512 J13 J514 15 116 1467 00 1 Assembly Harness CRUM J71 J710 16 116 1468 00 1 Circuit Board EEPROM 17 116 1469 00 1 Sub High Voltage Power Supply 18 116 1470 00 1 Switch Toner CTG IN Present W
54. Paper is Present adequate amount of paper Tray 2 No Toggle the No Paper Actuator Paper Tray 3 No Paper MPT No Paper Paper is Not Present Insert Paper into the MPT Tray Sensor Paper is Present Toggle the MPT No Paper Actuator PL6 1 37 to change the state Transfer Toner Waste Not Full Block the Toner Full Sensor Roller Toner PL5 1 13 to change the sensor Full Sensor state Image Unit Image Unit is Not Present Open Door C to change the state of Not Installed the Switch Sensor Fuser Fan Fuser Fan Alarm Sensor is OK Status only Note Perform a test print immediately prior to performing this test Rear Fan Alarm Sensor Rear Fan Alarm Sensor is OK Status only Note Perform a test print Absense of Media Paper Failure immediately prior to performing this test CTD ADC Dark Value Status only Sensor ee kis iid Remove the transfer roller to ensor observe change of state OHP Sensor OHP Reports Paper if opaque media is present Reports OHP or Absence of Media if OHP or no media is present Manually insert a sheet of paper backwards through the Registration Chute Assembly PL9 1 6 until the state of the sensor changes to Paper Error Messages and Codes 27 Service Diagnostics Tests and Functions Table cont d Test Clutch Tests Tests the functionality of the clutches by giving service personnel the ability to energize de energize one c
55. Phaser 6200 Color Laser Printer Service Manual PL 14 5 High Capacity Feeder Harness Board Motor FRU Parts List Table ID No Part Number Qty Name Description 1 116 1518 00 1 Circuit Board Lower Feeder 2 116 1519 00 1 Assembly OPT Feeder Plug 3 116 1520 00 1 Assembly Harness Tray 2 4 116 1521 00 1 Assembly Harness Tray 3 5 116 1522 00 1 Assembly Drive Feeder 6 1 Gear Idler NS part of PL 3 3 99 7 116 1354 00 2 Sensor No Paper Low Paper 1 per order 8 116 1524 00 2 Lever Low Paper 1 per order 9 116 1525 00 Assembly Indicator 10 116 1526 00 Assemlby Harness NPRSJ FRU Parts List 295 PL 15 1 Xerox Supplies and Accessories Repair Kits World Kits and Repacking Kits Description Part Number Kit Gear Paper Feed 116 1367 00 Kit Gear Exit Chute 116 1446 00 Kit OHP Sensor with Harness 116 1459 00 Printer Feet 116 1344 00 Kit Screw Assorted 116 1527 00 Kit Long Screw M3 x 85 2 each 212 0237 00 Kit E Rings Assorted 116 1528 00 Kit Sensor Actuator Assorted Actuators 116 1529 00 Kit Paper Feed Rollers 116 1331 00 2 interchangeable Rollers per Paper Pick Rollers 116 1353 01 2 interchangeable Rollers per Main Shipping Box 004 5258 00 Lower Tray Deck Shipping Box 004 5278 00 Phaser 6200 World Kit Plus Standard 061 4462 00 Media Sample Pack Phaser 6200 World Kit Plus Metric Media 061 4463 00
56. Questions Yes No 1 Check the Fuser Assembly for evidence Replace the parts Go to step 2 of fault or damage concerned 2 Remove the Fuser Assembly and check Replace the parts Go to step 3 for broken or bent pins concerned 3 Does the error recur after the Fuser Go to step 4 Complete Assembly has been replaced with a new one 4 Replace the Low Voltage Power Supply Go to step 5 Complete RRP 12 2 Does the error recur after the LVPS has been replaced 5 Troubleshoot using the wiring diagram Complete Go to step 6 Fuser Assembly on page 358 Does the printer function correctly after replacing any defective parts 6 Verify the voltage of P J61 4 on the Motor Replace the LVNC Go to step 7 Driver Board is 2 8 VDC Harness Assembly PL 13 1 1 7 Verify the voltage of P J42 11 on the Replace the Motor Go to step 8 Motor Driver Board is 2 8 VDC Driver Board RRP 12 3 8 Verify the voltage of P J12 20 on the Replace the Replace Front 1A Harness Assembly PL 13 1 7 Error Messages and Codes 71 Fuser Failure cont d Fuser CRUM Failure Code 45 CRUM data revise failure Code 46 CRUM setting value failure Code 47 This is the generic fuser code displayed when the printer cannot generate a specific error This error code can represent any fuser error code from 40 through 46 In this instance all of the Fuser Failure troubleshooting procedures need to be completed until the error is resolved
57. Right Cover RRP 14 2 Push down on the black bearing on the top of the indicator shaft lift up on the shaft and pull out of the hole in the HCF frame khOD Reassembly Note The Indicator Assembly has to be below the Low Paper Lever FRU Disassembly Removal and Replacement Procedures 241 RRP 14 8 Right Tray Guide PL14 3 5 Low Paper Lever PL 14 5 8 Vt o LCS lt D ASF 6200 199 Removal Guide Assembly Paper Tray Right Remove both Paper Trays from the HCF Remove the Front Covers RRP 14 1 Remove the Right Cover RRP 14 2 Remove the Chute Assembly Turn RRP 14 3 Remove the Feeder Drive Assembly RRP 14 6 Remove the Indicator Assembly RRP 14 7 Remove the HCF Circuit Board RRP 14 5 Remove the 1 screw securing the Low Paper Bracket to the HCF frame Remove the Bracket OMNOORWN 242 Phaser 6200 Color Laser Printer Service Manual 6200 200 10 Remove the 5 screws securing the Right Tray Guide to the HCF frame 11 Release the 7 tabs securing the Right Tray Guide to the HCF frame FRU Disassembly Removal and Replacement Procedures 243 z NSD 0 o 4 6200 201 12 Carefully remove the Low Paper Lever from the slit in the Right Tray Guide 13 Remove the Guide Assembly Right by rotating the top in 14 Repeat Steps 11 14 to remove the lower guide 244 Phaser 6200 Co
58. S6200 236 274 Phaser 6200 Color Laser Printer Service Manual PL 8 1 Transfer Roller and Fuser FRU Parts List Table ID No Part Number Qty Name Description 1 1a 016 2014 00 1 110 V Fuser Phaser 6200 with 7 and 8 1b 016 2015 00 1 220 V Fuser Phaser 6200 with 7 and 8 7 116 1447 00 1 Actuator Exit 8 116 1448 00 1 Actuator Spring 12 016 2013 00 1 Transfer Roller BTR 13 116 1449 00 1 Strap 14 116 1528 00 2 E Ring part of E Ring Kit 15 116 1450 00 2 Shaft Pivot 1 per order FRU Parts List 275 PL 9 1 Xerographics a AN DEO S6200 237 276 Phaser 6200 Color Laser Printer Service Manual PL 9 1 Xerographics FRU Parts List Table ID No Part Number Qty Name Description 1 116 1451 00 1 Laser Unit 2 116 1452 00 2 Spring ROS 1 per order 3 016 2012 00 1 Imaging Unit 4 116 1453 00 1 Bias Housing Assembly 5 116 1454 00 8 Plunger Stud 1 per order 6 116 1455 00 1 Assembly Chute Registration with 7 10 and 12 7 1 Registration Clutch NS 8 116 1413 00 1 Sensor Registration 9 116 1456 00 1 Actuator Registration 10 116 1457 00 1 Actuator Spring Registration 11 116 1458 00 1 Assembly Housing Electric 12 116 1459 00 1 OHP Sensor with Harness Kit FRU Parts List 277 PL 10 1 Holder Toner Cartridge Assembly
59. TOHLNOOD SNISN3 bSvld ayog 430334 Y3MO1 gerd e Aet MS 3ZIS H3dYd Paper Tray 3 367 S6200 263 Wiring Diagrams Blank Page 368 Phaser 6200 Color Laser Printer Service Manual
60. Transparency 4 Registration Sensor Detects the print media leading edge has reached the Registration Chute 5 Registration Clutch Transmits the drive from the main drive assembly to the registration rollers 330 Phaser 6200 Color Laser Printer Service Manual Transfer Roller and Fuser Assembly 6200 045 1 Fuser Assembly Using heat and pressure the fuser assembly fixes the transferred toner onto print media Parts of the Fuser Assembly Heat Roll Heat Lamp Thermostat Temperature Sensor Belt Unit Exit Roll Assembly Exit Sensor CRUM 2 Exit Sensor Detects passage of the print media after fusing 3 Fuser Fan Cools the fuser assembly to prevent overheating 4 Transfer Roller Consists of the transfer roller and a waste toner recovery system The transfer roller transfers the image from IDT 2 in the imaging unit onto the print media Theory of Operation 331 Fuser Drive Assembly Transmission Route FUSER DRIVE ASSY Exit Roll Assy FUSER ASSY 56200 034 332 Phaser 6200 Color Laser Printer Service Manual Xerographics 3 6200 046 1 Imaging Unit The Imaging Unit carries out the operations of the printing process such as charging developing and transfer The Imaging Unit consists of the following parts Drum Y MCK Developer Y MCK RTC YMCK Refresher Y M CK IDT 1 IDT 2 IDT 1 IDT 2 Cleaner IDT 1 Cleaner 2 Laser Unit The Lase
61. controller signals the sensor is dirty The controller will also signal the sensor as faulty in the event of extremely high output 308 Phaser 6200 Color Laser Printer Service Manual 2 Light Density Adjustment At the execution of automatic density control the light density adjustment is made just before the patches for toner density control are generated Light is emitted from the LED with the current light density setting to check if the output value of the CTD ADC sensor is within the specified range If the output value is low light density is increased If the output value is high the light density is decreased If the output value is less than the first lower limit the controller signals the sensor as dirty and generates a warning If less than the second lower limit the controler signals the sensor as faulty and stops the printing Theory of Operation 309 Color Registration Control The printer uses a quad system where drums and developers are used exclusively for yellow magenta cyan and black Images are formed on the drums in respective colors and layered to form one image To avoid a shift in color the color registration control calculates how much the registration is shifted and adjusts the laser write timing Color registration control is made depending on the internal temperature and print count at the execution of process control This control is outlined below 1 With no toner on the Transfer Roller
62. displayed on the front panel Some procedures require running service diagnostic test functions to verify a specific printer part is operating correctly For information on Service Diagnostics and all internal printer test functions see the table Service Diagnostics on page 23 To troubleshoot problems such as start up and power on media paper path print quality or image problems and electrical failures not associated with a front panel message or code refer to the section Troubleshooting on page 81 If an error message or code is not visible on the front panel the usage profile report and fault history list errors reported by the printer When an error first occurs record the error message and code then cycle power to the printer to see if the error recurs These can be accessed one of three ways Accessing Fault History 1 Print if possible the Usage Profile Report Log from the printer s front panel Support Menu The fault history will be detailed in this report log 2 View the printer s fault history on the front panel a Goto Support Menu gt Service Tools gt Fault History 3 If the printer is connected to a network and has a TCP IP address view the printer s web page using a web browser a Open a web browser b Enter the printer s IP address as the URL c Select the Troubleshoot link and the fault history will be displayed Error Messages and Codes 17 Contents Front Panel Message Page Jam E
63. measured in Step 3 is compared with the M About 3mm About 57mm target value set in Step to adjust the drum charging voltage and the developing DC voltage for each color according to the difference in value K v engine principle0046FA 56200 053 306 Phaser 6200 Color Laser Printer Service Manual Toner Density Control Toner density must be kept constant to attain a stable print image To keep the toner density constant the toner is dispensed at exactly the same rate it is consumed There are two systems to control toner density the PCDC and CTD working in conjunction PCDC Pixel Count Dispense Control The amount of toner consumed in the developing process is calculated by counting the video signals entered into the Laser Unit The video signal count is made by the charging and discharging of the capacitor in the CR circuit performed simultaneously to the video signal line The consumed toner quantity is calculated by the toner dispense time The toner motor is then driven by the calculated toner dispense time supplying toner to the developer CTD ADC Auto Density Control The patches of respective colors yellow magenta cyan and black for the toner density control are generated and transferred by the transfer roller The CTD ADC sensor measures this density The measured value is compared with the reference value and if the toner density is low the dispensed toner quantity is increased o
64. on the printer s control panel Since more than one job can have the same password all secure jobs with the same password are printed A secure job that has not been printed or released is retained on the internal hard drive through power cycles Saved Jobs Saved print allows the user to save print jobs to the internal hard drive of the printer The print job is not deleted after printing it is stored on the hard drive for print on demand This function requires an internal hard drive Printer Memory and RAM Capabilities The printer features two slots which accept 64 128 and 256 Mbyte of SDRAM All combinations are allowed for 64 128 192 256 320 384 and 512 Mbytes m PC133 DRAM Standard E 144 Pin SODIMM E Serial Presence Detect E 3 3 Volt The Startup Page and the Configuration Page list the amount of RAM installed in the printer If the memory does not meet the above specifications it will be ignored by the printer General Information 3 Parts of the Printer 6200 005 z o Description Top Cover Output Tray Control Panel Front Panel Front Cover Multi Purpose Tray Universal Paper Tray 1 High Capacity Feeder with Tray 2 and Tray 3 Door Latch B Door Latch A Oo CO NI OD oO A OIN Power On Off Switch 4 Phaser 6200 Color Laser Printer Service Manual 6200 006 No Description 1 Top Cover Toner
65. paper pick up operation of each tray based on communication with the Engine Control Board and information from the sensors and switches Major Functions m Communicates with the Engine Control Board E Receives information transmitted from the sensors and switches E Controls the Feeder Drive Assembly E Controls the paper pick process E Distributes the DC voltage power supplied from the print engine to each component 2 Feeder Drive Assembly Supplies the drive to the tray 2 and 3 3 Low Paper Sensor The actuator lowers as print media is used in the tray When the actuator lowers to a pre determined postion it blocks the sensor beam to trigger a low paper status The actuator position can be seen from the front of the HCF allowing confirmation of the print media quantity 322 Phaser 6200 Color Laser Printer Service Manual HCF Drive and Gears Transmission Route LJ GEAR IDLER FEED TURN CLUTCH GEAR IDLER IN GEAR FEED1 GEAR IDLER GEAR FEED H1 LOWER FEEDER DRIVE PAPER PICK 2T LER FEED GEAR IDLER TURN CLUTCH GEAR FEED1 GEAR IDLER IN GEAR FEED H1 GEAR IDLER PAPER PICK ASSY T3 6200 058 LOWER FEEDER DRIVE ASSY j i GEAR IDLER l 1 i i i i i GEAR IDLLER IN GEAR IDLLER FEED i 1 i i i i _ TURN CLUTCHASSY GEAR FEED H1 i i i i i i i i i i i i i f 1 1 i i i i i i i i i i i 1 i i Y GEAR
66. printer Parameter correction and control over the entire printing process is called process control There are two main controls E Bias Control m Toner Density Control To supplement these two controls the following are provided m High Area Coverage Mode m Admix Mode m CTD Sensor ADC Automatic Density Control LED light density setting Bias Control To attain stable image density the drum charging voltage and the developing DC voltage are continuously adjusted according to the developing capability of each color The adjusted drum charging voltage and the developing DC voltage are fed back to keep the image density constant The bias control is made immediately before the start of printing if any of the following conditions is satisfied E First print produced after the power on m Accumulative print count exceeds 16 after power on m When a cleaning cycle is executed during continuous printing The outline of toner density control is as follows 1 The Temperature Humidity Sensor detects the temperature and humidity and sets the target values of the drum charging voltage and developing DC voltage 2 The patches of respective colors yellow magenta cyan and black for the bias control are generated and transferred to the Transfer Roller About 11mm 3 The CTD ADC Sensor detects the density of the patches and area on the Transfer Roller where no toner VE About 12mm is present 4 The density
67. receiver Consult the dealer Xerox service or an experienced radio television technician for help Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user s authority to operate this product To ensure compliance use shielded interface cables A shielded parallel cable can be purchased directly from Xerox at www xerox com officeprinting 6200supplies Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards These standards are designed to mitigate interference caused or received by this product in a normal office environment This product is also suitable for use in a residential environment based on the levels tested In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules Operation is subject to the following two conditions 1 this device may not cause harmful interference 2 this device must accept any interference received including interference that may cause undesired operation This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications ICES 003 Le pr sent appareil num rique n met pas de bruits radio lectrique d passant les limits applicables aux appareils num riques de la classe B prescrites da
68. specific subject or add a comment on the results achieved through a previous action Caution A CAUTION indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment Warning A WARNING indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in injury or loss of life PL Correspondes to the FRU Parts List RRP Correspondes to the FRU Dissassembly Removal and Replacement Procedures Product Terms Caution A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area Danger A personal injury hazard exists in the area where you see the sign iii Power Safety Precautions Power source For 110 VAC printers do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector For 220 VAC printers do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord This manual assumes that the reader is a qualified service technician Warning Plug the three wire power cord with grounding prong into a grounded AC outlet only If necessary contact a licensed electrician to install a properly grounded outlet If the product loses its ground connection conta
69. step 3 Complete Low Sensor for the problem color If the test fails check the connector if it is ok replace the Toner Low Sensor for the problem color Does the error recur 3 Use service diagnostics to test the Toner Check the toner Go to step 4 Motor stirring auger or Caution Run this test for ONLY 5 gear for damage seconds to avoid packing the toner Does the Toner Motor function correctly 4 Replace the Toner Motor Complete Go to step 5 Does this fix the problem 5 Verify the auger tube of the problem color Go to step 6 Inspect the toner is full of toner near the hopper end cartridge for dispense problems 6 Check the Developer Drive Assembly Replace the part Go to step 7 PL 11 1 13 for evidence of fault or concerned damage 7 Does the printer function correctly after Complete Go to step 8 replacing the Motor Driver Board Error Messages and Codes 55 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 8 Troubleshoot using the wiring diagrams Replace the Complete See Developer Section 1 on page 356 Engine Control and See Drive Section on page 355 Board RRP 12 7 Replace any defective parts Does the error still appear Phaser 6200 Color Laser Printer Service Manual Dusty Density Sensor The printer s front panel displays Dusty Density Sensor The sensor has been cleaned and printer power has been cycled and the mes
70. step 4 problem 4 Verify the CRUM Harness is not damaged Go to step 4 Replace the Plate or improperly connected Dispense Left PL 10 1 9 5 Remove the left cover Damage can occur Go to step 5 Check the Gear Slide and the Rack V for ine Gear and damage or misalignment ACK are MOF IMNE proper position Is the Rack V out of alignment With Door C open See RRP 10 1 for more information push the Rack V up as far as it can go and then reinstall the gear slide 6 Check the CRUM Harness for continuity Go to step 4 Replace CRUM z Harness J170 lt gt J71 Assembly PL 10 1 15 Error Messages and Codes 79 Environmental Sensor Failure Code 102 Indicates an error was detected in the environment sensor circuit Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Temperature Humidity Sensor PL 3 2 2 Xerographics 1 on page 360 Temp Humidity Harness PL 3 2 1 Xerographics 2 on page 361 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Use service diagnostics to test the Go to step 2 Replace the Temperature Humidity Sensor Temp Hum Does the sensor function correctly Sensor RRP 3 5 2 Troubleshoot using the wiring diagrams Complete Replace the Xerographics 1 on page 360 and Engine Control Xerographics 2 on page 361 Baord RRP 12 7 Is the problem resolved 50 Phaser 6200 Color Laser Printer
71. the communication with the image processor board and input from the sensors and switches Incorporates functions of the High Voltage Power Supply Major Functions m Communicates with the Image Processor Board E Receives information from the sensors and or switches E Controls the Laser Unit E Supplies high voltage to the Imagning Unit to perform charging development primary transfer and secondary transfer Theory of Operation 339 2 Image Processor Board Receives data from the host Interfaces with the engine control board to produce prints 3 Motor Driver Board Controls motors through the signals received from the engine control board and sends information from the sensors and switches to the engine control board Power from the low voltage power supply is supplied to the engine control board through the motor driver board The interlock switch is mounted on the motor driver board Major Functions E Receives information from the sensors and switches E Controls the motor in the main drive assembly developer drive assembly fuser drive assembly duplex motor assembly and the holder toner cartridge motor assembly E Distributes the low voltage DC power from the low voltage power supply to each component E Controls the 24 VDC circuit through the interlock switch 4 Rear Fan Removes heat from the printer to prevent over heating 5 Low Voltage Power Supply Board Supplies AC power from the power source to the Fuser A
72. the Front Right Cover RRP 1 10 Remove the Right Cover RRP 1 6 Disconnect all the connectors on the Motor Driver Board Remove the 4 screws securing the Motor Driver Board to the printer and remove the board akhwnd 226 Phaser 6200 Color Laser Printer Service Manual RRP 12 4 Rear Fan PL 12 1 2 6200 167 Removal 1 Remove the Cover Rear RRP 1 7 2 Disconnect P J166 from the Low Voltage Power Supply board 3 Carefully shift the harness out of the 4 hooks on the Toner Cartridge Holder Assembly 4 Remove the 2 screws securing the Rear Fan to the printer and remove the fan Note When replacing the fan note the airflow direction the label side should face out FRU Disassembly Removal and Replacement Procedures 227 RRP 12 5 Card Cage 6200 173 Removal Note You do not need to remove the Laser Unit or Fan Note The Chute Assembly Registration and the Housing Assembly Bias MUST be removed prior to removing the Card Cage to prevent damaging the Bias Springs Remove the Chute Assembly Registration RRP 9 3 Remove the Housing Assembly Bias RRP 9 2 Remove the Motor Driver Board RRP 12 3 Remove the LVPS RRP 12 2 Disconnect P J151 from the Laser Unit Disconnect P J16 from the Paper Tray Feeder Disconnect P J141 P J1361 P J138 P J221 and P J139 from the bracket NO R
73. the error recur 5 Is the CTD ADC Harness connected to Go to step 6 Connect properly the CTD ADC Sensor correctly 6 Check J 136 lt gt J 1361 on the CTD Go to step 7 Replace the CTD ADC Harness for continuity ADC Harness RRP 5 2 7 Check J 1361 lt gt J 13 on the Front 1A Go to step 8 Replace the Front Harness for continuity 1A Harness Assembly PL 13 1 7 8 Verify the voltage between P J136 5 lt gt Replace the CTD Replace the P J136 3 on the Front 1A Harness ADC Sensor Engine Control Assembly is 0 VDC RRP 5 2 Board RRP 12 7 50 Phaser 6200 Color Laser Printer Service Manual Replace Transfer Roller or Transfer Roller is at End of Life The printer s front panel displays Replace Transfer Roller or Transfer Roller is at End of Life The transfer roller has been replaced Printer power has been cycled and the error still appears Note Look at the clear plastic window on the Transfer Roller If toner is present in the center of the window the Transfer Roller is at end of life and needs to be replaced If no toner is visible try cleaning the CTD ADC Sensor Note The Transfer Roller is at End of Life is a warning Replace Transfer Roller is a hard stop Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Toner Full Sensor PL 5 1 13 Xerographics 1 on page 360 Troubleshooting Procedure Table
74. the left side of the Duplex Actuator 4 Push the actuator to the left and remove out the right side removing the actuator with the spring still on the shaft Note Note the position of the actuator spring during removal to ensure proper reassembly Reassembly 6200 121 Removing the Duplex Sensor 1 Remove the Duplex Actuator 2 Release the 3 tabs securing the Duplex Sensor and remove the sensor 3 Disconnect the connector to the Duplex Sensor FRU Disassembly Removal and Replacement Procedures 177 RRP 6 4 Multi Purpose Tray Actuator PL 6 1 37 Multi Purpose Tray Sensor PL 6 1 4 6200 123 Removal of the Actuator 1 Remove the Front Left Cover RRP 1 11 2 Push down on the Multi Purpose Tray metal plate and push the actuator in 3 Slide the actuator to the left and remove to the right 4 Remove the spring from the actuator Caution Be careful not to lose or damage the spring Note spring orientation for reassembly 178 Phaser 6200 Color Laser Printer Service Manual REAR VIEW 6200 124 Removal of the Sensor 1 Remove the MPT Actuator 2 Open Door B 3 4 Disconnect P J135 from the Sensor From the back of the sensor release the 3 tabs securing the sensor and remove FRU Disassembly Removal and Replacement Proce
75. the output value of Sensor CTD ADC is measured to determine the threshold value 2 The patches for color registration control are generated on the Transfer Roller These 10mm K patches are composed of 10mm lines of K C ee K K M K and Y in this order by the amount of four dispense counts led by a black trigger IN 3 The density of patches generated by the CTD ADC sensor is read 4 The amount of registration shift is calculated from the threshold value determined in step 1 and the patch density measured in step 3 About one turn of BTR 5 The laser write timing is changed to compensate for the amount of registration shift MII MNI lt 86200 052 310 Phaser 6200 Color Laser Printer Service Manual Transfer Roller Assembly Control Detecting the Installation of the Transfer Roller Assembly The CTD Sensor detects the installation of the Transfer Roller when power to the printer is turned on or the front cover is opened and closed Light emits from the LED of the CTD sensor with the specified intensity and if the output of the CTD Sensor is greater than the specified value the controller signals installation of the Transfer Roller If printing is stopped by a jam the toner image will be placed on the Transfer Roller The this case the sensor output result is low causing the controller to report the transfer roller as missing To prevent this the Transfer Roller is rotated a half turn if output i
76. up 9 Does the Tray 3 Turn Clutch Assembly Go to step 14 Go to step 10 function correctly when feeding 1 sheet of paper Error Messages and Codes 45 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 10 Use service diagnostics to test the Tray 3 Check the clutch Go to step 11 Turn Clutch for slip or the Does the clutch function correctly gears for damage 11 Verify the voltage between P J83 13 lt gt Go to step 12 Replace the P J81 1 on the Lower Feeder Circuit Board is Lower Feeder 24 VDC Circuit Board PL 14 5 1 12 Check the Tray 3 Harness for continuity Go to step 13 Replace the Tray 3 Harness See Paper Tray 3 on page 367 Assembly PL 14 4 13 Remove the Assembly Clutch Turn Tray 3 Go to step 14 Replace the connector J835 Tray 3 Turn Is J835 1 lt gt J835 2 less than 200 ohms oun Assembly PL 14 4 18 14 Does the Feed Gear in the Tray 3 Feeder turn Check the Go to step 16 when feeding 1 sheet of paper Solenoid for damage 15 Use service diagnostics to test the Tray 3 Check the Go to step 17 Clutch Solenoid stopper on the Does the solenoid function correctly feed solenoid and replace if necessary 16 Verify the voltage between P J83 11 lt gt Go to step 17 Replace the P J81 1 on the Lower Feeder Circuit Board is Lower Feeder 24 VDC Circuit Board PL 14 5 1 17 Remove
77. voltage tolerances are used within this section Voltage Measurements Stated Measured 3 3 VDC 3 135 to 3 465 VDC 5 0 VDC 4 75 to 5 25 VDC 24 0 VDC 21 6 to 26 4 VDC 0 0 VDC Less than 0 5 VDC 22 Phaser 6200 Color Laser Printer Service Manual Service Diagnostics The Phaser 6200 Color Laser Printer has built in diagnostics to aid in troubleshooting problems with the printer The Service Diagnostics Menu provides a means to test sensors motors switches clutches fans and solenoids Diagnostics also contain built in test prints cleaning procedures printer status and some NVRAM access Service diagnostics are to be executed by a service technician only through the front panel Service Diagnostics can be entered one of two ways Entering without rebooting the printer 1 From the printer s main menu scroll to the Support Menu press OK and then scroll to the Service Tools Menu and press OK 2 Hold down the Up Arrow key and press the Down Arrow key 3 Scroll to Run Service Diagnostics and press OK Entering by reboooting the printer 1 Tur the printer power OFF 2 Hold down the Back and Information keys simultaneously and turn the printer back ON 3 Continue to hold the keys until the following mesage is displayed on the front panel Service Diagnostics V Initializing and then release the keys 4 The front panel displays the Service Diagnostics Menu You can print a Servi
78. when a set printing with a certain type and size of paper is completed and when the paper type or size is changed The cool down occurs evenly in the middle of several hundred sheets of continuous printing As a simple cool down the Pages Per Minute Down is provided This function idles the fuser during printing without feeding paper to improve temperature distribution on the heat roller The pages per minute execution timing is determined depending on the paper size and type Theory of Operation 313 Paper Path of the Printer Laser beam p Paper transfer A Paper sensors EXIT ROLL Vv MID ROLL DUPLEX ROLL fd TRANSFER ROLLER METAL ROLL IS REGISTRATION ROLL V l gt j FEED ROLL ASSY I RETARD ROLLER TURN ROLL TURN CHUTE ASSY T1 v TURN ROLL ASSY T1 TURN CHUTE ASSY T2 y TURN ROLL ASSY T2 PAPER FEED Tray PAPER PICK ROLLER T1 PAPER FEED PAPER PICK ROLLER T2 TURN CHUTE ASSY T3 PAPER PICK ROLLER T3 TURN ROLL ASSY T3 PAPER FEED ROLLER T1 PAPER FEED TRAY PAPER FEED ROLLER T2 PAPER FEED ROLLER T3 S6200 060 Paper Path of the printer shown with the optional High Capacity Feeder 314 Phaser 6200 Color Laser Printer Service Manual Paper Path Route Paper Tray 2 Paper Tray 3 y Paper Tray 1 M
79. 0 eee 114 Service Diagnostics PostScript NVRAM Resets 116 Cleaning and Maintenance 117 FRU Disassembly Removal and Replacement Procedures 119 Orientation of the Printer 02 220055 123 General Notes on Disassembly 000 0c ee eee 124 FRU Parts List 253 xiv Phaser 6200 Color Laser Printer Service Manual Theory of Operation Summary of the Printing Process 2 000 e eee eae Overview 2 0 0 0 ces Print Modes s daan aiaa 8 eked hag ace dk aah et Printer Controls aeara d i naura naa T cece eee Control of Paper Size 02020 eee Laser Quantity Control 0 0 0 c eee eee Process Control eacee da ai paadi taana cece eee a eee Bias Controles ies osat raaa a a aa a eee Toner Density Control asaussasassaaarannnearannnua Color Registration Control a na saaa aaaea Transfer Roller Assembly Control nananana aaaea Toner Contool aassi aan Taada Taau a E a wee ea Fuser Control a an anaana aana Paper Path of the Printer 0 02200055 Paper Path Route 2 0000 cece eee eee Major Assemblies and Functions 002 eee eee Plug Jack Locator Maps Print Engine Plug Jack Locator Table 000 High Capacity Feeder Plug Jack Locator Table Wiring Diagrams Main Wiring Diagram 1 2 eee Power Supply a iceca cece ier deaew ea das tae eRe ea ee Paper Dray T 2s vceea va aeatia ead da
80. 016 2002 00 Magenta Toner Cartridge High Capacity 016 2006 00 Cyan Toner Cartridge Standard Capacity 016 2001 00 Cyan Toner Cartridge High Capacity 016 2005 00 Black Toner Cartridge Standard Capacity 016 2004 00 Black Toner Cartridge High Capacity 016 2008 00 Imaging Unit 016 2012 00 Fuser 110 V 016 2014 00 220 V 016 2015 00 Transfer Roller 016 2013 00 Customer Replaceable Units CRUs Description Part Number Universal Paper Tray 1 2 3 016 1330 00 Paper Feed Roller Kit 116 1331 00 FRU Parts List 297 Software and Documentation Description Part Number Product CD 063 3414 00 Printer Management CD 063 3415 00 Interactive Documentation CD 063 3419 01 Service Manual 071 0784 00 Print Media Description Part Number Premium Paper A 500 Sheets 016 1368 00 Premium Paper A4 500 Sheets 016 1369 00 Glossy Coated Paper A 100 Sheets 016 1704 00 Glossy Coated Paper A4 100 Sheets 016 1705 00 Color Printing Labels A 30 per 100 Sheets 016 1812 00 Color Printing Labels A 6 per 100 Sheets 016 1813 00 Color Printing Labels A4 14 per 100 Sheets 016 1814 00 Color Printing Labels A4 8 per 100 Sheets 016 1815 00 Premium Cover Paper A 100 Sheets 016 1823 00 Premium Cover Paper A4 100 Sheets 016 1824 00 CD DVD Label and Applicator contains 1 016 1885 00 Applicator amp 1 Jewel Case CD DVD Labels and Inserts 1
81. 1 1 P J11 MOTOR DRIVER BOARD PL12 1 12 Interlock P J51 P J511 TCRU HOLDER ASSY Y PL10 1 1 25 26 27 14 28 TMOT_Y_XB 13 TMOT_Y_XB VL 24VDC morva PAM 12 TMOT_Y_A gt 16 2 4 TMOT_Y_B TMOT_Y_B plc 15 3 3 TMOT_Y_XA i TMOT_Y_XA 5 5 1 gt i Interlock P J51 P J512 TCRU HOLDER ASSY M PL10 1 2 Toner Motor M TCRU HOLDER Toner Motor C TCRU HOLDER Toner Motor K V L 24VDC P J11 P J41 6 5 TMOT_M_A TMOT_M_A 29 12 7 4 TMOT_M_B TMOT_M_B 30 gt C 11 8 3 TMOT_M_XA Motor M TMOT_M_XA 31 gt lt 10 Control 9 2 TMOT_M_XB TMOT_M_XB 32 rc 9 10 gt 1 ASSY C Interlock P J51 P J513 V L 24VDC au TMOT_C_A ns 19 gt TMOT_C_A gt 33 gt 8 20 gt 4 TMOT_C_B TMOT_C_B 34 rc 7 21 gt 3 TMOT_C_XA Motor C TMOT_C_XA TMOT_C_XB i 22 gt TMOT_C_XB P 36 gt K 5 23 1 ASSY K PL10 1 4 Interlock 24VDC P J51 VL 424VDC P J514
82. 1 1 6 Lever Drum PL 11 1 4 Lever Spring PL 11 1 5 RRP 11 3 Main Drive Assembly PL 11 1 14 RRP 11 4 Developer Drive Assembly PL 11 1 13 FRU Disassembly Removal and Replacement Procedures RRP Page 184 185 186 187 188 190 191 192 193 194 196 198 200 203 206 208 209 210 211 215 218 220 121 Contents cont d RRP RRP 11 5 Part Name Actuator I L PL 11 1 8 Spring I L PL 11 1 9 RRP 11 6 Earth Ground Circuit Board PL 11 1 16 RRP 12 1 RRP 12 2 RRP 12 3 RRP 12 4 RRP 12 5 RRP 12 6 RRP 12 7 RRP 12 8 RRP 14 1 RRP 14 2 RRP 14 3 RRP 14 4 RRP 14 5 RRP 14 6 RRP 14 7 RRP 14 8 RRP 14 9 RRP 14 10 RRP 14 11 RRP 14 12 RRP 14 13 RRP 14 14 122 RRP 12 Electrical AC Switch Harness Assembly PL 12 1 11 Low Voltage Power Supply PL 12 1 10 Motor Driver Board PL 12 1 12 Rear Fan PL 12 1 2 Card Cage Housing Assembly Contact PL 12 1 14 Engine Control Circuit Board PL12 1 1 Image Processor Board PL12 1 4 RRP 14 High Capacity Feeder Cover Front PL14 2 4 Cover Right PL14 2 1 Cover Left PL14 2 3 Turn Chute Assembly PL14 3 7 Tray 2 Harness Assembly PL14 5 3 Tray 3 Harness Assembly PL14 5 4 HCF Plug Harness Assembly PL14 5 2 Circuit Board HCF PL14 5 1 Drive Feeder Assembly PL14 5 5 Indicator Assembly PL14 5 9 Right Tray Guide PL14 3 5 Low Paper Lever PL 14 5 8 Left Tray Guide PL14 3 3 Link Actuator PL 14
83. 1 2 Turn Clutch PL 4 1 9 Friction Clutch Assembly PL 4 1 4 6200 100 6200 103 162 Phaser 6200 Color Laser Printer Service Manual Removal Remove the Retard Roller Housing Assembly RRP 4 1 Remove the e ring securing the Turn Clutch to the shaft and remove the clutch Remove the e ring securing the Turn Roll to the Retard Roller Housing Assembly Remove the left and right bearings Slide the shaft to the right and remove to the left of the assembly akhond FRU Disassembly Removal and Replacement Procedures 163 RRP 4 3 Retard Roll Assembly PL4 1 5 6200 183 6200 184 164 Phaser 6200 Color Laser Printer Service Manual 6200 102 Removal 1 Remove the Imaging Unit 2 Rotate the Retard Roller Assembly item 1 up slide to the right and remove to the left of the printer 3 Release the tab securing the Retard Roller Shaft raise the right end and remove the Retard Roller FRU Disassembly Removal and Replacement Procedures 165 RRP 5 1 Chute Assembly In PL 5 1 1 6200 105 Removal Remove the Fuser Assembly Remove the Transfer Roller Remove the Imaging Unit Remove all covers and the MPT RRP 1 7 and RRP 1 11 Remove the Chute Assembly Out RRP 6 1 Release latch A Door A and pull the Chute Assembly In forward to remove from the printer chassis aOuahwnhd 166 Phaser 6200 Color Laser Printer Service Manual RRP 5 2 CTD A
84. 10 1 6200 153 Note Use only a Type II Toner Vacuum to remove toner deposits before removing the Toner Cartridge Assembly Note When removing toner deposits be careful not to get toner into the sensors Removal 1 Remove the Imaging Unit CRU 2 Remove the Rear Cover RRP 1 7 Note Reinstall the toner cartridges to seal the toner system and prevent spillage 3 Disconnect P J166 from the Low Voltage Power Supply rear fan and shift the wiring harness through the tab on the right side of the printer being very careful not to break the tab 4 Disconnect P J51 from the Motor Driver Board FRU Disassembly Removal and Replacement Procedures 203 5 Disconnect P J144 yellow top and P J145 gray bottom from the EEPROM Board item 4 Disconnect the third connector P J71 from the bracket on the left side printer Disconnect P J5020 P J5030 and P J5011 from the Sub High Voltage Power Supply Board item 3 8 Release P J5011 from the clamp NO 6200 154 9 Release the 2 tabs securing the Gear Slide item 1 and remove the slide 10 Remove the Rack V item 2 from the printer 204 Phaser 6200 Color Laser Printer Service Manual 11 Remove the 8 screws securing the Toner Cartridge Holder Unit and remove the un
85. 1431 00 2 Core Roll MPT 1 per order 27 116 1432 00 1 Assembly Feed Roll 28 1 Shaft MPT NS 35 116 1433 00 1 Plate Out MPT 36 116 1434 00 1 Sensor Spring MPT 37 116 1435 00 1 Actuator MPT 38 116 1436 00 1 Solenoid Stopper 39 116 1437 00 1 Solenoid Spring 40 116 1438 00 1 Feed Solenoid MPT 41 1 Chute Out NS 42 116 1439 00 1 Assembly Bottom Plate MPT 43 116 1440 00 1 Assembly Wire Earth GRND FRU Parts List 271 PL 7 1 Chute Assembly Exit V 1 with 2 11 2 woo with 2 9 11 3 s GQ 5 Lf Le Af Soe GAY a8 6200 235 272 Phaser 6200 Color Laser Printer Service Manual PL 7 1 Chute Assembly Exit FRU Parts List Table ID No Part Number Qty Name Description 1 116 1441 00 1 Chute Assembly Exit with 2 11 2 2 Gear Roll NS part of PL 7 1 99 3 2 Bearing Earth NS 4 116 1442 00 1 Roll Exit 5 116 1443 00 1 Roll Mid 6 116 1444 00 1 Chute Exit Lower 7 2 Bearing NS 8 116 1445 00 1 Assembly Duplex Motor 9 1 Gear 42 NS part of PL 7 1 99 10 2 Gear 40 42 NS part of PL 7 1 99 11 2 Gear 48 NS part of PL 7 1 99 99 116 1446 00 1 Chute Assembly Exit Gear Kit with 2 9 11 FRU Parts List 273 PL 8 1 Transfer Roller amp Fuser Assembly CRCs seis AY A ee 8 1 with 7 and 8 cL Mg yy Pea ee d L 4 p s N ba Aline fe f 7
86. 2 2 S 3 J2211 V 1 with 2 43 6200 234 PL 6 1 Chute Assembly Out FRU Parts List Table ID No Part Number Qty Name Description 1 116 1410 00 1 Assembly Chute Out with 2 43 2 116 1411 00 270 1 Assembly Harness Front 2 Phaser 6200 Color Laser Printer Service Manual PL 6 1 Chute Assembly Out FRU Parts List Table ID No Part Number Qty Name Description 3 116 1412 00 1 Assembly Harness Front Panel 4 116 1413 00 3 Sensor Full Stack Paper Present 1 per order 5 116 1414 00 1 Actuator Output Tray Full Full Stack 6 116 1415 00 4 Spring Pinch Exit 1 per order 7 116 1416 00 2 Roll Pinch Exit 1 per order 8 116 1417 00 2 Roll Pinch 1 per order 9 116 1418 00 1 Eliminator Assembly 10 116 1419 00 1 Gear 30 11 1 Bearing Ground NS 12 116 1420 00 1 Roll Dup Duplex 13 116 1421 00 1 Actuator Duplex 14 116 1422 00 1 Actuator Cover 15 116 1423 00 1 Spring Sensor Dup Duplex 16 1 Bearing NS 17 1 Latch Plate NS 18 1 Latch Out NS 19 1 Latch Holder NS 20 116 1425 00 1 Latch Spring Out 21 116 1426 00 2 Spring N F MPT 250GF 1 per order 22 116 1427 00 1 Gear MPT 23 116 1428 00 1 Assembly Harness Duplex 24 2 Bearing MPT NS 25 116 1430 00 2 CAM MPT 1 per order 26 116
87. 2 Removal 1 Open Door A 2 Remove the 2 screws securing the Front Right Cover 136 Phaser 6200 Color Laser Printer Service Manual ea Ax oe lt y Z gt Reelin ES TOP VIEW LINK LEVER R p wy N S6200 073 Close Door A and open Door B Pull the Front Right Cover slightly away from the Chute Assembly Out With a flat blade screwdriver spread apart both sides of the metal retaining clip holding the Link to the Front Right Cover and disengage the Link Remove the Front Right Cover oO oo FRU Disassembly Removal and Replacement Procedures 137 RRP 1 11 Front Left Cover Assembly PL1 1 29 6200 076 138 Phaser 6200 Color Laser Printer Service Manual Removal Remove the Multi Purpose Tray RRP 1 9 Remove the Front Cover RRP 1 1 Remove the Front Right Cover RRP 1 10 Open Door B Spread apart both sides of the metal retaining clip with a flat blade screwdriver to disengage the Link holding the Front Left Cover Remove the 2 screws securing the Front Left Cover to the Chute Assembly Out Release the 2 tabs securing the Front Left Cover to the Chute Assembly Out and remove the Front Left Cover from the printer NO ROWN FRU Disassembly Removal an
88. 3 2 24 VDC 9 Check the following for fault or damage Replace if Complete 24V Harness Assembly damaged or defective Motor Driver Board Troubleshooting 89 Media Jams and the Paper Path Media based problems 1 ouahwhd 7 Check that the correct type of media is being used for the correct media types and weights see Printer Specifications on page 10 The customer should be using a quality laser printer paper The printer may have trouble picking slick finish paper Only Phaser 6200 transparency film can be used in this printer Inspect the paper for bent torn or folded corners Ensure that the correct media type is set in the front panel Ensure that the paper guides are set correctly Ensure that the media is a supported type for the tray See Media and Tray Specifications on page 14 for the correct media types sizes and weights for each tray Load a fresh ream of paper in the tray Multiple sheet pick 1 2 Ensure that the paper is in good condition and appropriate for a laser printer quality office laser printer paper works best Ensure that the printer is printing within its environmental specifications by using the built in service diagnostics temperature humidliy test 3 Remove the tray and ensure the paper is correctly loaded the guides are securely against the paper and the tray has not been over filled 4 Try loading paper from a fresh ream fan the pa
89. 3 screws securing the Fuser Drive Assembly to the Chute Assembly In Remove the Fuser Drive Assembly Note Note the routing of the wires for reassembly FRU Disassembly Removal and Replacement Procedures 169 RRP 5 5 Latch R Door A PL 5 1 21 o 4 6200 109 Removal for Latch R 1 ou 170 Remove the Fuser Assembly CRU 2 Remove the Front Right Cover RRP 1 10 3 4 Release the hook on the lower part of the spring item 4 securing it to the Chute Open Door A Assembly In Release the tab securing Latch R item 3 to the Chute Assembly In Remove Latch R Phaser 6200 Color Laser Printer Service Manual RRP 5 6 Latch L PL 5 1 30 6200 110 Removal Remove the Fuser Assembly Remove the Front Left Cover RRP 1 6 Open Door A Release the tab securing Latch L to the left side of the Chute Assembly In Remove the Latch L akon FRU Disassembly Removal and Replacement Procedures 171 RRP 6 1 Chute Assembly Out Duplex PL6 1 1 RIGHT SIDE VIEW 6200 111 Removal 1 Remove the Imaging Unit CRC 2 Remove the Fuser Assembly CRC 3 Remove the Transfer Roller CRC 4 Remove all Covers and the MPT RRP 1 7 and RRP 1 11 5 Remove the strap RRP 8 2 Caution In the following steps you will need to latch the Chute Assembly Out Door B and the Chu
90. 345 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the Go to step 2 damage part s concerned Exit Actuator amp Sensor PL 8 1 7 Fuser Assembly PL 8 1 1 Front Cover PL 1 1 2 Chute Assembly In PL 5 1 1 Transfer Roller PL 8 1 12 Imaging Unit PL 9 1 3 2 Remove the Fuser and check for broken or Replace the parts Go to step 3 bent pins concerned 3 Use service diagnostics to test the Exit Go to step 8 Replace the Sensor Fuser Assembly Does the sensor function correctly Go to step 4 4 Does an error occur after the Fuser Go to step 5 Complete Assembly has been replaced 5 Insert a sheet of paper into the Fuser Go to step 7 Go to step 6 Assembly Verify the voltage on the Fuser Harness P138 3 lt gt P138 2 is OVDC 6 Check all pins on the FSR 2 Fuser Go to step 7 Replace the Harness Assembly PL5 1 10 for Assembly continuity Harness FSR 2 PL 5 1 9 7 Check all pins on the Front 1A Harness Go to step 8 Replace the Assembly for continuity Assembly Front 1A PL 13 1 7 8 If possible print one sheet of paper Replace the Go to step 9 Does the Fuser Motor Turn gear s if Inspect the gears for damage defective Error Messages and Codes 31 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No
91. 4 6 HCF Paper Pick Assembly PL14 4 1 Idler Gear PL14 5 6 No Paper Low Paper Sensor PL14 5 7 Paper Size Switch Assembly PL14 3 6 RRP Page 221 222 223 224 226 227 228 230 231 233 234 235 236 237 239 240 241 242 245 247 248 250 251 252 Phaser 6200 Color Laser Printer Service Manual Orientation of the Printer FRU Disassembly Removal and Replacement Procedures 6200 063 123 General Notes on Disassembly Preparation Before you begin any Removal and Replacement Procedure 1 Switch OFF the printer power and disconnect the power cord from the wall outlet 2 Remove the Imaging Unit and protect it from exposure to light by covering it with a light proof bag or by placing it in a light tight container Disconnect all computer interface cables from the printer 3 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards 4 Remove the Fuser Assembly or wait at least 5 minutes after you have switched OFF printer power for the Fuser to cool before you work on or around the Fuser Work Notes Note Many parts are secured by plastic tabs DO NOT over Flex or force these parts Do not over torque the screws threaded into plastic parts Note Names of parts that appear in the RRPs may not be exactly the same as the names appear in the Parts List For example a part called the Registration Chute Assembly in an RRP m
92. 4 Phaser 6200 Color Laser Printer Service Manual 6200 261 365 Drive Section gt C na ea fm KC uv ev m K vz gt a ea fm uv ev jm Oane 7 4d0 ON led oler 08d Oler Ol d let id ez gt ov ov i va oraj lt vz gt ev zy ji ea a fi k kje DAE E led oer Ol8d oler Oled erld Y oane s gt eig 1g eiv Ly i CE 92 NLH oz gt lt IY ply a siaii krg C 1 it lt _ _ _ _ gt zig zg ZIY ZY DONAT Sz k yoopayu 7 1 ALON sz gt SUTEEN car cts oane O 7 4 led orBr Ol8d Ober Oled lerld Oanre yooueyul rt gt ciy zv i ela 19 fi lt __ _ 7 1 LOWHas va 9 gt 9 jones gt lt ola o i oiv vy fi lt _ lt ez ax Hdd i ax Has s D gt s J010 gt ea sol ev sv ml ____ zz vx Ydd Jepee i VX Ydd z gt gt z gt sg oc i ev ov fl le iz i aua L r 19 19 voi a 0z gt e a Y Ydd Vyda r gt v led over Ol8d ober Obed lerld 5 Smem Oanre Tl vere vend gS vh 1d ASSV AAG 430334 OaAve y ou ul VS yh ld quvog 430334 YAMO1 VE ehkld duvog TOHLNOD ANISNA Wiring Diagrams Paper Tray 2
93. 9 1 3 4 Does the image quality improve if Replace the Laser Replace the Engine the Laser Unit is replaced Unit RRP 9 1 Control Board RRP 12 7 100 Phaser 6200 Color Laser Printer Service Manual Solid Dark or Dirty Prints No Border The prints appear very dirty and brown over the entire page This print quality symptom is a composite image of all colors with no margin This is caused by a charge voltage failure For information on the Imaging Unit charge contacts see Theory of Operation on page 301 6200 292 Step Check Yes No 1 Is the problem resolved after Complete Go to step 2 replacing the Imaging Unit 2 Inspect the Imaging Unit charge Complete Go to step 3 voltage contacts PL9 1 5 and the Bias Housing Assembly PL 9 1 4 in the printer for any damage or defects See Imaging Unit Charge Voltage Contacts on page 334 3 Is the problem resolved after Complete Replace the Engine replacing the Sub High Voltage Control Board RRP Supply Board 12 7 Note After replacing any component in Step 2 or 3 run the Clean the Imaging Unit IDT1 and IDT2 rollers from the Maintenance section of Service Diagnostics See Service Diagnostics Tests and Functions Table on page 24 Troubleshooting 101 Missing Band Voids Or Streaks In a Single Color or All Colors Parallel to the Leading Edge 6200 273 There are areas of the image that are extreme
94. 9 3 Chute Assembly Registration PL 9 1 6 Housing Electric Assembly PL 9 1 11 6200 144 Removal 4 5 Disconnect P J32 blue from the OHP Sensor 196 1 Open Door A and Door C 2 3 Release the 2 tabs securing the Electric Housing Assembly to the printer and Remove the Imaging Unit remove straight up Disconnect P J18 blue from the Registration Chute Assembly Phaser 6200 Color Laser Printer Service Manual 1 6200 145 6 Remove the 4 screws securing the Registration Chute Assembly 7 Raise the left side of the Registration Chute Assembly and pull towards the left side of the printer to remove Note Ensure the mylar strip item 1 is not bent or pinched but seated properly in the middle cavity of the Registration chute when reassembling FRU Disassembly Removal and Replacement Procedures 197 RRP 9 4 Registration Sensor Actuator PL 9 1 9 Registration Sensor PL 9 1 8 FRONT P P TOP S6200 146 Removal of Actuator 1 Remove the Chute Assembly Registration RRP 9 3 2 Shift the actuator to the left lift up on the right side and remove 3 Remove the actuator spring from the Actuator Note Make note of the orientation of the spring for reassembly 198 Phaser 6200 Color Laser Printer Service Manual 6200 147 Removal of Sensor 1 Remove the Registra
95. 9 Use service diagnostics to test the Fuser Replace Engine Go to step 10 Motor Control Board Does the Fuser Motor function correctly RRP 12 7 10 Verify the voltage between P 52 1 lt gt P Go to step 11 Replace the 60 2 on the Motor Driver Board is 24 Motor Driver VDC Board RRP 12 3 11 Replace the Fuser Motor Complete Go to step 12 Does the Fuser Motor function correctly 12 Check the DRV 1 Harness for continuity Replace the Replace the Engine Control DRV 1 Harness Board RRP 12 7 PL 13 1 2 32 Phaser 6200 Color Laser Printer Service Manual Jam at Duplex Jam D The printer s front panel displays Jam at Duplex and any obstruction media and debris has been removed from the duplex paper path printer power has been cycled and the error still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Duplex Sensor PL 6 1 4 Drive Section on page 355 Actuator Kit PL 15 1 Gear Kit PL 7 1 99 Paper Feed on page 362 Chute Assembly Exit PL 7 1 7 Map 1 on page 345 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the Go to step 2 or damage damaged part Chute Assembly Exit PL 7 1 7 Duplex Motor Assembly PL 7 1 8 Duplex Sensor PL 6 1 4 Duplex Actuator PL 6 1 5 Chute Assembly Out PL 6 1 1 2 Use service diagnos
96. Assembly PL14 3 7 6200 195 Removal 1 Remove both Paper Trays from the HCF 2 Holding the Chute Asssembly Turn grip at both ends push it down and release the 2 tabs from the hole in the Fame Top 3 Release the tabs securing the Chute Assembly Turn to the Tray Guide Left and Right and remove the Chute Assemlby Turn 236 Phaser 6200 Color Laser Printer Service Manual RRP 14 4 Tray 2 Harness Assembly PL14 5 3 Tray 3 Harness Assembly PL14 5 4 HCF Plug Harness Assembly PL14 5 2 L Removal 1 Remove both Paper Trays from the HCF Assembly 2 Remove the Front Covers RRP 14 1 3 Remove the Cover Right RRP 14 2 FRU Disassembly Removal and Replacement Procedures S6200 197 237 Harness Assembly Tray 2 4 Disconnect P J82 gray from the HCF Circuit Board 5 Remove the Harness Assembly Tray 2 Harness Assembly Tray 3 6 Disconnect P J83 blue from the Power Feeder Circuit Board and remove the Harness Assembly Tray 3 Harness Assembly Feeder Plug Note The wide slot in the middle of the plug faces outward Note The tabs on the bottom of J810 can be easily damaged during the removal process Disconnect P J81 yellow from the Power Feeder Circuit Board Remove J810 by lifting out of the hole in the top of the HCF frame Lift the entire Harness Assembly Feeder Plug through the hole in the
97. Caution The yellow and gray harnesses on the EEPROM Board item 1 contain the same number of pins but are NOT interchangeable Make sure P J144 yellow is connected on the top and the P J145 gray is connected to the bottom 2 Disconnect P J144 and P J145 from the EEPROM Board on the left side of the printer 3 Remove 1 screw securing the EEPROM Board and remove the board Note When a new EEPROM Board is installed in the printer the CRUM data written to the EEPROM makes it unique to that printer The EEPROM board cannot be re used in another printer 210 Phaser 6200 Color Laser Printer Service Manual RRP 10 6 Sub High Voltage Power Supply Board PL 10 1 17 6200 159 Removal 1 Remove the Left Side Cover RRP 1 6 2 Disconnect P J5011 P J5030 and P J5020 from the Sub High Voltage Power Supply Board 3 Remove the 4 screws securing the board to the printer and remove the Sub High Voltage Power Supply Board FRU Disassembly Removal and Replacement Procedures 211 RRP 11 1 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 Lever Spring PL 11 1 5 y A l AN f fa aa ao ws wae Ay lt A gt ga rex cl 6200 160 Removal 1 Remove the Left Cover RRP 1 6 2 Remove the Top Imaging Unit Cover Door C RRP 1 5 3 Unhook the Left Link Spring PL1 1 23 212 Phaser 6200 Color Laser Prin
98. DC Sensor PL 5 1 11 Ce TPS 6200 106 Removal 1 Open door A 2 Remove the Transfer Roller Assembly CRC 3 Release the 4 tabs securing the CTD Sensor Assembly to the Chute Assembly In Caution The CTD Sensor is under spring tension be careful not to damage or lose the springs 4 Raise the sensor slightly to disconnect P J136 yellow from the Chute Assembly In 5 Remove the CTD Sensor 6 Remove the springs from the Sensor CTD ADC Assembly Reassembly Note The left spring has an aligning post on the Chute Assembly In FRU Disassembly Removal and Replacement Procedures 167 RRP 5 3 Toner Full Sensor PL 5 1 14 6200 107 Removal Open Door A Remove the Transfer Roll Assembly CRU Disconnect P J142 from the Chute Assembly In Release 2 tabs securing the Toner Full Sensor with a small screwdriver Remove the Toner Full Sensor from the Chute Assembly In akhoND 168 Phaser 6200 Color Laser Printer Service Manual RRP 5 4 Fuser Drive Assembly PL 5 1 18 6200 108 Removal NOORWN 9 Remove the Fuser Remove Transfer Roller CRC Remove the Chute Assembly Out RRP 6 1 Remove the Chute Assembly In RRP 5 1 Remove Latch A RRP 5 5 Remove the 1 screw securing the fuser ground wire to the Fuser Drive Assembly Shift the harness attached to the Fuser Drive Assembly from its clamp and housing Remove the
99. IDLLER TURN ROLL ASSY GEAR FEED 1 PAPER FEED ROLL ASSY PICK UP ASSY T2 GEAR IDLER IN Y TURN CLUTCH ASSY GEAR IDLLER 1 1 1 1 1 1 1 1 1 1 1 1 ra i TURN ROLL ASSY GEAR IDLLER FEED 1 1 f GEAR FEED H1 H 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 GEAR FEED1 PAPER FEED ROLL assy PAPER PICK ASSY T3 6200 057 Theory of Operation 323 Retard Housing Assembly 6200 042 1 Roll Turn The turn roll is rotated by the main drive assembly through the turn clutch to feed paper from the MPT to the registration chute Registration Roll See Xerographics on page 333 2 Turn Clutch Transfers drive energy from the main drive assembly to the roll turn through a friction clutch 324 Phaser 6200 Color Laser Printer Service Manual Chute Assembly In 6200 043 1 CTD ADC Sensor Detects the presence of the Transfer Roller and monitors the density of toner on the surface of the transfer roller then sends it back to the process control 2 Fuser Assembly See Transfer Roller and Fuser Assembly on page 331 3 Toner Full Sensor Detects when the waste toner collect space in the transfer roller assembly is full 4 Fuser Drive Assembly Supplies the drive to the Fuser Assembly Theory of Operation 325 Chute Assembly Out Duplex S6200 007 o Phaser 6200 Color Laser Printer Service Manual 326 1 Full Stack Output Tra
100. M Life Yellow Toner Y Life Transfer Roller Life Restores the CRU Life Count value Caution This function is for Troubleshooting ONLY Do NOT attempt to extend the life of the CRU Doing so may cause Print Quality problems or premature failure of other internal printer components Printer Page Count Restore the print engine life count IP Controller Diagnostics Tests the basic functionality of the Image Processor Board Error Messages and Codes 29 Service Diagnostics Tests and Functions Table cont d Test Front Panel Display and Test Definition RAM Executing Performs an extended memory test Read Write Passed on the Image Processor Board Test Note Cycle power to the printer after executing this test Exit Exits service diagnostics and reboots the printer 30 Phaser 6200 Color Laser Printer Service Manual Jam at Fuser Jam F The printer s front panel displays Jam at Fuser The fuser has been removed reseated and locked into place Any obstruction media and debris has been removed from the fuser paper path printer power has been cycled and the error still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Fuser PL 8 1 1 Drive Section on page 355 Exit Sensor Actuator PL 8 1 7 Fuser Assembly on page 358 Motor Driver Board PL 12 1 12 Map 1 on page
101. No 1 Cycle power to the printer Go to step 2 Complete Does the error recur 2 Check the Fuser Assembly for fault or Replace the Fuser Go to step 3 damage Assembly CRC PL 8 1 1 Power cycle the printer after replacing the Fuser 3 Does the error recur after replacing the Go to step 4 Complete Fuser Assembly 4 Check the Fuser Harness FSR2 110V_ Go to step 5 Replace the or Fuser 22 220V for continuity Fuser Harness FSR 2 110 V See Fuser Assembly on page 358 FSR 22 220 V PL 5 1 9 5 Check theFRONT 1A Harness for Replace the Engine Replace the continuity Control Board FRONT 1A 0 RRP 12 7 Harness See Fuser Assembly on page 358 Assembly PL 13 1 7 52 Phaser 6200 Color Laser Printer Service Manual Replace Fuser or Fuser is at End of Life The printer s front panel displays Replace Fuser or Fuser is at End of Life The Fuser has been replaced and is firmly locked into position Printer power has been cycled and the error still appears Note The Fuser is at End of Life is a warning Replace Fuser is a hard stop Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References EEPROM Board PL 10 1 16 Laser Unit on page 359 CRUM Harness Assembly PL 10 1 15 Fuser Assembly on page 358 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the connector to the Fuser Connect properly Go to step 2 Asse
102. ONT 1A Harness Assembly Chute Assembly In CTD ADC Sensor 2361 3 Temp Hum Harness Assembly Temp Humidity Sensor 5011 3 Sub HVPS Engine Control Board 5020 3 Sub HVPS Chute Assembly In 5030 3 Sub HVPS Chute Assembly In 344 Phaser 6200 Color Laser Printer Service Manual Map 1 434 6200 264 135 345 Plug Jack Locator Maps 346 Map 2 l Toa U Z T A x xg PA TER My teases ali MY I Y io 155 ip 56200 265 Phaser 6200 Color Laser Printer Service Manual Map 3 23 14 15 311 140 19 32 30 21 18 S6200 266 347 Plug Jack Locator Maps Map 4 348 6200 267 Phaser 6200 Color Laser Printer Service Manual High Capacity Feeder Plug Jack Locator Table P J No Connect to Other end connected to 81 Circuit Board Lower Feeder Assembly Harness HCF PLUG 82 Circuit Board Lower Feeder Tray 2 Harness Assembly 83 Circuit Board Lower Feeder Tray 3 Harness Assembly 84 Circuit Board Lower Feeder Assembly HCF Motor Harness 810 Assembly Harness HCF Main Circuit Board HCF 821 Switch Paper Size T2 Tray 2 Harness Assembly 822 Sensor No Paper T2 Tray 2 Harness Assembly 823 Sensor Low Paper T2 Tray 2 Harness Assembly 824 Solenoid Feed Tray 2 Circuit Board HCF 825 Assembly Clu
103. P 12 7 Assembly PL 13 1 3 42 Phaser 6200 Color Laser Printer Service Manual Misfeed at Tray 2 The printers front panel displays Misfeed at Tray 2 indicating a paper misfeed has occurred in the printer Tray 2 is free of defects and correctly installed in the HCF Any obstruction media and debris has been removed from the paper path and there is adequate paper in the paper tray Printer power has been cycled and the error still displays Troubleshooting Reference Table Jam T2 Applicable Parts Wiring and Plug Jack Map References Paper Pick Roller Kit PL 14 4 3 Paper Tray 2 on page 366 Paper Feed Roller Kit PL 14 1 2 Paper Feed on page 362 HCF Paper Pick Assembly PL 14 4 1 Troubleshooting Procedure Table and close the front door Observe the Turn Roller Dose the Turn Roller turn while the machine is warming up Steps Actions and Questions Yes No 1 Does the printer feed paper correctly from Go to step 2 See Misfeed at Tray 1 Tray 1 Jam T1 on page 40 2 Does the HCF Motor run when printing one Tray 2 Go to step 3 sheet Go to step 9 3 Use service diagnostics to test the HCF Replace the Go to step 4 Motor Engine Control Does the HCF motor function correctly Board i RRP 12 7 4 Verify the voltage between P J84 3 lt gt Go to step 7 Go to step 5 P J81 1 on the Lower Feeder Circuit Board is 24 VDC
104. P J11 P J41 24 gt 5 TMOT_K_A TMOT_K_A 37 rr 4 25 gt 4 TMOT_K_B TMOT_K_B 39 TMOT_K_XA icy 3 Motor K s TMOT_K_XA 39 K 2 27 2 TMOT_K_XB TMOT_K_XB 40 gt K 1 28 gt 1 Wiring Diagrams TCRU Toner Cartridge S6200 253 357 Fuser Assembly z See laser assembly FUSER ASSY PL8 1 1 i P J145 EEPRONDATA J138 P138 J232 P321 P144 H 24 EEPROM CLOCK ee yh 3 HC 3 2 B2 3 EEPROM 3 3VDC gt 2 a ric 2 3 B3 2 1 14 B4 P J13 ui ueaa eine J138 P138 J232 P321 P323 17 DK 51 As At 18 C 42 A4 A2 jE Exit Sensor EXIT PAPER SENSED L 3 3VDC_ PH 19 D lt 33 A3 A3 jE P J13 FUSER STS J138 P138 J232 20 gt a lt 24 mk A2 21 gt lt 15 A MOTOR DRIVER P J12 P J42 HE HEATER ON Pitana 20 ric 11 P J61 P J165 PUN62 aon 22 C 25 gt K 3 2 J324 15 ACL 5 K 1 Thermal Breaker t F or P J161 4 2 yY J235 J234 J233 J232 1 DHI 1 BH 4 6200 254 358 Phaser 6200 Color Laser Printer Service Manual Laser Unit ENGINE CONTROL BOARD PL12 1 1 5VDC A LASER ASSY 7 Scanner Motor
105. PL1 1 10 Remove the 2 screws securing the Top Main Cover to the printer Release the 4 tabs securing the Top Main Cover to the printer Raise the Top Main Cover slightly from the printer flexing both the front edges then lift off by moving the cover toward the rear of the printer NO oOhON 130 Phaser 6200 Color Laser Printer Service Manual RRP 1 5 Image Unit Top Cover Door C PL1 1 10 6200 068 Removal Remove the Top Main Cover RRP 1 4 Open Door A Open Door C Remove the Left Cover RRP 1 6 Remove the right and left Stud Top Hinge pins item 2 PL1 1 21 from the Image Unit Top Cover and remove the cover akhond FRU Disassembly Removal and Replacement Procedures 131 RRP 1 6 Right Side Cover PL1 1 24 and Left Side Cover PL1 1 30 6200 071 Removal 1 2 3 4 132 Remove the Top Main Cover RRP 1 4 Remove screw securing the Right Side Cover and or Left Side Cover to the printer Release the tab at the front of the printer securing the Ride Side Cover and or Left Side Cover to the printer Flex the cover slightly and slide off to remove from the printer Phaser 6200 Color Laser Printer Service Manual RRP 1 7 Rear Cover PL 1 1 20 6200 069 Removal 1 Remove the Right and Left Side Covers RRP 1 6 2 Raise the Rear Cover slightly and release the 7 tabs item 2 securing the cover to the printer and remove
106. Phaser 6200 Color Laser Printer Service Manual Restore Factory Settings Margins You can reset margin settings to the factory default values Caution Use caution when resetting your margins to the factory default settings Changing these settings back to factory defaults may not be the last saved settings if you have previously calibrated your margins 1 From the Main Menu highlight Support and press OK 2 Highlight Improve print quality and press OK 3 Highlight Calibrate Margins Menu and press OK 4 Highlight Restore Factory Settings and press OK 5 Highlight Restore Factory Settings and press OK to reset the margin settings Reset Calibrations color and margins Note Resetting calibrations resets the color and margin settings 1 From the Main Menu highlight Support and press OK 2 Highlight Improve print quality and press OK 3 Highlight Reset Calibrations NOW and press OK to reset the color margins and paper transfer settings to factory defaults Resetting job defaults Resetting the job defaults resets the paper source print quality mode 2 sided printing image smoothing and tekcolor corrections to their default values 1 From the Main Menu highlight Print Setup Menu and press OK 2 Highlight Job Defaults Menu and press OK 3 Reset Job Defaults is displayed press OK 4 Highlight Reset Job Defaults NOW and press OK to reset the job defaults Resetting Printer setup values to default Resettin
107. Processor Board to the new board See Image Processor Board on page 9 for the exact locations of each component RUN Memory Hard Drive if installed Configuration Upgrade Chip i Button NVRAM Print a Configuration Page after the new board is installed to ensure the customers configuration is correct FRU Disassembly Removal and Replacement Procedures 233 RRP 14 1 Cover Front PL14 2 4 Lane Removal 1 Remove Paper Trays 1 and 2 2 Carefully pry up on the 3 tabs securing the Cover Front to the frame and remove the Cover Front Reassembly Note When replacing the Cover Front note the orientation Align the edge with the slit in the Feeder Frame 234 Phaser 6200 Color Laser Printer Service Manual RRP 14 2 Cover Right PL14 2 1 Cover Left PL14 2 3 6200 193 Right side shown Removal A 2 3 4 5 Remove Paper Trays 1 and 2 Remove the Front Covers RRP 14 1 Remove the 5 screws securing the Cover Right and the 5 screws securing the Cover Left Holding both ends of the cover lift the cover and move left and right flexing slightly to release the tabs from the holes in the Feeder frame Slide the cover toward the front to remove the Indicator Assembly Note The Indicator Assembly flags will pop off 6 Remove the Cover Right Left FRU Disassembly Removal and Replacement Procedures 235 RRP 14 3 Turn Chute
108. RRP 6 11 MPT Bottom Plate PL 6 1 42 6200 128 Removal 1 Remove the Chute Out Assembly RRP 6 1 2 Remove the 2 screws securing the plate to the Chute Out Assembly 3 Remove the left and right springs from the MPT Shaft Note In the following steps shift the actuator out of the hole in the Plate bottom when removing the Plate 4 Remove the MPT Bottom Plate Assembly 186 Phaser 6200 Color Laser Printer Service Manual RRP 7 1 Chute Assembly Exit PL 7 1 1 LEFT 6200 129 Removal 1 Remove the Front Cover RRP 1 1 2 Remove the Front Left Cover RRP 1 11 3 Disconnect P J131 and shift the harness to the side of the Chute Assembly Out 4 Remove the 2 screws the upper screw is attached to the static discharge harness securing the Chute Assembly Exit to the Chute Assembly Out FRU Disassembly Removal and Replacement Procedures 187 RRP 7 2 Exit Roller PL 7 1 4 6200 130 Removal Exit Roller Remove the Front Cover RRP 1 1 Release the tab securing the Gear Roll to the shaft and remove the Gear Roll Remove the bearing from the left side of the shaft on the Roll Exit Remove the e ring securing the right end of the shaft of the Roll Exit Remove the bearing Raise the right side of the shaft and pull the Roll Exit to the right and up to remove oOahwhd 188 Phaser 6200 Color Laser Printer Service Manual RRP 7 3 Mid Roller PL 7 1 5 6200 131 Removal Rem
109. Reference Table Jam T3 Applicable Parts Wiring and Plug Jack Map References Paper Pick Roller Kit PL 14 4 3 Paper Tray 3 on page 367 Paper Feed Roller Kit PL 14 1 2 Paper Feed on page 362 HCF Paper Pick Assembly PL 14 4 1 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Does the printer feed paper correctly from Go to step 2 See Misfeed at Tray 1 Tray 1 Jam T1 on page 40 2 Does the HCF Motor run when printing one Go to step 10 Go to step 3 sheet 3 Use service diagnostics to test the HCF Replace the Go to step 4 Motor Engine Control Does the HCF motor function correctly Board RRP 12 7 4 Verify the voltage between P J84 3 lt gt Go to step 7 Go to step 5 P J81 1 on the Lower Feeder Circuit Board is 24 VDC 5 Verify the voltage between P J81 2 lt gt Replace the Go to step 6 P J81 1 on the Lower Feeder Circuit Board Lower Feeder HCF is 24 VDC Circuit Board PL 14 5 1 6 Verify the connector between the HCF and Replace the Go to step 7 the printer is connected properly and not damaged part damaged 7 Does the error recur after the HCF Motor has Go to step 8 Complete been replaced with a new one 8 Perform steps 1 through 3 in RRP 14 3 Open Go to step 12 Go to step 9 and close the front door Observe the Turn Roller Dose the Turn Roller turn while the machine is warming
110. Safety Summary General Guidelines For qualified service personnel only Refer also to the preceding Power Safety Precautions Avoid servicing alone Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present Use care when servicing with power Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is on Disconnect power before removing the power supply shield or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come into contact with dangerous voltages and currents Power source This product is intended to operate from a power source that will not apply more then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110 volt AC outlet between the supply conductors or between either supply conductor and ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Warning Labels Read and obey all posted warning labels Throughout the printer warning labels are displayed on potentially dangerous components As you service the printer check to make certain that all warning labels remain in place Safety Interlocks Make sure covers and panel are in place and that all interlock switches are functioning correctly
111. Sensor is ON Actuator PL8 1 7 located in the Fuser to toggle the sensor state Duplex Sensor is OFF Actuate de actuate the Duplex Sensor Sensor is ON Actuator PL6 1 13 located in the Fuser to toggle the sensor state Full Stack Sensor is OFF Actuate de actuate the Output Tray Sensor Sensor is ON Full Actuator PL6 1 4 at the output tray to toggle the sensor state Black Toner Toner is NOT Low Displays current state of the sensor K Low Cyan Toner C Low Magenta Black Toner Cartridge Present Cyan Toner Cartridge Present Magenta Toner Cartridge Present Yellow Toner Cartridge Present Sensor is OFF Sensor is ON Toggle the toner cartridge switch for the appropriate color Toner Cartridge is in the LOCKED position Toner Cartridge is in the UNLOCKED position 26 Phaser 6200 Color Laser Printer Service Manual Service Diagnostics Tests and Functions Table cont d Alarm Sensor Failure Test Front Panel Display and Test Definition Tray 1 Low Size XXXX Move the Rear Guide in the paper Paper tray to the desired paper size and Tray 2 Low verify the sensor output matches Paper the paper size selected Tray 3 Low Paper Paper is Not Low Insert and fill Tray 1 2 3 with paper to the fill line Paper is Low Insert one sheet of paper in Tray 1 2 3 to change the sensor state Tray 1 No Paper is Not Present Insert Tray 1 2 3 with an Paper
112. Supported Envelopes Weight 20 24 lb Bond envelopes Commercial 10 4 12x9 5 in Monarch Envelope 3 87 x 7 5 in A7 Envelope 5 25 x 7 25 in MPT Only Custom DL Envelope 110 x 220 mm C5 Envelope 162 x 229 mm C6 Envelope 114 x 162 mm B5 Envelope 176 x 250 mm Envelopes with hot melt type glue are not supported in this printer Specialty Premium Phaser 6200 Transparencies Media Letter 216x279mm 8 5x11 in MPT and A4 210x297mm 8 27 x 11 69 in Tray Only Other sizes will be handled through the Multi Purpose Tray with use of the custom size option 14 Phaser 6200 Color Laser Printer Service Manual Media and Tray Specifications cont d Specification Trays Tray Capacity Standard Paper Transparency Envelopes Universal Tray 500 Sheets 100 Sheets N A MPT 100 Sheets 50 Sheets 10 each Tray 1 MPT only General Information 15 16 Phaser 6200 Color Laser Printer Service Manual Error Messages and Codes This section covers troubleshooting procedures for the Phaser 6200 Color Laser Printer s front panel error messages and codes Only jams and fatal errors will produce an associated numeric code Error messages and codes are generally specific making it important that service personnel and users record errors exactly when reporting problems with the printer Any code associated with an error message or jam can be viewed by pressing the INFO key and scrolling to the bottom of the help text
113. T 1A Harness Assembly MPT No Paper Sensor 136 2 Assembly Front In FRONT 1A Harness Assembly Sensor CTD ADC Assembly 137 1 Front Cover Fan Fuser Motor Driver Board 138 3 FRONT 1A Harness Assembly Fuser Assembly 139 3 FRONT 1A Harness Assembly Chute Assembly Out MPT Feed Solenoid Duplex Jam Sensor Full Stack Sensor MPT No Paper Sensor 140 3 Connects Engine Control Board CRUM Harness Assembly Toner Full Sensor Harness Assembly EEPROM Circuit Board 141 3 EEPROM Harness Assembly Chute Assembly In Toner Full Sensor 142 2 Chute Assembly In EEPROM Harness Assembly Toner Full Sensor 144 3 EEPROM Circuit Board Engine Control Board 342 Phaser 6200 Color Laser Printer Service Manual Plug Jack Locator Table cont d P J Map Connected to Other end connected to No 145 3 EEPROM Circuit Board CRUM Harness 151 2 Laser Unit Engine Control Board 161 2 LVPS Assembly Power Cord 162 2 LVPS Assembly Fuser Assembly 163 2 LVPS Assembly Motor Driver Board 164 2 LVPS Assembly Engine Control Board 165 2 LVPS Assembly Motor Driver Board 166 2 LVPS Assembly Rear Fan 167 2 LVPS Assembly Engine Control Board 181 3 Chute Assembly Registration Engine Control Board Registration Sensor 210 2 Lower Feeder Harness Assy HCF Plug 220 1 Front Panel OPEPANE Harness Assembly 221 3 OPEPANE Harness Assembly Front Panel 231 4 Temp Humidity S
114. THE DOCUMENT COMPANY LE Phaser 6200 i E Color Laser Printer T cee TTET Tektronix 7 COLOR PRINTERS BY XEROX FP PHASER 6200 COLOR LASER PRINTER Service Manual Warning The following servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so First Printing March 2002 071 0784 00 Copyright 2002 Xerox Corporation Printed in the United States of America All rights reserved Contents of this publication may not be reproduced in any form without permission of Xerox Corporation Xerox and all product names and product numbers mentioned in this publication are trademarks Other marks are trademarks or registered trademarks of the companies with which they are associated ii Phaser 6200 Color Laser Printer Service Manual Service Terms Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action Be aware of all symbols and terms when they are used and always read NOTE CAUTION and WARNING messages Note A NOTE may indicate an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A NOTE may also provide additional information related to a
115. ace the Motor P J41 22 on the Motor Driver Board is 0 Control Board Driver Board VDC RRP12 7 RRP 12 3 Close the Front Cover during the check Error Messages and Codes 47 Install or Reseat Imaging Unit The printer s front panel displays Install or Reseat Imaging Unit the imaging unit is correctly installed in the printer Door C is fully closed and printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Imaging Unit PL 9 1 3 Laser Unit on page 359 Fuser Assembly on page 358 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Remove the Imaging Unit Remove foreign Go to step 2 i materials Inspect the printer cavity for damage foreign material and loose toner under the Vacuum out loose auger area which could prevent the toner if found Imaging Unit from being seated properly Is there foreign material or damage 2 Inspect and reseat the Imaging Unit Replace the Imaging Go to step 3 checking for possible defects or damage Unit PL 9 1 3 3 Remove the left cover Damage can occur if Go to step 4 Check the Gear Slide and the Rack V for the Gear and sae damage or misalignment position With Door See Toner Cartridge Holder Unit C open push the Assembly PL 10 1 on page 203 for Rack V up as far as more information RRP 10 1 it c
116. acity Feeder Assembly with wheels and an internal 10 Gbyte hard drive Page Description Languages PDL m PCLSc not available on the Phaser 6200B m Adobe PostScript 3 m PDF not available on the Phaser 6200B requires internal hard drive Resident Fonts m 136 PostScript Type 1 m 115 Central European PostScript Type 1 m 46 PCL fonts more fonts are available with the optional internal hard drive 2 Phaser 6200 Color Laser Printer Service Manual Proof Jobs A proof job is a specific case of a multiple copy job With a proof job the customer assigns a password and copy count at the client workstation before printing The first set of prints are printed immediately The original number of requested sets are printed after the customer enters the matching password on the printer s control panel The customer has the option of printing the original number of requested sets or deleting the job Since more than one job may be associated with the same password the customer can print all the jobs delete all the jobs or select or delete individual jobs A proof job that has not been printed is retained on the optional internal hard drive through power cycles Secure Jobs Secure printing allows the customer to defer printing of a job until a matching password is entered from the control panel The customer assigns the password at the client workstation before printing The job is stored and printing is delayed until the password is entered
117. after you have completed a printer service call If you bypass an interlock switch during a service call use extreme caution when working on or around the printer CLASS 1 LASER PRODUCT The Phaser 6200 Color Laser Printer is certified to comply with Laser Product Performance Standards set by the U S Department of Health and Human Services as a Class 1 Laser Product This means that this is a class of laser product that does not emit hazardous laser radiation this is possible only because the laser beam is totally enclosed during all modes of customer operation When servicing the printer or laser unit follow the procedures specified in this manual and there will be no hazards from the laser vi Phaser 6200 Color Laser Printer Service Manual Servicing Electrical Components Before starting any service procedure switch off the printer power and unplug the power cord from the wall outlet If you must service the printer with power applied be aware of the potential for electrical shock Warning Turning the power off using the On Off switch does not completely de energize the printer You must also disconnect the printer power cord from the AC outlet Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency Warning Do not touch any electrical component unless you are instructed to do so by a service procedure Servicing Mechanical Components Manually
118. age 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 253 Changes to Xerox products are made to accommodate improved components as they become available It is important when ordering parts to include the following information m Component s part number E Product type or model number E Serial number of the printer Serial numbering Particular fields in the serial number indicate the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows E The text S N followed by the serial number in the barcode E The barcode does not include a field identifier E The nine digit serial number is based on the following format PPPRSSSSS PPP Three digit alphanumeric product code Product Model Voltage Product Code 6200 N 110V LPH 6200 DP 110V LPH 6200V N 220V LPK 6200V DP 220V LPK R Single digit numeric revision digit To be rolled when a major product change occurs Initiated with a change request SSSSS Five digit numeric serial number Serial Number Example LPH453072 LPH Product code for the 110V Printer 4 Revision level 53072 Serial number 254 Phaser 6200 Color Laser Printer Service Manual Using the Parts List f 2 3 8 9 No The callout number from the exploded part diagram Part Number The ma
119. age 365 PL 6 1 23 11 Does the error recur after replacing the Go to step 12 Complete Duplex Motor 12 Check J 12 lt gt J 42 pins on the DRV 2 Replace the Replace the Harness for continuity Engine Control Assembly See Drive Section on page 365 Board RRP 12 7 Harness DRV2 PL 13 1 3 34 Phaser 6200 Color Laser Printer Service Manual Jam at Registration Roller Jam RR The printer s front panel displays Jam at Registration Roller and any obstruction media and debris has been removed from the Chute Assembly Registration and the Turn Chute Assembly in the tray 1 cavity Printer power has been cycled and the error still appears In some instances the error code will clear after power is cycled to the printer but will reappear with the next print Check to see if there is a piece of paper fan folded behind the turn chute assembly or below the registration roller Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Chute Assembly Registration PL 9 1 6 Paper Feed on page 362 Troubleshooting Procedure Table Steps Action and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Registration Actuator PL 9 1 9 Chute Assembly Registration PL 9 1 6 2 Use service diagnostics to test the Go to step 6 Go to step 3 Registration Sensor Does sensor functio
120. ailed diagrams refer to the section Plug Jack Locator Maps on page 341 and Wiring Diagrams on page 351 for complete information on test point locations and signal names Troubleshooting Procedures often ask you to replace a printer component The section FRU Disassembly Removal and Replacement Procedures on page 119 provides detailed steps for removing and replacing all major parts of the printer The section FRU Parts List on page 253 details the location quantity and part number for all spared parts of the printer General Notes on Troubleshooting Ti Unless indicated otherwise the instruction switch ON printer main power means for you to switch ON printer power and let the printer proceed through POST to a Ready condition Conventions used to represent connectors Plug Jack S6200 282 When instructed to take voltage continuity or resistance readings on wiring harness proceed as follows Check P J 232 1 to P J 210 5 by placing the red probe of your meter on pin 1 of P J 232 and place the black probe of your meter on pin 5 of P J 210 When you are instructed to take resistance readings between P J 232 lt gt P J 210 without specified pin numbers check all pins Refer to the the section Wiring Diagrams on page 351 for the location of all wiring harnesses and pins When you are instructed to take a voltage reading the black probe is ge
121. alues Control Board Temperature Humidity reported seem to agree with the RRP 12 7 Sensor RRP 3 5 actual conditions 106 Phaser 6200 Color Laser Printer Service Manual Incomplete Fusing or Cold Offset Incomplete Fusing The toner is not completely fused to the paper and easily rubs off Cold Offset Portions of the image are not fully fused and flake or rub off 6200 224 6200 286 Step Check Yes No Is the problem resolved by running Remove Print Smears from the printer s front panel Is the problem resolved by changing the paper type setting on the printer Hot offset One type lighter Cold offset Incomplete fusing One type heavier Complete Go to step 2 Replace the Fuser Assembly Does the problem recur after the Fuser is replaced Replace the LVPS RRP 12 2 Complete Troubleshooting 107 Mis Registration Color Layer not Correctly Registered in the Proces Direction 6200 287 The four colors of the image are not registered correctly into one image If the mis registration is in the horizontal direction perform the color registration adjustment See Color Registration on page 113 If the mis registration is in the vertical direction clean the CTD ADC Sensor cycle power to the printer once and let the printer adjust the registration check to see if the problem still appears before using this procedure
122. an go and then reinstall the gear slide 4 Verify the CRUM connector is not Replace the Plate Go to step 5 damaged or improperly connected Dispenser Left PL 10 1 9 5 Check the CRUM Harness for continuity Go to step 6 Replace CRUM i Harness See Laser Unit on page 359 Assembly PL 10 1 15 6 Check the EEPROM Harness for Replace the Engine Replace continuity Control Board EEPROM van RRP 12 7 Harness See Laser Unit on page 359 Assembly PL 13 1 10 48 Phaser 6200 Color Laser Printer Service Manual Replace Imaging Unit or Imaging Unit is at End of Life The printer s front panel displays Replace Imaging Unit or Imaging Unit is at End of Life and the imaging unit has been replaced Printer power has been cycled and the message still appears Note The Imaging Unit is at End of Life is a warning Replace Imaging Unit is a hard stop Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Laser Unit on page 359 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following parts for evidence of Replace the parts Go to step 2 fault or damage concerned Imaging Unit CRC PL 9 1 3 CRUM Connector on the Plate Dispenser 2 Replace the Imaging Unit Go to step 3 Complete Does the error recur 3 Verify the CRUM Harness is properly Go to step 4 Replace the connected
123. ars and the paper path Chapter 9 Plug Jack Locator Maps This chapter contains detailed Plug Jack locator maps for all wiring harnesses within the printer Chapter 10 Wiring Diagram The Master Wiring Diagram is contained in this chapter xi xii Phaser 6200 Color Laser Printer Service Manual Table of Contents Power Safety Precautions Electrostatic Discharge ESD Precautions Service Safety Summary 0 00 0 ce eee eee Servicing Electrical Components Regulatory Specifications Manual Organization 00 0 cee eee eee General Information Phaser 6200 Color Laser Printer Overview Printer Memory and RAM Capabilities Parts of the Printer 0 00 0 0 00000 cca CRC Life Counter Behavior Error Messages and Codes Service Flowchart 0000 c eee eee Using the Troubleshooting Procedures Service Diagnostics 0 00 0 e ee eee Service Diagnostics Tests and Functions Table Troubleshooting Procedures Troubleshooting System Boot Sequence 00000 2 ee eeaee Power On Self Test POST 0002000 POST Diagnostics Test Descriptions Power Supply 0002000 e eect teens Front Panel and Printer Malfunctions Table of Contents Front Panel Configuration 000 eae Image Processor
124. as instructed in the appropriate troubleshooting procedure Use the Engine Test Print page 96 to isolate problems with the Image Processor Board Step 4 Correct the Problem 1 2 Use the Parts List to locate a part number Use the Removal and Replacement Procedures to replace the part Step 5 Final Checkout 1 Test the printer to be sure you have corrected the initial problem and there are no additional problems present 20 Phaser 6200 Color Laser Printer Service Manual Using the Troubleshooting Procedures 1 Each Step in a Troubleshooting Procedure instructs you to perform a certain action or procedure The steps are to be followed sequentially in the order given until the problem is fixed or resolved The Actions and Questions box contains additional information and or additional procedures you must follow to isolate the problem When a procedure instructs you to test a component using service diagnostics See Service Diagnostics on page 23 for the detailed steps and functions for testing parts of the printer The action is followed by a question If your response to the question is Yes then follow the instructions for a Yes reply If your response to the question is No then follow the instructions for a No reply Troubleshooting Procedures may ask you to take voltage readings or test for continuity at certain test points within the printer For det
125. aser Replace the Engine the Laser Unit is replaced Unit RRP 9 1 Control Board RRP 12 7 Troubleshooting 103 Repeating and or Random Spots Spots of toner are randomly scattered across the page or at a fixed repeating interval 6200 276 Step Check Yes No 1 Print the Repeating Defects Page Replace the Go to step 2 from the Support lt gt Improve Print indicated CRU Quality Menu Do the defects correspond to a Customer Replaceable Consumable See Repeating Defects Identification Chart on page 95 2 Does the image quality improve if Replace the Go to step 3 the Imaging Unit is replaced Imaging Unit CRC PL 9 1 3 3 Check the Heat Roller and NIP Belt Replace the Fuser Go to step 4 in the Fuser Assembly for evidence Assembly PL 8 1 1 of contamination or damage See Transfer Roller and Fuser Assembly on page 331 4 Does the imaging quality improve if Replace the Go to step 5 the Transfer Roller is replaced Transfer Roller CRC PL 8 1 12 5 Does the image quality improve if Replace the Go to step 6 the SUB HVPS is replaced SUB HVPS RRP 10 6 6 Does the image quality improve if Replace the Laser Replace the Engine the Laser Unit is replaced Unit RRP 9 1 Control Board RRP 12 7 104 Phaser 6200 Color Laser Printer Service Manual Background Contamination There is toner contamination on all or most of the page The contaminatio
126. ation 9 Printer Specifications Physical Dimensions Printer Dimensions Value Height 445 mm 17 52 in Width 439 cm 17 28 in Depth 638 mm 25 12 in Weight Approximately 36 5 kg 80 5 Ib Print engine Approximately 56 5 kg 124 5 Ib with Paper Tray s installed Physical Dimensions Optional High Capacity Feeder Dimensions Value Height 336 mm 13 23 in Optional Paper Tray Assembly Width 439 cm 17 28 in Depth 563 cm 22 17 in Weight Approximately 15 kg 33 Ib no Paper Tray s installed Approximately 20 kg 44 Ib with Paper Tray s installed Printer Clearances Clearances Value Top 350 mm 13 78 in Left 100 mm 3 94 in Right 150 mm 5 91 in Front 600 mm 23 62 in Rear 200 mm 7 87 in Mounting surface level tolerance Within 3 degrees of horizontal with all four feet in contact with the surface 10 Phaser 6200 Color Laser Printer Service Manual Functional Specifications Functional Specifications Characteristic Specification Printing process Imaging System 4 tandem drums electro photographic system using intermediate drum transfer rolls IDTs Exposure System Semiconductor laser simultaneous scanning by 4 beams Development System Dry type 2 component developer Fusing System Heat fusing free nip belt system Color medium Cyan Magenta Y
127. ay appear on the Parts List as Assembly Chute REGI When working on an RRP ignore any prerequisite RRP if you have already performed that removal procedure Caution Always use the correct type and size screw Using the wrong screw can damage tapped holes Do not use excessive force to either remove or install either a screw or a printer part Warning Unplug the AC power cord from the wall outlet before removing any printer part Notations in the RRP text m When needed the orientation of the printer is called out in the procedure for locating printer parts refer to the printer orientation graphic on page 123 for locating the right left front and back sides of the printer m The notation RRP X Y in an RRP step directs you to another RRP for information on how to perform a related or prerequisite procedure m The notation item X points to the illustration that corresponds to the RRP you are performing m The notation PLX_X_X indicates that this component is listed in the FRU Parts List m Bold arrows in an illustration show direction of movement when removing or replacing a component 124 Phaser 6200 Color Laser Printer Service Manual RRP 1 1 Front Cover PL 1 1 2 6200 278 Removal 1 Open Door B Caution Do not separate the Front Cover from the Chute Assembly Out until the two wiring connectors have been disconnected 2 Release the four tabs securing the Front Cover to the C
128. bly 82 mm 3 23 in Troubleshooting 95 Using the Print Engine Only Test Print Print quality and engine logic problems can be easily isolated to either the Image Processor Board or the Print Engine by running the Print Engine Only Test Print Turn printer power OFF Remove the Image Processor Board Turn printer power ON Look inside the Image Processor Board cavity on the rear of the Engine Control Board locate jumper pins 1 and 2 on connector P31 With a long screwdriver touch the pins to short and start the test process the pins must remain shorted to execute the test 6 The printer will begin to print the 600 x 600 engine test print unless an error status from the Engine Control Board is present Printing will continue until the jumper is removed from pin 1 to 2 The prints that are in process will be completed khOD a Note Power to the front panel is disabled during this test The front panel graphics and all LED s are off 96 Phaser 6200 Color Laser Printer Service Manual Light Prints 6200 283 Verify the media used is supported by this printer See Media and Tray Specifications on page 14 for the correct media types sizes and weights for each tray Verify the media settings are correct at the front panel and that color calibration has been performed prior to using this troubleshooting procedure Step Check Yes No 1 Check the Imaging Unit Fuse
129. ce Diagnostics Menu Map by highlighting Print Service Diagnostics Menu and press OK The printer will run through POST and return to Ready You will need to re enter service diagnostics Service Diagnostics Key Press and Function Table Key Function BACK Returns to the prior higher level menu structure if available If help text is displayed on the front panel pressing BACK will restore the current menu item and remove the help text CANCEL Terminates the current test Cancels current INFO display INFO Provides help information if available Pressing INFO again restores the current menu item and removes the help text UP Scrolls up one menu item within a menu list This control does not wrap Used to increment data in tests requiring user input DOWN Srolls down one menu item within a menu list This control does not wrap the end of a menu list is designated by three asterisks Used to decrement data in tests requiring user input OK Enters the highlighted menu Executes the current test item Used to select a data value entered by the user Error Messages and Codes 23 Service Diagnostics Tests and Functions Table Test Front Panel Display and Test Definition Print Service Menu Map Prints the service diagnostics menu page General Status Provides the following print engine status Status lt No Status to Report gt No Status to Report the printer is on
130. ce the Engine Control Board RRP 12 7 Engine Firmware Failure cont d Code 70 Task Table overflow Code 71 Timer Table overflow Code 73 Queue Buffer overflow Code 74 Communications buffer overflow Code 78 ESS Video data fail Code 79 This is a generic Engine Firmware Failure code generated when any other Engine Firmware Failure code fails to report to the controller properly Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Is the problem application related Forward the application information to ESS for evaluation Go to step 2 Turn printer power off and then back on Does the error recur If the error re occurs replace the Engine Control Board RRP 12 7 Complete 76 Phaser 6200 Color Laser Printer Service Manual Imaging Unit Firmware Failure Code 75 This is an Imaging Unit CRUM data error Caution the unit or placing in a light proof bag Troubleshooting Reference Table Wiring and Plug Jack Map References Fuser Assembly on page 358 Troubleshooting Procedure Table Protect the imaging unit from exposure to light by covering Steps Actions and Questions Yes No 1 Check the Imaging Unit for defects or Replace the parts Go to step 2 possible damage concerned Replace the Imaging Unit 2 Does the error recur if the Imaging Unit is Go to step 3 Comp
131. crew FRU Parts List 255 PL 1 1 Covers V 99 with 26 and 27 V 2 with 3 7 V 10 with 11 19 S 6200 228 Phaser 6200 Color Laser Printer Service Manual 256 PL 1 1 Covers FRU Parts List Table No Part Number Qty Name Description 1 333 4382 00 1 Control Panel Front Panel Display 2 116 0003 00 1 Cover Assembly Front with 3 7 3 1 Cover Front NS part of PL 1 1 2 4 1 Holder Lever Out NS 5 1 Lever Out NS 6 1 Con Amp 175694 3 NS 7 116 0004 00 1 Fan Fuser 8 116 0005 00 1 Cover Assembly Top 9 116 0006 00 1 Cover Top Main 10 116 0007 00 1 Cover Assembly Top Image Unit with11 19 Door C 11 1 CAM I R NS 12 1 Cover CAM NS 13 116 0010 00 1 Spring CAM I R 14 116 0011 00 1 Latch Top Right 15 1 Handle Top NS 16 1 Shaft Latch Top NS 17 1 Spring Handle NS 18 116 0014 00 1 Latch Top Left 20 116 0016 00 1 Cover Rear 21 116 0492 00 2 Stud Top 1 per order 22 116 0586 00 2 Spring Link 1 per order 23 116 0963 00 2 Link 1 per order 24 116 0974 00 1 Cover Side Right 25 116 1322 00 1 Cover Assembly Front Right 26 1 A Multi Purpose Tray NS part of Multi Purpose Tray 27 1 eee Tray Slide NS part of Multi Purpose Tray 28 116 1325 00 1 Assembly MPT Base 29 116 1326 00 1 Cover Assembly Front Left 30 116 1327 00 1 Cover Side Left 31 1 Cove
132. ct with conductive parts may cause an electrical shock Disconnecting Power Warning Turning the power off using the On Off switch does not completely de engergize the printer You must also disconnect the printer power cord from the AC outlet Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency Disconnect the power plug by pulling the plug not the cord Disconnect the power cord in the following cases if the power cord or plug is frayed or otherwise damaged if any liquid or foreign material is spilled into the case if the printer is exposed to any excess moisture if the printer is dropped or damaged if you suspect that the product needs servicing or repair whenever you clean the product iv Phaser 6200 Color Laser Printer Service Manual Electrostatic Discharge ESD Precautions Some semiconductor components and the respective sub assemblies that contain them are vulnerable to damage by Electrostatic discharge ESD These components include Integrated Circuits ICs Large Scale Integrated circuits LSIs field effect transistors and other semiconductor chip components The following techniques will reduce the occurrence of component damage caused by static electricity Caution Be sure the power is off to the chassis or circuit board and observe all other safety precautions Immediately before handling any semiconductor component
133. ction details all major components of the printer and their relative functions These components are broken down into the following areas based on the configuration of the printer and the optional High Capacity Feeder Frame and Drive Assemblies 2 6200 048 1 Developer Drive Assembly Supplies the drive to the Imaging Unit Developer 2 Main Drive Assembly Supplies the drive to the following parts E Paper Feeder E Retard Housing Assembly m Chute Assembly Out MPT position m Chute Assembly Registration E Imaging Unit IDT 1 IDT 2 Drum E Transfer Roller 316 Phaser 6200 Color Laser Printer Service Manual Main Drive Assembly Transmission Route MAIN DRIVE ASSY GEAR IDLER IN k d TURN CLUTCH ASSY GEAR IDLLER y y TURN ROLL ASSY GEAR IDLLER FEED y GEAR FEED H1 y GEAR FEED1 y PAPER FEED ROLLER PAPER TRAY TURN CLUTCH MPT GEAR TURN ROLL RETARD HOUSING ASSY I y Theory of Operation PAPER FEED ROLLER Regi Clutch Regi Roll REGI CHUTE TRANSFER ROLLER 6200 032 317 Gear Layout Print Engine and Tray 1 CHUTE ASSY OUT IMAGING UNIT TRANSFER ROLLER Ge REGISTRATION er CLUTCH s 0 V gt O REGISTRATION aw CHUTE ASSY A o MAIN DRIVE ASSY
134. d Replacement Procedures 139 RRP 2 1 Paper Feed Roller PL 2 1 1 CRC as Kit 6200 077 Removal te 2 3 4 Pull the paper tray out of the printer Release the tab securing the Feed Cover to the Paper Tray and open the Feed Cover Carefully release the hook securing the Paper Feed Roller to the Retard Shaft Slide the Paper Feed Roller off the shaft to remove Note The Paper Feed Roller Kit contains two rollers One roller 140 for the Paper Tray and one Roller for the Paper Feeder PL 3 3 23 The Paper Feed Rollers are interchangeable Phaser 6200 Color Laser Printer Service Manual RRP 3 1 Turn Chute Assembly PL3 1 2 6200 080 6200 081 Removal Pull the paper tray out of the printer Push in on the Turn Chute Assembly to releae the 2 tabs Rotate the Turn Chute Assembly 90 degrees downward from the Paper Feeder Release the tabs securing the right and left shaft of the Turn Chute Assembly to the Paper Feeder Pull out the Turn Chute Assembly from the Paper Feeder to remove khOD a FRU Disassembly Removal and Replacement Procedures 141 RRP 3 2 Printer Chassis 6200 082 Removal Remove the Imaging Unit Remove the Paper Tray Rear Cover Remove Paper Tray 1 Remove the Top Main Cover RRP 1 4 Remove the Front Right Cover RRP 1 10 Remove the Right and Left Side Covers RRP 1 6 Remove the Turn Chute As
135. d the message still appears Note This is a media TYPE mismatch error indicating a malfunction of the OHP Sensor Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References OHP Sensor Kit PL 9 1 12 Paper Feed on page 362 Troubleshooting Procedure Table Chute Assembly Registration PL 9 1 6 Assembly Chute Registration Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace OHP Go to step 2 or damage Sensor and Harness OHP Sensor and Harness PL 9 1 12 RRP 95 Does the OHP Sensor function correctly Board RRP 12 7 RRP 9 3 2 Using service diagnostics test the OHP Replace the Go to step 3 Sensor Engine Control Has P J32 2 lt gt P J32 1 changed from 0 VDC to 3 3 VDC Control Board RRP 12 7 3 Verify the voltage between P J32 2 lt gt Go to step 4 Go to step 5 P J32 1 on the Engine Control Board is 0 VDC 4 Block the OHP Sensor Replace Engine Go to step 5 5 Verify the voltage between P J32 3 lt gt P J32 1 on the Engine Control Board is 5 VDC Replace the OHP Sensor RRP 9 5 Replace the Engine Control Board RRP 12 7 Error Messages and Codes 67 Laser Failure Code 7 Laser power has failed Code 8 SOS start of scan failure 1 Code 9 SOS failure 2 Code 10 Warm up failure Code 11 This is the generic laser used by the engine if a lower level error cann
136. dures 179 RRP 6 5 Static Eliminator Assembly PL 6 1 9 6200 116 Removal 1 Remove the Front Cover Assembly RRP 1 1 2 Remove screw securing the Eliminator Assembly to the Chute Assembly Out 3 Raise the left end up and remove the Eliminator Assembly 180 Phaser 6200 Color Laser Printer Service Manual RRP 6 6 Duplex Roller PL 6 1 12 6200 117 Removal 1 2 3 4 Remove the Front Left Cover RRP 1 11 Release the tab securing Gear 30 item 4 See Gear Layout Print Engine and Tray 1 on page 318 and remove the gear Remove the bearing securing the left end of the shaft item 5 Raise the left end of the roller and shift the right bearing out item 3 then remove the Duplex Roller FRU Disassembly Removal and Replacement Procedures 181 RRP 6 7 Latch Plate PL 6 1 17 Latch Out PL 6 1 18 Latch Holder PL 6 1 19 Latch Spring Out PL 6 1 20 Coo A J x 6200 120 Removal Remove the Front Right Cover RRP 1 10 Remove the Front Left Cover RRP 1 11 Remove the Spring Out item 3 from the Chute Assembly Out Release the 2 tabs from the inside of the Chute Assembly Out Slide the Holder Latch item 2 to the right and remove Remove the Latch Out from the Holder item 1 akhOQN 182 Phaser 6200 Color Laser Printer Service Manual RRP 6 8 MPT Paper Pick Assembly PL 6 1 27 Roll Feed 6200 122 Removal 1 Remov
137. e Tray1 Tray2 Tray3 MPT Simplex 600 dpi 15 16 5 18 14 5 Duplex 600 dpi 23 5 25 26 5 23 Simplex 1200 dpi 24 5 27 5 30 5 23 5 Duplex 1200 dpi 39 5 42 5 45 5 38 5 Warm up time 30 seconds from cold start power off condition Electrical Specifications Electrical specifications Characteristic Specification Primary line voltages 100 120 V Printer 97 132 V 13 amp circuit 220 240 V Printer 198 264 V 7 8 amp circuit Primary line voltage frequency range 100 120 V Printer 50 60 Hz 2 Hz 220 240 V Printer 50 60 Hz 2 Hz Power consumption Mode Condition 100 115 VAC 240 VAC Print Mode Max 850 W or less 850 Wor less Ready Mode Fuser On 180 W or less 180 W or less Sleep Mode Fuser Off 45 W or less 45 W or less 12 Phaser 6200 Color Laser Printer Service Manual Environmental Specifications Environmental Specifications Characteristic Specification Temperature Operating Transportation Storage 24 month maximum 1 month maximum Optimal print quality range 62 to 80 F 17 to 26 C 10 C to 32 C 50 F to 90 F 30 C to 50 C 22 F to 122 F Normal 0 C to 35 C 32 F to 95 F Severe 20 C to 40 C 4 F to 104 F Humidity Optimal print quality range 35 to 70 Operating 10 85 Transportation 30 85 Storage 5 95 Altitude Operating 0 2 500 meters 8 000 ft Transportation 0
138. e crea ae ene ees Drive Sections dra seas a a bee ne ee al eae Developer Section 1 2000 cee eee eee BY 6 0 2 i rea paaa i aa a a a E a A Fuser ASS MDIy once ce cc et a ee Laser Unit oscisecaaewies sel a A ee ald wa etc XGEMOGaphiCS 1s eee een tagn ed ea ee eae ee aS XerographicS 2 0 0 0 ee Paper Feed 0 0000 eee eee Image Processor Board 000 eee eee eae High Capacity Feeder Wiring Diagrams 04 Drive Section esseer sce ee eke ee ee ee bee ee Paper Way 2 2 dian red dag aaea canbe dag eine diag oeaes Paper tay S aiacnadadd facies eG ae doe au eGdcad geben ead sd Table of Contents 301 302 304 304 305 305 305 306 306 307 310 311 312 313 314 315 316 341 341 349 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 XV xvi Phaser 6200 Color Laser Printer Service Manual General Information The Xerox Phaser 6200 Color Laser Printer Service Manual is the primary document used for repairing maintaining and troubleshooting the printer To ensure complete understanding of the product participation in Xerox Phaser 6200 Service Training is recommended 6200 001 Phaser 6200 Color Laser Printer shown with the optional High Capacity Feeder General Information Phaser 6200 Color Laser Printer Overview The Phaser 6200 Color Laser Printer combines a single pass tandem color laser
139. e line Image Size the image height should be 261 mm between the top and bottom lines The image width should be 192 mm between the left and right lines o ous Note Some of the graphics on this page contain composite black with heavy fill images exceeding 240 coverage Transfer roll offsetting may occur as a result Test Prints Adjustments and NVRAM 111 Analyizing the 600 x 600 Service Test Print This test print is used to verify margins and color registration The colors should be aligned vertically and horizontally Black K Yellow Y Cyan C Magenta M 128 dot 9 a0 About 2 mm 128 dott About 2 mm 6200 227 Color Calibration Color calibration procedures adjust the printer for optimal color output color settings may need adjustment upon initial printer set up or when toners and imaging units are replaced There are two procedures Lighten Darken Colors and Balance Colors If the overall image appears either too light or dark use the Lighten Darken colors procedure If a finer adjustment of the primary colors cyan magenta and yellow is needed continue with the balance colors procedure Print the Color Calibration Tutorial from the printer s front panel Improve Print Quality Menu and follow the instructions detailed on the page 112 Phaser 6200 Color Laser Prin
140. e the Front Left Cover RRP 1 11 2 Release the tab securing the roll core to the shaft and slide right 3 Push down on the MPT metal plate and feed roller 4 Slide the Paper Pick Roller to the right and pull out the front to remove FRU Disassembly Removal and Replacement Procedures 183 RRP 6 9 MPT Feed Solenoid PL 6 1 40 6200 125 Removal 1 Remove the Chute Assembly Out RRP 6 1 2 Unhook the N F MPT spring from the Solenoid Stopper 3 4 Remove 1 screw securing the Feed Solenoid to the Chute Assembly Out and Disconnect P J132 from the Solenoid remove Reassembly Note Make sure the solenoid seats properly on the aligning pins The pins are plastic 184 Phaser 6200 Color Laser Printer Service Manual RRP 6 10 Multi Purpose Tray Shaft PL 6 1 28 6200 127 Removal 1 Remove the Chute Assembly Out RRP 6 1 2 Remove the spring from the Solenoid Stopper 3 Release the tab securing the Solenoid Stopper to the shaft and remove 4 Release the tab on the MPT Gear item 5 and remove the gear Note Note the orientation of the springs for reassembly A long eye hook attaches to the shaft 5 Remove the 2 springs item 1 and 4 from the left and right side of the shaft Note In the following step do not lose the pins when moving the AMs 6 Slide the CAMs item 3 in 7 Slide the shaft to the right and remove FRU Disassembly Removal and Replacement Procedures 185
141. eed and the gear idler feed are disengaged stopping the paper retard feed roller This allows one sheet to be fed at a time 4 Turn Clutch Assembly Transfers the drive energy from the main drive assembly to the roll turn assembly 5 Paper Size Switch Detects print media size and installation of the paper tray 320 Phaser 6200 Color Laser Printer Service Manual 6 Gear Feed See Paper Pick Rollers 7 Spring Feed See Paper Pick Rollers 8 Gear Idler Feed See Paper Pick Rollers 9 Feed Solenoid Controls the operation rotation stop of the Feed Roller Assembly by controlling the rotations of the Gear Feed 10 Low Paper Sensor The actuator lowers as print media is used in the tray When the actuator lowers to a pre determined postion it blocks the sensor beam to trigger a low paper status The actuator position can be seen from the front of the paper tray allowing confirmation of the print media quantity 11 Paper Feed Roll See paper Pick Rollers 12 Roll Turn Assembly The roll turn assembly receives drive energy from the main drive through the turn clutch and transports the print media out of the paper tray to the registration roller Note Tray I paper pick assembly has a different part number than the HCF tray 2 and tray 3 paper pick assembly High Capacity Feeder Trays 2 3 6200 061 Theory of Operation 321 6200 062 1 HCF Feeder Circuit Board Controls the
142. ellow and Black Toner Cartridges Resolution Addressability Standard amp Draft Enhanced 2400 x 600 dpi Factory Default Photo 1200 x 1200 dpi Not available on the Phaser 6200B Not Available on the Phaser 6200B or Phaser 6200N 600 x 600 dpi Operating Modes Running Mode Print Engine capable of making prints immediately Ready Mode 20 seconds from completion of a print Sleep Low Power Power Saver Mode entered after a specified period of Print Engine inactivity since completion of the last print Continuuous Operating Printing Speed ppm pages per minute ipm image per minute Mode Paper Size wt g m Simplex Duplex 600 dpi Letter A4 65 105 16 ppm 10 ipm 100 159 8 ppm N A 160 216 8 ppm N A 1200 2400 dpi Letter A4 65 105 8 ppm 5 ipm 100 159 8 ppm N A 160 216 8 ppm N A 600 1200 dpi Envelope Postcard 160 216 8 ppm N A Mode OHP 600 dpi Letter A4 8 ppm N A 1200 dpi Letter A4 8 ppm N A Cleaning Cycle interval for continuous printing Print speed will be reduced if the print job is larger than the cleaning cycle interval IU Print Volume Standard Draft Enhanced Photo pages pages 0 5 K Pages 48 24 5 10 K Pages 32 16 10 15 K Pages 32 16 15 20 K Pages 32 16 20 25 K Pages 20 10 25 30 K Pages 16 8 General Information 11 Functional Specifications cont d Characteristic Specification First Print Out in seconds Letter A4 Mod
143. eloper Y 3 Development Drum M IDT2 Cleaner Devel M eveloper M 8 Cleaning 3 Development IDT2 5 Secondary transfer 7 Tertiary transfer RTC 1 Charging with electricity Developer C 3 Development Drum C 4 Primary transfer 5 Secondary transfer IDT1 Cleaner 6 Cleaning RTC 1 Charging with electricity Developer K 3 Development Drum K Refresher Refresher 6200 011 Flow chart of the printing process Theory of Operation 303 Overview of the Phaser 6200 Color Laser Printer Theory of Operation Print Modes There are three types of print modes draft standard mode enhanced mode and photo mode These are based on the resolution 600 dpi 1200 dpi and process speed full speed half speed Setting the process speed to half speed and the video data transfer speed to twice the speed at 600 dpi attains the resolution of 1200 dpi E Standard Draft mode Used for printing with a resolution of 600 dpi m Enhanced mode Used for printing on plain paper with a resolution of 2400 X 600 dpi m Photo mode Gloss is raised by setting half speed with plain paper with a resolution of 1200 x 1200 dpi 304 Phaser 6200 Color Laser Printer Service Manual Printer Controls Control of Paper Size The paper size control is determined by a paper size switch located in each paper tray slot The switch setting is set by moving the tray which in turn s
144. en emptied of all paper printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Actuator Kit PL 6 1 5 Paper Feed on page 362 Full Stack Sensor PL 6 1 4 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Actuator Full Stack PL 6 1 Full Stack Sensor PL 6 1 2 Use service diagnostics to test the Full Replace Engine Go to step 3 Stack Sensor Control Board Does the sensor function correctly RRP 12 7 3 Replace the Full Stack Sensor Go to step 4 Complete Does the sensor report an error once replaced 4 Troubleshoot the wiring using the wiring Replace defective Replace Engine diagram Paper Feed on page 362 parts Control Board RRP 12 7 58 Phaser 6200 Color Laser Printer Service Manual Insert Tray 1 or Tray 1 Missing The printer s front panel displays Insert Tray 1 or Tray 1 is Missing The tray 1 cavity is free of debris and obstructions The paper tray is free of defects and properly inserted into the printer Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Paper Size Switch Assembly PL 3 2 4 Paper Tray 1 on page 354
145. ensor Temp Humidity Harness Assembly 232 2 Fuser Assembly FRONT 1A Harness Assembly 311 3 Engine Control Board LVPS Assembly 321 3 OHP Sensor Engine Control Board 431 1 Holder Assembly MQ Y Motor Driver Board Toner Present Sensor 432 1 Holder Assembly MQ M Motor Driver Board Toner Present Sensor 433 1 Holder Assembly MQ C Motor Driver Board Toner Present Sensor 434 1 Holder Assembly MQ K Motor Driver Board Toner Present Sensor 441 1 Holder Assembly MQ Y Motor Driver Board Low Toner Sensor 442 1 Holder Assembly MQ M Motor Driver Board Low Toner Sensor 443 1 Holder Assembly MQ C Motor Driver Board Low Toner Sensor 444 1 Holder Assembly MQ K Motor Driver Board Low Toner Sensor 471 4 Paper Size Switch Assembly Motor Driver Board Plug Jack Locator Maps 343 Plug Jack Locator Table cont d P J Map Connected to Other end connected to No 472 4 No Paper Sensor Motor Driver Board 473 4 Low Paper Sensor Motor Driver Board 474 4 Feed Solenoid Motor Driver Board 475 4 Clutch Turn Assembly Motor Driver Board 511 1 Holder Assembly MQ Y Motor Driver Board Toner Motor 512 1 Holder Assembly MQ M Motor Driver Board Toner Motor 513 1 Holder Assembly MQ C Motor Driver Board Toner Motor 514 1 Holder Assembly MQ K Motor Driver Board Toner Motor 710 1 Plate Dispenser L EEPROM Harness Assembly 810 4 High Capacity Feeder Engine Control Board 1361 3 FR
146. er E Clean dry lint free cloth m Black light protective bag Cleaning Caution Never apply alcohol to any parts in the printer Caution Never use a damp cloth to clean up toner Warning If you remove the Imaging Unit place it in a light protective bag Record number of sheets printed Print several sheets of paper to check for problems or defects Turn off the printer Remove the Toner Cartridges the Imaging Unit and both side covers prior to cleaning Remove the front cover and clean the Fuser Fan with a brush or dry cloth to remove excess dust 6 Remove the rear cover and clean the Rear Fan with a brush or dry cloth to remove excess dust 7 Remove any debris or foreign objects from the Transfer Roller Fuser Assembly Laser Unit and Imaging Unit 8 Vacuum out any loose toner from the interior of the printer with a Type II toner vacuum only 9 Open left side door and clean up any toner inside 10 Remove and clean the paper trays 11 Clean pick rollers with a slightly damp lint free cloth khOD a Cleaning and Maintenance 117 118 Phaser 6200 Color Laser Printer Service Manual FRU Disassembly Removal and Replacement Procedures This section contains the removal and replacement procedures for selected parts of the printer according to the Field Replaceable Units FRUs Parts List Not all Replacement Procedures are included in this Service Manual In most cases to reinstall a part simply reverse the Remova
147. er 6200 Color Laser Printer Service Manual Contents cont d RRP Part Name RRP 6 9 MPT Feed Solenoid PL 6 1 40 RRP 6 10 Multi Purpose Tray Shaft PL 6 1 28 RRP 6 11 MPT Bottom Plate PL 6 1 42 RRP 7 Chute Assembly Exit RRP 7 1 Chute Assembly Exit PL 7 1 1 RRP 7 2 Exit Roller PL 7 1 4 RRP 7 3 Mid Roller PL 7 1 5 RRP 7 4 Duplex Motor Assembly PL 7 1 8 RRP 8 Transfer Roller and Fuser CRC RRP 8 1 Exit Actuator Fuser PL 8 1 7 RRP 8 2 Strap PL 8 1 13 RRP 9 Xerographics RRP 9 1 Laser Unit PL 9 1 1 RRP 9 2 Bias Housing Assembly PL 9 1 4 RRP 9 3 Chute Assembly Registration PL 9 1 6 Housing Electric Assembly PL 9 1 11 RRP 9 4 Registration Sensor Actuator PL 9 1 9 Registration Sensor PL 9 1 8 RRP 9 5 OHP Sensor and Harness Kit PL 9 1 12 RRP 10 Toner Cartridge Assemblies RRP 10 1 Toner Cartridge Holder Unit Assembly PL 10 1 RRP 10 2 Toner Cartridge Holder Assembly Y PL 10 1 1 M PL 10 1 2 C PL 10 1 3 K PL 10 1 4 RRP 10 3 Toner Present Switch PL 10 1 18 RRP 10 4 Toner Low Sensor PL 10 1 8 RRP 10 5 EEPROM Board PL 10 1 16 RRP 10 6 Sub High Voltage Power Supply Board PL 10 1 17 RRP 11 Frame and Drive Assemblies RRP 11 1 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 Lever Spring PL 11 1 5 RRP 11 2 Lever Plate Right PL 11 1 7 Lever Bracket PL 11 1 2 Lever Link PL 1
148. er Size Switch Assembly PL 3 2 4 Tray 1 PL 2 1 2 Use service diagnostics to test the Paper Replace the Go to step 3 Size Switches using the table below Engine Control Does the switch function normally Board RRP12 7 3 Does the printer function correctly after Complete Go to step 4 replacing the Motor Driver Board 4 Troubleshoot using the wiring diagram Complete Replace the Paper Tray 1 on page 354 Engine Control Does the printer function correctly after Board RRP 12 7 replacing any defective parts Paper Size Switches are indicated as SW1 SW2 and SW3 Paper Size Paper Size Switch Swi SW2 SW3 LEGAL14 ON ON ON LEGAL13 ON ON OFF EXECUTIVE ON OFF ON B5 ON OFF OFF A4 OFF ON ON A OFF OFF ON A5 OFF ON ON Used for reference only Supported by MPT only No Tray OFF OFF OFF Error Messages and Codes 65 Load Tray 2 3 with size type The printer s front panel displays Load Tray 2 or 3 with a specific size and or type of paper The tray cavity is free from debris and obstructions The paper tray is free from defects fully loaded with paper and all paper guides are seated securely against the paper Printer power has been cycled and the message still appears Note This is a media SIZE mismatch error Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Paper Size Switch Tray
149. er Tray 3 on page 367 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the Go to step 2 damage parts concerned Paper Size Switch Tray 2 3 PL 14 3 6 Actuators on the side of the Tray 2 3 2 Use service diagnostics to test the Tray 2 Replace Engine Go to step 3 3 Paper Size Switches use the table below Control Board for reference RRP 12 7 Do the switches function correctly 3 Troubleshoot using the Paper Tray 2 3 Complete Replace the wiring diagrams Engine Control Does the printer function correctly after eke RRP replacing any defective parts Paper Size Paper Size Switch swi Sw2 SW3 LEGAL14 ON ON ON LEGAL13 ON ON OFF EXECUTIVE ON OFF ON B5 ON OFF OFF A4 OFF ON ON A OFF OFF ON A5 OFF ON ON Used for reference only Supported by MPT only No Tray OFF OFF OFF 60 Paper Size Switches are indicated as SW1 SW2 and SW3 from the above one Phaser 6200 Color Laser Printer Service Manual Tray 1 Paper is Low The printers front panel displays Tray 1 Paper is Low when paper tray is full Tray 1 has been inspected for defects Printer power has been cycled and the error still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Low Paper Sensor PL 3 3 4 Paper Tray 1 on page
150. er and lower Remove the HCF Circuit Board RRP 14 5 Remove the Right Tray Guide RRP 14 8 Release the 3 tabs securing the Sensor to the HCF frame and remove the sensor OWMNONRWN Note Use caution the Sensor tabs are easily broken FRU Disassembly Removal and Replacement Procedures 251 RRP 14 14 Paper Size Switch Assembly PL14 3 6 6200 202 Removal 1 Remove the Right Tray Guide Assembly RRP 14 8 2 Remove the 1 screw securing the Paper Size Switch to the Right Guide Assembly and remove the switch 252 Phaser 6200 Color Laser Printer Service Manual FRU Parts List Parts List Contents Print Engine PL 1 1 Covers PL 2 1 Universal Paper Tray PL 3 1 Paper Feed PL 3 2 Paper Feed Il PL 3 3 Paper Feed Ill PL 4 1 Housing Assembly Retard PL 5 1 Chute Assembly In PL 6 1 Chute Assembly Out PL 7 1 Chute Assembly Exit PL 8 1 Transfer Roller amp Fuser Assembly CRCs PL 9 1 Xerographics PL 10 1 Holder Toner Cartridge Assembly PL 11 1 Frame and Drive Assemblies PL 12 1 Electrical PL 13 1 Harness Assemblies Optional High Capacity Feeder PL 14 1 High Capacity Feeder Paper Trays 2 amp 3 PL 14 2 High Capacity Feeder Covers PL 14 3 High Capacity Feeder Guides and Turn Chute Assembly PL 14 4 Paper Pick Assembly Trays 2 amp 3 PL 14 5 High Capacity Feeder Harness Board and Motor Supplies and Accessories PL 15 1 Xerox Supplies and Accessories FRU Parts List P
151. ests and Functions Table cont d Test ability to energize Front Panel Display and Test Definition Motors Fans Tests Tests the functionality of motors and fans by giving service personnel the de energize the motor and fans one at a time Main Motor Normal Speed Half Speed Normal Speed Continuous Half Speed Continuous Audible verification of motor functionality The motor tests are pulsed or continuous Duplex Motor Forward Normal Speed Forward Half Speed Forward Double Speed Reverse Normal Speed Reverse Half Speed Reverse Double Speed Forward Normal Speed Contiuous Forward Half Speed Contiuous Forward Double Speed Contiuous Reverse Normal Speed Contiuous Reverse Half Speed Contiuous Reverse Double Speed Contiuous Audible verification of motor functionality Fuser Motor Normal Speed Half Speed Normal Speed Continuous Half Speed Continuous Audible verification of motor functionality Developer Motor Caution Do NOT allow this motor to run any longer than necessary to verify operation Normal Speed Half Speed Audible verification of motor functionality Caution Only run the developer motor test once per power cycle to avoid excessive amounts of toner being forced inside the developer resulting in possible damage HCF Motor Normal Speed Half Speed Normal Speed Continuous Half Speed Continuous Audible verification of motor functionality
152. ets the plastic fingers on the sides of the paper tray to a specific postion Paper Size Switches are indicated as SW1 SW2 and SW3 Paper Size Paper Size Switch swi sw2 SW3 LEGAL14 ON ON ON LEGAL13 ON ON OFF EXECUTIVE ON OFF ON B5 ON OFF OFF A4 OFF ON ON A OFF OFF ON A5 only supported from MPT OFF ON ON No Tray OFF OFF OFF Selective Control Paper Pick When not controlled by the Engine Control Board the paper pick selected at power ON is Tray 1 Trays in the optional High Capacity Feeder are Tray 2 and Tray 3 respectively Laser Quantity Control Image data is transmitted to the laser diodes in the Laser Unit as digital signals and the laser diodes convert the image data from digital signals to optical signals data expressed with blinking laser beams If variations in the light intensity from the laser beams or variations in the optical system such as lenses or drum sensitivity cannot obtain a proper electrostatic image then the laser diodes monitor and adjust the light intensity of the laser beams to control and attain a stable electrostatic image The Laser Unit in the Phaser 6200 printer has four laser diodes one each for yellow magenta cyan and black that adjust the light intensity for each color automatically Theory of Operation 305 Process Control For stable printing the parameters related to the image forming must be monitored and adjusted by the
153. from the paper path and there is adequate paper in the MPT Printer power has been cycled and the error still displays Troubleshooting Reference Table Jam T0 Applicable Parts Wiring and Plug Jack Map References Roll Feed Assembly PL 6 1 27 Paper Tray 1 on page 354 Paper Present Sensor PL 6 1 4 Paper Feed on page 362 MPT Actuator PL 6 1 37 Drive Section on page 355 MPT Feed Solenoid PL 6 1 40 Main Wiring Diagram on page 352 Chute Assembly Registration PL 9 1 6 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following parts for fault or Replace any Go to step 2 damage damaged or Multi Purpose Tray EKCPSSIVSIV WONN parts Remove any foriegn objects or debris in the paper path Registration Sensor PL 9 1 8 Main Drive Assembly PL 11 114 2 Use service diagnostics to test the Go to step 6 Go to step 3 Registration Sensor Does the sensor function normally 3 Check that the connection between the Go to step 4 Connect or Harness and the Registration Sensor is replace the properly connected and seated faulty part 4 Check J 18 4 lt gt J 18 5 on the Go to step 5 Replace the Registration Clutch Harness for Registration continuity Chute See Paper Feed on page 362 oo RRP 5 Verify the voltage between P J18 3 lt gt Replace Sensor Go to step 6 P J18 2 This measurement point can be Regis
154. g diagram Complete Replace the Main Wiring Diagram on page 352 Engine Control Replace any defective parts Board RRP 12 7 Does the printer function correctly after replacing any defective parts 74 Phaser 6200 Color Laser Printer Service Manual Generic Fan Failure Code 52 This is a generic fan error generated by the Rear Fan or the Fuser Fan circuit Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Fuser Fan PL 1 1 7 Main Wiring Diagram on page 352 Rear Fan PL 12 1 2 Drive Section on page 355 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the Go to step 2 or damage defective fan Rear Fan PL 12 1 2 Fuser Fan PL 1 1 7 2 Isolate the problem fan by running service Go to the If both fans pass diagnostics testing both the Rear Fan and troubleshooting diagnostics Fuser Fan procedure for the replace the 19 specific fan Enginge Control Did one of the fans fail Board RRP 12 7 Error Messages and Codes 75 Engine Firmware Failure Code 72 NVRAM verify error Code 77 NVRAM data error Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Does an error occur even if the power is turned off and on Engine Control Board RRP 12 7 If the error returns again repla
155. g the Printer setup values resets the job defaults front panel language Intellegent ready MPT Tray setup Tray 1 3 setup startup page front panel intensity front panel contrast PostScript error information and energy star to their default values 1 From the Main Menu highlight Network Setup Menu and press OK 2 Highlight Reset Network Setup and press OK 3 Reset Network Setup NOW is displayed press OK Test Prints Adjustments and NVRAM 115 Resetting network setup values to default Resetting the network setup values resets the TCP IP address TCP IP address menu settings gateway broadcast etc CentreWare IS EtherTalk Netware set IPX frame type IPP and Ethernet speed to their default values 1 From the Main Menu highlight Network Setup Menu and press OK 2 Highlight Reset Connection Setup and press OK 3 Reset Connection Setup NOW is displayed press OK Caution Make note of the current network settings or Print a configuration page to reference the customers current network settings prior to resetting the network setup to the factory default values Resetting All Printer Default Settings PostScript NVRAM Resetting the NVRAM restores all printer values stored in the IP controller NVRAM including network printer setup job defaults color margin and calibrations to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset From the Main Menu highli
156. ge 367 Troubleshooting Procedures Table Steps Actions and Questions Yes No 1 Fill the tray with paper Go to step 2 Complete Does the error occur if the tray is full 2 Check the following for evidence of fault or Replace the parts Go to step 3 damage concerned Low Paper Sensor PL 14 5 7 Low Paper Lever PL 14 5 8 3 Use service diagnostics to test the Replace the Go to step 4 Tray 2 3 Low Paper Sensor Engine Control Do the sensor and actuator function aoe 7 properly ia 4 Does the printer function correctly after Complete Go to step 5 replacing the Circuit Board HCF 5 Troubleshoot using the Paper Tray 2 3 Complete Replace the wiring diagrams Engine Control Does the printer function correctly after sue 7 replacing any defective parts ii 62 Phaser 6200 Color Laser Printer Service Manual MPT Empty Load Paper The printer s front panel displays MPT Empty Load Paper but the MPT has paper The MPT is securely attached to the printer and the guides are resting securely against the both sides of the paper in the tray Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References MPT No Paper Sensor PL 6 1 4 Paper Feed on page 362 MPT Actuator PL 6 1 37 Troubleshooting Procedure Table Steps Actions and Questi
157. ght Support and press OK Highlight Service Tools Menu and press OK Reset NVRAM is displayed press OK Highlight Reset NVRAM and Reset Printer NOW and press OK to reset all the settings to their factory default values khOD Service Diagnostics PostScript NVRAM Resets Resetting the NVRAM restores all printer values stored in the IP controller NVRAM including network printer setup job defaults color margin and calibrations to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset 1 Enter Service Diagnostics 2 Highlight NVRAM Access and press OK 3 Highlight PostScript NVRAM Reset and press OK 4 Resetting NVRAM Are you sure Is displayed highlight Yes and press OK The printer now exits Service Diagnostics and reboots While booting NVRAM is reset 116 Phaser 6200 Color Laser Printer Service Manual Cleaning and Maintenance Service preventive maintenance procedure Perform the following procedures whenever you check service or repair a printer Cleaning the printer as outlined in the following steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical and how often cleaning the machine is necessary Record the number of sheets printed Recommended tools E Toner vacuum cleaner E Clean wat
158. hWND 228 Phaser 6200 Color Laser Printer Service Manual 8 Disconnect P J18 P J19 P J32 and P J24 from the Engine Control board 9 Disconnect P J 2361 going to the Temperature Humidity Sensor 1 S6200 174 10 Remove the screw securing the ground wire Note Remove the two screws from the metal of the card cage not the two screws secured in the plastic 11 Remove the 4 screws securing the Card Cage to the printer and remove the card cage item 1 Reassembly Note When reinstalling the Card Cage make sure the Chute Assembly Registration and the Bias Housing Assembly are installed after reinstalling the Card Cage to prevent damaging the bias springs Note The black connector P30 is not used FRU Disassembly Removal and Replacement Procedures 229 RRP 12 6 Housing Assembly Contact PL 12 1 14 6200 172 Removal 1 Remove the Card Cage Assembly RRP 12 5 2 Release the 2 tabs securing the Housing Assembly Contact to the Card Cage and remove the contact 230 Phaser 6200 Color Laser Printer Service Manual RRP 12 7 Engine Control Circuit Board PL12 1 1 6200 165 Caution Observe proper ESD procedures when removing any circuit board from the printer Removal 1 Remove the Card Cage RRP 12 5 2 Remove the Housing Assembly C
159. he Link Actuator apart 4 Remove the link actuator from the bracket in the printer and remove 156 Phaser 6200 Color Laser Printer Service Manual RRP 3 12 Feed Solenoid PL3 3 17 6200 095 Removal Remove the Paper Feeder Assembly Unit RRP 3 2 Remove the Paper Pick Assembly RRP 3 3 Remove 1 screw securing the Feed Solenoid to the Paper Pick Assembly Separate the Feed Solenoid slightly and shift the harness to disconnect P J474 gray Remove the Feed Solenoid khOND a FRU Disassembly Removal and Replacement Procedures 157 RRP 3 13 Turn Clutch Assembly PL3 3 18 6200 096 Removal 1 Remove the Paper Feeder Unit Assembly RRP 3 2 2 Remove the Paper Pick Assembly RRP 3 3 3 Release the tab securing the Stopper Clutch item 2 to the shaft on the right side of the Paper Pick Assembly 4 Pull out the Stopper Clutch item 1 5 Disconnect P J475 blue from the Paper Pick Asssembly 6 Pull out the Turn Clutch Assembly 158 Phaser 6200 Color Laser Printer Service Manual RRP 3 14 Roll Turn Assembly PL3 3 20 6200 097 Removal khOND a Remove the Paper Feeder Assembly Unit RRP 3 2 Remove the Paper Pick Assembly RRP 3 3 Remove the Clutch Turn Assembly RRP 3 13 Release the tab securing the Gear Feed 2 item 1 to the shaft of the Paper Pick Assembly and pull out the Gear Feed 2 Pull out the Idler Gear item 2 and Idler
160. hen a new EEPROM Board is installed in the printer the CRUM data written to the EEPROM makes it unique to that printer The EEPROM board cannot be re used in another printer FRU Parts List 279 PL 11 1 Frame and Drive Assemblies IG ow 6200 239 Phaser 6200 Color Laser Printer Service Manual 280 PL 11 1 Frame and Drive Assemblies FRU Parts List Table ID No Part Number Qty Name Description 1 1 Lever Plate Left NS 2 116 1471 00 2 Lever Bracket 1 per order 3 116 1472 00 1 Lever Link Left 4 116 1473 00 8 Lever Drum 1 per order 5 116 1474 00 8 Lever Spring 1 per order 6 116 1475 00 1 Link Lever Right 7 1 Lever Plate Right NS 8 116 1476 00 1 Actuator I L 9 116 1477 00 1 Spring I L 10 116 1478 00 2 Press Gear IDL 1 per order 11 116 1479 00 1 Press Gear Right 12 116 1480 00 1 Spring IDT Right 13 116 1481 00 1 Assembly Developer Drive 14 116 1482 00 1 Assembly Main Drive 15 116 1483 00 1 Registration Film 16 116 1484 00 1 Circuit Board Earth GRND Ground 17 116 1485 00 1 Spring IDT Left 18 116 1486 00 1 Press Gear Left FRU Parts List 281 PL 12 1 Electrical J166 a 6200 240 282 Phaser 6200 Color Laser Printer Service Manual PL 12 1 Electrical FRU Parts List Table
161. hute Assembly Out FRU Disassembly Removal and Replacement Procedures 125 6200 065 3 Slightly separate the Front Cover from the printer and remove connector P J220 from the Front Panel and P J 137 from the Fuser Fan 4 Remove the Front Cover 126 Phaser 6200 Color Laser Printer Service Manual RRP 1 2 Front Panel PL 1 1 1 BOTTOM VIEW 6200 064 Removal 1 Remove the Front Cover RRP 1 1 2 Release the 3 hooks securing the Front Panel to the Front Cover and remove the Front Panel FRU Disassembly Removal and Replacement Procedures 127 RRP 1 3 Fuser Fan PL 1 1 7 Phaser 6200 Color Laser Printer Service Manual 128 Removal 1 Remove the Front Cover RRP 1 1 2 Remove the 2 screws securing the Fuser Fan Holder item 1 to the rear of the Front Cover and remove the Fuser Fan Holder 3 Disconnect P J137 from the Fuser Fan Holder 4 Release the 4 tabs securing the Fuser Fan item 2 to the Fuser Fan Holder and remove the Fuser Fan Replacement 1 Assemble in reverse order Note When replacing the Fuser Fan note the airflow direction The label on the fan should face out FRU Disassembly Removal and Replacement Procedures 129 RRP 1 4 Top Main Cover PL1 1 9 S 6200 067 Removal Remove the Top Cover Output Tray Remove all the Toner Cartridges Open Door A Open Door C Top Image Unit Cover
162. ine Replace the Front 1A Control Board RRP 12 7 Harness Assembly PL 13 1 7 Troubleshooting 105 Residual Image Ghosting or Hot Offset 6200 284 There are faint ghostly images appearing on the page The images may be either from a previous page or from the page currently printed The printer displays no error code Hot Offset A light image of the print is repeated and offset 82m See Repeating Defects Identification Chart on page 95 Step Check Yes No 1 Was the customer printing numerous Avoid long runs of Go to step 2 copies of the same image the same image 2 Set the paper to the next heaviest Complete Go to step 3 type Does this resolve the problem 3 Does the ghosting appear in only Replace the Go to step 4 one or 2 colors Imaging Unit CRC PL 9 1 3 4 Check the Heat Roller and NIP Belt Replace the Fuser Go to step 5 in the Fuser Assembly for evidence Assembly CRC of contamination or damage PL 8 1 1 5 Does the image quality improve after Complete Go to step 6 the Fuser has been replaced 6 Does the imaging quality improve if Complete Go to step 7 the Transfer Roller is replaced 7 Does the image quality improve if Complete Go to step 8 the LVPS is replaced The fuser control circuit is located on the LVPS 8 Print a usage profile do the Replace the Engine Replace the temperature and humidity v
163. inter 4 Remove the 1 screw securing the Temperature Humidity Sensor and remove the sensor Replacement Note Seat the sensor onto the Guide Pins with needle nose pliers then re insert the screw Reconnect connector P J2361 FRU Disassembly Removal and Replacement Procedures 147 RRP 3 6 High Capacity Feeder Harness PL3 2 3 REAR 6200 084 Removal Remove the Printer Chassis RRP 3 2 Shift the HCF Harness from the Right Housing Release the 2 tabs securing the harness to the Right Housing Pull the HCF Harness down from the Housing Assembly to remove hOND 148 Phaser 6200 Color Laser Printer Service Manual RRP 3 7 Paper Size Switch Assembly PL3 2 4 6200 085 Removal Remove the Printer Chassis RRP 3 2 Disconnect P J471 from the Paper Size Switch Remove 1 screw securing the Paper Size Switch to the Right Housing Rotate the front of the Paper Size Switch to free the tab and remove hOND FRU Disassembly Removal and Replacement Procedures 149 RRP 3 8 Low Paper Lever PL3 2 7 Indicator PL3 2 8 and Indicator Guide PL3 2 10 6200 087 Removal Indicator and Guide Indicator 4 5 Pull the Guide Indicator item 3 together with the Indicator Spring item 5 and 1 Remove the Paper Feeder Unit Assembly RRP 3 2 2 3 Hold the tip of the Paper Level Indicator item 1
164. ions Engine Power Up Sequence Engine Control Board logic check Imaging Unit Detached NVRAM CRUM Error CRUM ID Life Over Fuser Detached NVRAM CRUM Error Life Over Toner Cartridge Detached Life Over Transfer Roller Detached Life Over CTD Sensor Error All paper sensor Jam OHP sensor Jam Door s Open 10 Environment Sensor Error 11 NVRAM NVRAM error 12 Image Processor Board POST Diagnostic check OONOOARWND Printer Does Not Come to a Ready State 1 See AC Power Supply Troubleshooting on page 88 No Front Panel Display After Power Switch is Turned On 1 Remove and reseat the Image Processor Board 2 See DC Power Supply Troubleshooting on page 88 3 Replace the Front Panel wiring harness RRP 1 2 4 Replace the Front Panel RRP 1 2 5 Replace the Image Processor Board RRP 12 8 Front Panel LED is on no Front Panel Message Blank Display 1 Remove and reseat the Imaging Processor Board 2 Replace the Front Panel wiring harness RRP 1 2 3 Replace the Front Panel RRP 1 2 4 Replace the Image Processor Board RRP 12 8 Front Panel Continually Displays Warming Up 1 Verify the correct Fuser 110V vs 220V is installed in the printer 2 See the Engine Power Up Sequence Front Panel Continually Displays Install or Reseat Imaging Unit 1 See Install or Reseat Imaging Unit on page 48 Troubleshooting 87 AC Power Supply Troubleshooting T
165. irst determine if the defect occurs in all colors or only one color and if it is repeating or random Defects occurring in only one color are usually attributable to the Imaging Unit Continuous defects in the process direction such as voids and lines are the most difficult to diagnose The visible surfaces of all rollers should be inspected for obvious defects If no defects are observed the Imaging Unit Transfer Roller and Fuser should be changed one at a time until the defect has been eliminated 94 Phaser 6200 Color Laser Printer Service Manual Some print quality problems can be associated with specific assemblies the most common problems and the associated assemblies are listed below Also refer to the specific print quality troubleshooting procedure for more information E Imaging Unit E Streaks E Fine Lines m Banding in Process Direction m Uneven Density E Voids E Repeating Defects m Transfer Roller E Toner on the back side of the printed page simplex mode m Light Prints E Repeating Defects m Fuser m Hot or Cold Offsetting E Repeating Defects Repeating Defects Identification Chart FRU Component Distance between Defects Imaging Unit Developer Roller YMCK 28 mm 1 10 in Drum YMCK 62 mm 2 44 in Drum Charge Rollers 25 mm 1 in IDT 1 Y and M C and K 132 mm 5 20 in IDT 2 all colors together 132 mm 5 20 in Transfer Roller Transfer Roller 64 mm 2 52 in Fuser Assembly Fuser Assem
166. is installed 6 7 8 9 Toner Cartridge Y M C K Individaul toner bottles containing toner mixture 10 11 12 13 Toner Cartridge Holder Assembly and Toner Motors Y M C K The Toner Cartridge Holder Assemblies each contain a toner motor which supplies the drive to the Agitator in the Toner Cartridges and to the Auger in the Toner Cartridge Holder supplying toner to the developer in the Imaging Unit 14 15 16 17 Low Toner Sensor Y M C K Detects level of toner in each auger tube 18 Circuit Board EEPROM Consumable use Fuser and Imaging Unit NVRAM Data information is stored and communicated to the Engine Control Board 336 Phaser 6200 Color Laser Printer Service Manual 6200 281 1 Agitator Assembly with film 2 Toner Motor 3 Auger Assembly 4 Auger Tube Theory of Operation 337 Toner Motor Drive Assembly Transmission Route TONER MOTOR ASSY GEAR IDLER1 GEAR IDLER2 GEAR TCRU GEAR AUGER GEAR AGITATOR Heh AUGER ASSY AGITATOR ASSY Film Agitator PIPE AUGER TONER CARTRIDGE 6200 279 bi Developer Assembly Transmission Route DEVELOPER DRIVE ASSY e A o ae ees Developer Y Developer M f Developer C Developer K IMAGING UNIT S6200 033 338 Phaser 6200 Color Laser Printer Service Manual Electrical 6200 049 1 Engine Control Board Controls printing operation based on
167. it Note The 4 screws on the right side of the printer are below the toner motors 6200 155 Replacment 1 Replace in reverse order Note Damage can occur if the Gear and Rack are not in the proper position With Door C open push the Rack V up as far as it can go and then replace the gear FRU Disassembly Removal and Replacement Procedures 205 RRP 10 2 Toner Cartridge Holder Assembly Y PL 10 1 1 M PL 10 1 2 C PL 10 1 3 K PL 10 1 4 6200 149 Removal 2 Remove the Left and Right Covers RRP 1 6 3 Remove the Holder Toner Cartridge Assembly Unit RRP 10 1 Note Reinstall the toner cartridges to prevent spillage Note The holders need to be removed in Y M C K order There are small locking tabs between the holders on each end that lock them together 4 Inthe Holder Toner Assembly Unit release the tab securing the auger tube from the Plate Dispensor PL 10 1 9 with a small screwdriver and remove by sliding to the right Note You will need to disconnect the all connectors before removing the holder in the next steps 206 Phaser 6200 Color Laser Printer Service Manual 5 Disconnect the following Plug Jacks from each dispenser item 6 E Y P J511 P J441 and P J431 mM P J512 P J442 and P J432 mC P J513 P J443 and P J433 mK P J514 P J444 and P J434 6 Near the toner low sensor shift the harness s from the tabs on the Toner Cartridge Holder As
168. l Procedure shown In some instances the Replacement Procedure is included because it may contain special steps For specific assemblies and parts refer to the FRU Parts List on page 253 Contents RRP Part Name RRP Page RRP 1 Covers Print Engine RRP 1 1 Front Cover PL 1 1 2 125 RRP 1 2 Front Panel PL 1 1 1 127 RRP 1 3 Fuser Fan PL 1 1 7 128 RRP 1 4 Top Main Cover PL1 1 9 130 RRP 1 5 Image Unit Top Cover Door C PL1 1 10 131 RRP 1 6 Right Side Cover PL1 1 24 and Left Side Cover PL1 1 30 132 RRP 1 7 Rear Cover PL 1 1 20 133 RRP 1 8 Left and Right Links PL 1 1 23 134 RRP 1 9 Multi Purpose Tray MPT PL1 1 99 135 RRP 1 10 Front Right Cover PL 1 1 25 136 RRP 1 11 Front Left Cover Assembly PL1 1 29 138 RRP 2 Universal Paper Tray I RRP 2 1 Paper Feed Roller PL 2 1 1 CRC as Kit 140 RRP 3 Paper Feed RRP 3 1 Turn Chute Assembly PL3 1 2 141 RRP 3 2 Printer Chassis 142 RRP 3 3 Paper Pick Assembly PL3 3 1 144 RRP 3 4 Right and Left Housing PL 3 2 146 RRP 3 5 Temperature Humidity Harness PL3 2 1 and Sensor PL3 2 2 147 RRP 3 6 High Capacity Feeder Harness PL3 2 3 148 FRU Disassembly Removal and Replacement Procedures 119 Contents cont d RRP Part Name RRP 3 7 Paper Size Switch Assembly PL3 2 4 RRP 3 8 Low Paper Lever PL3 2 7 Indicator PL3 2 8 and Indicator Guide PL3 2 10 RRP 3 9 Paper Pick Rollers PL3 3 3 RRP 3 10 RRP 3 11
169. lete replaced 3 Is the CRUM Harness connector Replace the Plate Go to step 4 damaged or improperly connected Dispense Left PL 10 1 9 4 Remove the left cover Damage can occur Go to step 5 Check the Gear Slide and the Rack V for Me Gear and damage or misalignment acs ale Noein proper position Is the Rack V out of alignment With Door C open See RRP 10 1 for more information push the Rack V up as far as it can go and then reinstall the gear slide 5 Check J710 lt gt J71 on the CRUM Go to step 6 Replace the Plate Harness for continuity Dispense Left Use the wiring diagram Fuser ead Assembly on page 358 ae 6 Check J71 lt gt J140 on the EEPROM Replace the Engine Replace the Harness Assembly for continuity Control Board RRP EEPROM Use the wiring diagram Fuser 12 7 Hellas Assembly on page 358 PL 13 1 10 Error Messages and Codes 77 Controller to Engine Communications Failure Code 81 This is a communication failure between the Image Processor Board and the engine control board Note When replacing the Image Processor Board the NVRAM memory configuration chip i button and the hard drive must be transferred to the new Image Processor Board Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Cycle power to the printer Is the error Complete Go to step 2 cleared 2 Is the error cleared by reseating the Complete Go to step 3 Image Processor B
170. line and ready to print Displays an engine status that will prevent printing Status is displayed sequentially on line at a time Engine Board ROM Version Engine FW Displays the engine firmware version installed Printer Configuration Memory MB Hard Drive Not Installed or Displays current memory installed Detects presence of Hard Drive Test Prints Prin Installed option HCF Installed Detects presence of High Capacity Not Installed Feeder option Ambient Temperature XX C Displays the current Temperature Temperature Humidity 4 and Humidity for the printer Humidity Fuser Temperature XX C Displays the printers current Fuser Temperature temperature Fault History Device Status Displays Fault occurrence since last Jams Hardware Errors Firmware Errors Fan Motors CTD Sensor Errors Fuser Failure Laser Failure Life Over Trays Miscellaneous ts test prints stored in the Engine Control Board The prints are used by service personnel to identify repair and validate the operability of the printer power cycle Blank Page Continuously prints blank pages until Print stopped by the user 600 x 600 Test Continuously prints the step pattern Pattern until stopped by the user See Test Prints Adjustments and NVRAM on page 109 for specific test print information 24 Phaser 6200 Color Laser Printer Service Manual Service Diagnostics T
171. lock switch function Paa 3 correctly N 10 Verify the voltage between SW 1 lt gt Replace the Go to step 11 P J60 2 and SW 2 lt gt P J60 2 on the Motor Driver Motor Driver Board is 24 VDC Board Close the Interlock Switch RRP ie at 11 Check the power supply by verifing the Replace the Motor See DC Power voltage between P J60 1 lt gt P J60 2 on Driver Board Supply the Motor Driver Board is 24 VDC RRP 12 3 Troubleshooting on page 88 12 Check the power supply by verifing the Go to step 13 Go to step 14 voltage between P J61 8 lt gt P J61 7 on the Motor Driver Board is 5 VDC 13 Check the power supply by verifing the Go to step 15 Go to step 14 voltage between P J61 6 lt gt P J61 5 on the Motor Driver Board is 3 3 VDC 14 Check the LVNC Harness for continuity See DC Power Replace the hta n Supply Harness LVNC See Main Wiring Diagram on page 352 Troubleshooting PL 13 1 4 on page 88 15 Check the DRV 1 Harness for continuity Replace in the Replace the See Drive Section on page 355 following order DRV 1 Harness n Assembly Main Drive PL 13 1 1 Assembly RRP 11 3 Engine Control Board RRP 12 7 16 Perform steps 1 through 3 in RRP 3 1 Go to step 21 Go to step 17 Open and close the front door Observe the Turn Roller Dose the Turn Roller turn while the machine is warming up 17 Use service diagnostics to test the Tray 1 Check the clutch Go to step 18 Turn Clutch and gea
172. lor Laser Printer Service Manual RRP 14 9 Left Tray Guide PL14 3 3 6200 203 Removal Remove both Paper Trays from the HCF Remove the Front Covers RRP 14 1 Remove the Left Cover RRP 14 2 Remove the Chute Assembly Turn RRP 14 3 Remove the 5 screws securing the Left Tray Guide Assembly to the HCF frame Release the 6 tabs securing the Left Tray Guide Assembly to the HCF frame aOuahwhd FRU Disassembly Removal and Replacement Procedures 245 ig S6200 204 7 Remove the Guide Assembly by rotating the top inward 8 Repeat Steps 1 7 to remove the lower guide 246 Phaser 6200 Color Laser Printer Service Manual RRP 14 10 Link Actuator PL 14 4 6 6200 207 Removal 4 5 Remove the actuator 1 Remove both Paper Trays from the HCF 2 3 Reach in through the rear of the printer and spread the tabs of the Link Actuator Remove the paper tray Rear Cover apart Remove the link actuator from the bracket in the printer Note When replacing positon the Actuator so that the wider portion is on the right side viewe from the front Replace it after passing the tip of the Link Actuator into the hole in the HCF frame FRU Disassembly Removal and Replacement Procedures 247 RRP 14 11 HCF Paper Pick Assembly PL14 4 1 6200 208 6200 209 248 Phaser 6200 C
173. lutch at a time Front Panel Display and Test Definition Registration Clutch MPT Turn Clutch Tray 1 Turn Clutch Tray 2 Turn Clutch Tray 3 Turn Clutch Solenoid Tests Clutch is ON Clutch is OFF Tests the functionality of the clutches by energize de energize one solenoid at a time Audible verification of Clutch functionality You should hear the clutch engage click once giving service personnel the ability to MPT Turn Clutch Tray 1 Turn Clutch Tray 2 Turn Clutch Tray 3 Turn Clutch Solenoid is ON Solenoid is OFF Maintenance Cleans the Intermediate Transfer Unit within the Imaging Unit Audible verification of the Solenoid function Clean the Imaging Unit IDT 1 Clean the Imaging Unit IDT 2 NVRAM Access Printing This menu lets you read set or reset the following values Printing is displayed on the Front Panel during the IDT cleaning cycle The test continuously cycles paper through the printer until the Cancel key is pressed PostScript NVRAM Reset Resetting PostScript NVRAM Are you sure Yes NO CRU Life Reset The following options are available for CRU Life Reset Restores the Printers setup values to their factory defaults For more information on resetting NVRAM See Resetting NVRAM on page 114 28 Phaser 6200 Color Laser Printer Service Manual Service Diagnostics Tests and Functions Table c
174. ly light or missing entirely These missing areas form bands parallel to the leading edge Step Check Yes No 1 Is the 600x600 test pattern printed Replace the Image Go to step 2 from service diagnostic correct Processor Board RRP 12 8 2 Is the paper wrinkled dimpled or Complete Go to step 3 show any signs of having a high moisture content Is the problem resolved by loading fresh dry paper 3 Print a Repeating Defects Page Replace the Go to step 4 Do the defects correspond to a indicated CRU Customer Replaceable Unit See Repeating Defects Identification Chart on page 95 4 Does the image quality improve if Replace the Go to step 5 the Imaging Unit is replaced Imaging Unit CRC PL 9 1 5 Check the Heat Roller and NIP Belt Replace the Fuser Go to step 6 in the Fuser Assembly for evidence Assembly CRC of contamination or damage PL 8 1 1 6 Does the imaging quality improve if Replace the Go to step 7 the Transfer Roller is replaced Transfer Roller CRC PL 8 112 7 Check the following pins for Go to step 8 Replace the defective continuity J5030 and J5020 lt gt wire Transfer Roller 8 Does the image quality improve if Replace the Go to step 9 the SUB HVPS is replaced S HVPS RRP 10 6 9 Does the image quality improve if Replace the Laser Replace the Engine the Laser Unit is replaced Unit RRP 9 1 Control Board RRP 12 7 102 Phaser 6200 Colo
175. ly Out Duplex 326 Chute Assembly Exit 328 Duplex Drive and Gears 329 Transfer Roller and Fuser 331 Registration Chute Assembly 330 Xerographics 333 Toner Cartridge Unit 336 Developer and Toner Drive 338 Electrical 339 Theory of Operation 301 Summary of the Printing Process The Phaser 6200 Color Laser Printer is a full color laser printer applying the principals of an electrophotgraphic system The system comprising a drum and developing unit for each color yellow magenta cyan and black YMCK places the toner image of each color onto print media producing full color prints through three intermediate transfer units IDT1 2 IDT2 1 The following procedures are summarized The printing process is composed of the following steps see the illustration on the following page as a reference 1 Charging The drum surface rotates at a constant speed while being uniformly charged with negative electricity This process is performed simultaneously for YMCK 2 Exposure The charged drum surface is scanned by laser beams to form an invisible electrostatic latent image on the drum surface This process is performed simultaneously for YMCK 3 Development Toner is electrostatically attached to the invisible latent image on the drum surface to form the visible image on the drum This process is performed simultaneously for YMCK 4 Primary Transfer drum gt IDT 1 The toner image formed on the individual drum surface is tran
176. ly if defective Toner Present Switch YMCk PL 10 1 18 Toner Present Switch Connector YMCk PL 10 1 3 Replace the Motor Driver Board Go to step 4 Complete Does the error recur 4 Troubleshoot the problem color using the Complete Replace the wiring diagram in the Developer Section Engine Control 1 on page 356 Board RRP 12 7 Replace any defective parts 54 Phaser 6200 Color Laser Printer Service Manual Replace Y M C K Toner Cartridge or Y M C K Toner Cartridge Empty The printer s front panel displays Replace Y M C or K Toner Cartridge or Y M C or K Toner Cartridge Empty The corresponding cartridge has been replaced power to the printer has been cycled and the error still appears Note Y M C K Toner Cartridge Empty is a warning condition Replace Y M C K Toner Cartridge is a hard stop error Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Toner Low Sensor PL 10 1 8 Developer Section 1 on page 356 Motor Driver Board PL 12 1 14 Drive Section on page 355 Toner Cartridge Holder Assembly PL 10 1 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Verify Toner Cartridge replacement of the Go to step 2 Complete of the problem color Does the error recur 2 Use service diagnostics to test the Toner Go to
177. mbly for damage or replace the parts concerned Power cycle the printer 2 Does the error recur after the Fuser has Go to step 3 Complete been replaced with a new one 3 Replace the EEPROM Board Troubleshoot Complete using the wiring diagram Fuser Assembly on page 358 Does the error recur Replace the Engine Control Board RRP 12 7 Error Messages and Codes 53 Install or Lock Y M C K Toner Cartridge The printer s front panel displays Install or Lock Yellow Magenta Cyan or Black Toner Cartridge The corresponding toner cartridge is correctly seated all shipping tape has been removed and the cartridge is fully locked into position Printer power has been cycled and the error still appears Note Follow this troubleshooting procedure using the Y M C or K steps as appropriate for the color indicated by the front panel error message Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Toner Present Switch PL 10 1 18 Developer Section 1 on page 356 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Use service diagnostic to test the toner Replace the Engine Go to step 2 present switch of the problem color Control Board Does the Toner Present Switch YMCK RRP 12 7 function normally 2 Check the following for evidence of fault or Complete Go to step 3 damage replace the assemb
178. n Cover RRP 1 4 Remove the Front Right Cover RRP 1 10 Remove the Right Cover RRP 1 6 Remove the screw securing the ground wire to the LVPS Release the tabs securing the harness cable guide to the AC Switch bracket and move aside Disconnect P J161 from the LVPS Press in on the tabs and remove the Harness Assembly AC Switch from the printer NO akhwhd FRU Disassembly Removal and Replacement Procedures 223 RRP 12 2 Low Voltage Power Supply PL 12 1 10 224 6200 168 6200 169 Phaser 6200 Color Laser Printer Service Manual Removal 1 Remove the Right Cover RRP 1 6 2 Lift the Holder Toner Assembly Unit off the aligning tabs and move out of the way Remove the 4 screws securing the Motor Driver Board and move out of the way Remove the Harness Cable Guide Assembly items 1 2 3 Remove the Harness Assembly AC Switch RRP 12 1 Disconnect P J162 P J163 P J164 P J165 and P J166 from the Low Voltage Power Supply Board Remove the 3 screws securing the board to the printer and remove the Low Voltage Power Supply board ou amp N FRU Disassembly Removal and Replacement Procedures 225 RRP 12 3 Motor Driver Board PL 12 1 12 sd v4 Z Ls rie m Wag sae ra Ay le jl Z T I E IS ri 6200 171 Removal Remove the Top Main Cover RRP 1 4 Remove
179. n appears as a very light gray dusting The printer displays no error code Before using this procedure Ensure the TekColor Correction is not set to None in the printer s dialog box Ensure 6200 285 the customer is making less than 2 000 prints per day Making more than 2 000 prints a day exceeds the duty cycle specifications for the printer Step Check Yes No 1 Check the Imaging Unit Fuser Replace or reinstall Go to step 2 Assembly and the Transfer Roller for the affected correct installation damage or component contamination 2 Does the image quality improve if Replace the Go to step 3 the Imaging Unit is replaced Imaging Unit CRC PL 9 1 3 3 Check the Heat Roller and NIP Belt Replace the Fuser Go to step 4 in the Fuser Assembly for evidence Assembly CRC of contamination or damage See PL 8 1 1 Transfer Roller and Fuser Assembly on page 331 4 Does the imaging quality improve if Complete Go to step 5 the Transfer Roller is replaced 5 Check the following pins to the Go to step 6 Replace the defective transfer roller contacts for continuity wire J5030 lt gt Transfer Roller J5020 lt gt Transfer Roller 6 Does the image quality improve if Complete Go to step 7 the Laser Unit is replaced 7 Does the image quality improve if Complete Go to step 8 the S HVPS is replaced 8 Check J 5011 lt gt J13 for continuity Replace the Eng
180. n correctly 3 Check that the connection between the Go to step 4 Reconnect Harness and the Registration Sensor is properly properly connected and seated 4 Check J181 lt gt J18 on the Registration Go to step 5 Replace the Chute Clutch Harness for continuity Assembly Registration See Paper Feed on page 362 RRP 9 3 5 Verify the voltage between P J 18 3 lt gt Go to step 6 Replace the P J 18 2 on the Engine Control Board is Registration 0 VDC Sensor RRP 9 4 6 Use service diagnostics to test the Go to step 8 Go to step 7 Registration Clutch Close the Interlock Switch during the test Does the clutch function correctly 7 Remove the connector J18 Go to step 8 Replace the Chute Is J 18 4 lt gt J 18 5 less than 2009 Assembly Registration RRP 9 3 Error Messages and Codes 35 Troubleshooting Procedure Table cont d Steps Action and Questions Yes No 8 Verify the voltage between P 18 4 lt gt P Replace the Chute Replace the 18 2 on the Engine Control Board is Assembly Engine Control 24 VDC Registration Board Close the Interlock Switch while checking RRP 9 3 BRE ed the voltage 36 Phaser 6200 Color Laser Printer Service Manual Misfeed at MPT The printers front panel displays Misfeed at MPT indicating a paper misfeed has occurred in the printer The MPT is securly attached to the printer and any obstruction media and debris has been removed
181. n replacing the Printer Chassis check to make sure none of the wiring harnesses between the Printer and Feeder Unit are pinched FRU Disassembly Removal and Replacement Procedures 143 RRP 3 3 Paper Pick Assembly PL3 3 1 6200 098 144 Phaser 6200 Color Laser Printer Service Manual Removal 1 Remove the Paper Feeder Assembly Unit from the printer chassis RRP 3 2 2 Disconnect P J471 yellow from the Paper Size Switch in the Paper Feeder Unit Assembly 3 Carefully free the wires yellow blue from their guides noting the postion of the wires for reassembly 4 Remove the 2 screws securing the Paper Pick Assembly from the Paper Feeder Unit Assembly 5 Raise the Paper Pick Assembly out of the Paper Feeder Unit Assembly FRU Disassembly Removal and Replacement Procedures 145 RRP 3 4 Right and Left Housing PL 3 2 6200 088 Removal 1 Remove the Paper Pick Assembly RRP 3 3 2 Remove the 4 screws securing the Left Right Housing Assembly Feeder to the bottom plate 3 Turn the Housing Assembly Feeder in slightly and extract the 3 hooks out of the holes on the Bottom Plate 146 Phaser 6200 Color Laser Printer Service Manual RRP 3 5 Temperature Humidity Harness PL3 2 1 and Sensor PL3 2 2 6200 083 Removal 1 Remove the Top Main Cover RRP 1 4 2 Remove the Left Side Cover RRP 1 6 3 Disconnect P J2361 gray from the pr
182. n the next print or if the toner density is high the dispensed toner quantity is reduced on the next print The dispensed toner quantity is calculated by the toner dispense time This calculation is made for each color Even allotment in first 8 prints lt gt Correction amount by ADC 16 6 00 00 00O OO 68 O86 CO Total dispense counts 4 5 3 4 2 2 3 4 3 2 Correction amount by ADC 8 O oO O O O QO Total dispense counts 1 2 0 1 0 0 0 0 2 2 Dispense counts by PCDC A 6200 051 Theory of Operation 307 High Area Coverage Mode Continuous printing of an image with density exceeding the toner dispense capability causes the toner density in the developer to be lowered below the target toner density The high area coverage mode retards the next page fed and dispenses toner during this time so that the toner density time reaches the specified value during continuous printing Admix Mode If the high area coverage mode can not deal with the reduction of toner density in the developer or if the machine is used in a high humidity environment and is relocated to a low humidity environment the reference value for the toner density will change This causes a large discrepancy between the measured values from the CTD sensor and the referenced value for the toner density Admix mode dispenses the toner immediately to prevent low toner density If the patch density result measured by the CTD Se
183. nd that color calibration has been performed prior to using this troubleshooting procedure Step Check Yes No Check the Imaging Unit for correct installation damage or contamination Verify the shipping seals are completely removed Replace the Imaging Unit CRC PL 9 1 3 Go to step 2 Is the affected color s toner supply empty Replace Toner Cartridge PL 10 1 Go to stop 3 Check for foreign objects or contamination present in the laser beam path between the Laser Unit and the Imaging Unit Remove object and or contamination Go to step 4 Inspect the Developer Bias Plunger Stud of the effected color for proper spring pressure compare to the other colors Check for contamination Go to step 5 Replace the Housing Assembly Bias RRP 9 2 Check the following pins between the Engine Control Board and the Housing Assembly Bias for continuity depending on the color affected J 601 lt gt DEVE Y contact J 602 lt gt DEVE M contact J 603 lt gt DEVE C contact J 604 lt gt DEVE K contact Go to step 6 Replace the Housing Assembly Bias RRP 9 2 Replace the Laser Unit RRP 9 1 Does the image quality improve if the Laser Unit is replaced Complete Replace the Engine Control Board RRP 12 7 98 Phaser 6200 Color Laser Printer Service Manual Blank Prints The entire image area is blank 6200 288
184. nerally connected to a pin that is either RTN Return or SG Signal Ground You can substitute any RTN pin or test point in the printer and you can use FG frame ground in place of any SG pin or test point Before measuring voltages make sure the printer is switched ON the Imaging Unit and the paper trays are in place and the interlock switches are actuated unless a troubleshooting procedure instructs otherwise Error Messages and Codes 21 7 All voltage values given in the troubleshooting procedures are approximate values The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating a voltage drop occurs during component actuation Gating signals may be nothing more than a pulse resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi meter 8 When a troubleshooting procedure instructs you to replace a non spared component and that component is part of a parent assembly you should replace the entire parent assembly Voltage Measurements Power and signal grounds are connected to the frame ground All circuit troubleshooting can be performed using the metal frame chassis as the grounding point To locate connectors or test points refer to the section Plug Jack Locator Maps on page 341 or Wiring Diagrams on page 351 for more information Unless otherwise specified the following
185. ns le R glement sur le brouillage radio lectrique dict par le ministere des Communications du Canada NMB 003 Declaration of Conformity Xerox Corporation declares under our sole responsibility that the printer to which this declaration relates is in conformity with the following standards and other normative documents viii Phaser 6200 Color Laser Printer Service Manual In the European Union following the provisions of the Low Voltage Directive 73 23 EEC and its amendments EN 60950 IEC 950 Safety of Information Technology Equipment including Electrical Business Equipment following the provisions of the Electromagnetic Compatibility Directive 89 336 EEC and its amendments EN55022 1998 CISPR 22 Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment Class B EN61000 3 2 1995 A1 1998 A2 1998 IEC61000 3 2 Part 3 Limits Section 2 Limits for harmonic current emissions equipment input current less than or equal to 16A per phase EN61000 3 3 1995 IEC61000 3 3 Part 3 Limits Section 3 Limitation of voltage fluctuations and flicker in low voltage supply systems for equipment with rated current less than or equal to 16A EN55024 1998 CISPR 24 Information technology equipment Immunity characteristics Limits and methods of measurement CISPR 24 Immunity Phenomena Basic Standard Tes
186. nsor is lower than the reference value from the toner density control then the admix mode is generated LED Light Density CTD ADC Control of Sensor The CTD ADC sensor is a reflective sensor that emits light from an LED in the sensor and detects the reflected light from the transfer roller For exact density measurement the sensor output value reflected light density must be the specified value when no toner is put on the Transfer Roller The reflected light density varies depending on the Transfer Roller surface condition or dirty condition of CTD ADC sensor surface The light density emitted from the LED is controlled so that the reflected light density meets the specified value This control is implemented in two ways 1 Sets the light density so that the light reflected satisfies a specific value 2 Adjusts the subsequent light density to be within a specific tolerance value 1 Light Density Setting The reflected light density can vary greatly if the transfer roller has been replaced or the CTD ADC sensor has been cleaned To deal with this variance the light density is reset when the power is turned on or the front cover is opened and closed The intensity of the LED increases gradually and the set value is adjusted when the output of the CTD ADC sensor exceeds the specified value If the output of the CTD ADC sensor does not reach the specified value even though the light density is increased to the maximum limit the
187. o to step 14 voltage between P J61 6 lt gt P J61 5 on the Motor Driver Board is 3 3 VDC 14 Check the LVNC Harness for continuity See DC Power Replace the Main Wiri Supply Harness LVNC See Main Wiring Diagram on page 352 Troubleshooting PL 13 11 on page 88 15 Check the DRV 1 Harness for continuity Replace in the Replace the See Drive Section on page 355 following order DRV 1 Harness Assembly Main Drive PL 13 14 Assembly RRP wees 11 3 Engine Control Board RRP 12 7 16 Perform steps 1 through 3 in RRP 3 1 Go to step 19 Go to step 17 Open and close the front door Observe the Turn Roller Dose the Turn Roller turn while the machine is warming up 17 Using service diagnostics test the MPT Check the Clutch Go to step 18 Turn Clutch for slip or the gear Does the Turn Clutch Assembly function for damage normally Replace if In the test actuate the Interlock switch necessary 38 Phaser 6200 Color Laser Printer Service Manual Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 18 Remove the clutch connector J19 Replace the Replace the A PRN Engine Control MPT Turn Check the following pins Board RRP 12 7 Clutch RRP Is J19 1 lt gt J19 2 less than 2009 3 13 19 Does the Feed Gear in the MPT turn Check parts for Go to step 20 when printing 1 sheet of paper damage or obstructions in the paper path 20 Use service diagno
188. oard to Engine Control Board 3 Is the error cleared after replacing the Complete Replace the Image Processor Board Engine Control Board See note above RRP 12 7 Engine NVRAM Error Code 83 Engine NVRAM is being corrupted or receiving erroneous data from a CRUM Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Cycle power to the printer Go to step 2 Complete Does the error still appear 2 Perform the troubleshooting procedure on Complete Go to step 3 page 71 for codes 45 amp 46 Did this resolve the problem 3 Perform the troubleshooting procedure Complete Replace the Code 75 Imaging Unit Firmware Engine Control Failure on page 77 Board RRP 12 7 Did this resolve the problem 78 Phaser 6200 Color Laser Printer Service Manual Non Xerox Imaging Unit Code 95 A non Xerox Imaging Unit has been detected in the printer Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Laser Unit on page 359 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Is the Imaging Unit the correct Xerox part Go to step 2 Have customer numbered Imaging Unit order the correct consumable 2 Check the Imaging Unit for defects or Replace the parts Go to step 3 possible damage concerned 3 Does replacing the Imaging Unit fix the Complete Go to
189. olor Laser Printer Service Manual POST Diagnostics Test Descriptions POST Diagnostics Test Descriptions Test Fault Description Code SDRAM 1 Hard This test fails if the boot loader finds no RAM present or faulty RAM Boot loader posts the message RAM error to the front panel and blinks the front panel LED I O ASIC 2 Hard This test determines if the I O chip is functioning properly Local Bus 3 Hard Performed during the POST firmware initialization Front Panel phase If the front panel is unplugged a hard fault is indicated by the heath LED P Button 5 Hard This test checks to see if the i button Configuration configuration chip is present If no chip is present the Chip test will fail and the front panel message Please Install i button will display EEPROM 10 Hard This test checks addressing of the EEPROM Ethernet 11 Hard This test checks the ethernet core CPU Interrupts 12 Hard This test checks that each interrupt source to the CPU is functioning USB 13 Hard This test checks that the USB core is functioning properly Real Time Clock 14 Soft The real time clock is tested RAM DIMM 15 Soft This test examines bad or incompatible RAM Presence DIMMs RAM Limits 16 Soft Checks that there is at least 128 Mbytes installed and ignores more than 512 Mbytes IDE Disk 20 Soft Checks the disk controller core and runs a DIAGNOSE c
190. olor Laser Printer Service Manual Removal 1 Remove the Right and Left Tray Guide Assemblies RRP 14 8 and RRP 14 9 2 Remove the Link Actuator RRP 14 10 3 Remove the 2 screws securing the Paper Pick Assembly to the right side of the HCF frame 4 Release 2 tabs on the Paper Pick Assembly from the 2 slits and window on the left side of the HCF frame 5 Disconnect P J824 P J8220 and P J825 6 Remove the Paper Pick Assembly through the window Note When removing or replacing the the screws be careful not to damage the Gear or Spring with the screwdriver When passing the Paper Pick Assembly through the window be careful not to damage the rubber parts FRU Disassembly Removal and Replacement Procedures 249 RRP 14 12 Idler Gear PL14 5 6 6200 210 Removal 1 Remove the Tray 3 Guide Assembly Right and Left RRP 14 8 RRP 14 9 2 Remove the Link Actuator RRP 14 10 3 Remove the Paper Pick Assembly for Tray 3 RRP 14 11 4 Remove the Gear Idler Note When replacing the larger side of the gear must face the HCF frame 250 Phaser 6200 Color Laser Printer Service Manual RRP 14 13 No Paper Low Paper Sensor PL14 5 7 6200 211 Remove Remove the Paper Trays Remove the Cover Front RRP 14 1 Remove the Cover Right RRP 14 2 Remove the Chute Assembly Turn Remove the Indicator Assembly RRP 14 7 Remove the Bracket Low Paper upp
191. ommand on the hard drive Engine Command 22 Hard Memory 24 Hard This test checks 64 bit reads and writes to memory Troubleshooting 85 Power Supply Low voltage Power Supply Overcurrent Protection Circuit This circuit stops all outputs if the 24 VDC 5 VDC or 3 3 VDC power supply is shorted The circuit is reset when the short is removed the power is turned off and then on again Low voltage Power Supply Overvoltage Protection Circuit This circuit stops all outputs if the 24 VDC 5 VDC or 3 3 VDC power supply exceeds the specified voltage The operating point is 32 VDC or more for 24 VDC 7 VDC or more for 5 VDC or 6 VDC or more for 3 3 VDC Fan Output Circuit For the Fan Rear ON H signal the output voltage varies depending on the status of FAN LOW signal and FAN STOP signal 24 VDC Output Stopped By Interlock Switch Opening Door A B or C deactivates the front cover interlock switch This shuts off the 24 VDC supplied by the Motor Driver Board to the motors clutches and solenoids Outline of Paper Size Switch Assembly Paper size and tray installation is determined by a combination of ON OFF statuses of the upper middle and lower switches of the Switch Paper Size Assembly Paper size LEGAL14 eee ooo for eas CL e we o p LETTER OFF A5 for reference only supported in the MPT only OFF JON ON 86 Phaser 6200 Color Laser Printer Service Manual Front Panel and Printer Malfunct
192. ons Yes No 1 Fill the MPT with paper Go to step 2 Complete Does the error occur even if the MPT is full 2 Check the following for evidence of fault Replace the parts Go to step 3 or damage concerned MPT No Paper Sensor PL 6 1 4 MPT Actuator PL 6 1 37 3 Use service diagnostics to test the MPT Replace Engine Go to step 4 No Paper Sensor Control Board Does the Sensor function correctly RRE 127 4 Replace the MPT No Paper Sensor Go to step 5 Complete Does the error recur after the MPT No Paper Sensor was replaced 5 Troubleshoot using the wiring diagram Complete Replace Engine Paper Feed on page 362 Control Board RRP 12 7 Does the problem recur if any defective parts are replaced Error Messages and Codes 63 Tray 1 Empty Load Paper The printer s front panel displays Tray 1 Empty Load Paper when the tray is full The tray 1 cavity is free of debris and obstructions The tray is free of defects and is properly positioned within the printer Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References No Paper Sensor PL 3 3 4 Paper Tray 1 on page 354 Link Actuator PL 3 3 6 No Paper Actuator PL 3 3 5 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Fill Tray 1 Go to step 2 Complete Does the error occur even if the tray is full 2
193. ons and Questions Yes No 1 Check the Fuser Fan for evidence of fault Replace the Fuser Go to step 2 or damage Fan RRP 1 3 2 Does an error recur after the Fuser Fan Replace the Go to step 3 has been replaced Engine Control 3 Does the error recur after the Motor Go to step 4 Driver Board has been replaced Complete 4 Troubleshoot using the wiring diagram Complete Drive Section on page 355 Replace any defective parts Does the printer function correctly after replacing any defective parts Go to step 5 5 Print one sheet Replace the DRV2 Verify the voltage between P J12 4 lt gt P J12 17 on the Engine Control Board is 3 3 VDC PL 13 1 3 Harness Assembly Replace the Engine Control Board RRP 12 7 Error Messages and Codes 73 Rear Fan Failure Code 51 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Rear Fan PL 12 1 2 Main Wiring Diagram on page 352 Low Voltage Power Supply PL 12 1 10 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the Rear Fan for evidence of fault Replace the Rear Go to step 2 or damage Fan RRP 12 4 2 Does an error occur after the Rear Fanis Go to step 3 Complete replaced 3 Replace the Low Voltage Power Supply Go to step 4 Complete Board Does the error recur after the LVPS is replaced 4 Troubleshoot using the wirin
194. ont d Toner M Life Yellow Toner Y Life Transfer Roller Life and record the va Test Front Panel Display and Test Definition Black Toner Resets the CRU Life Count to 0 K Life Confirmed Reset Note Record the current value in Cyan Toner lt if successful gt the CRU Life Read Menu prior to C Life resetting the valure to 0 Caution This function is for Magenta Uncontinmed Reset troubleshooting ONLY lt if unsuccessful gt Note The primary life tracking device for the transfer roller is the clear plastic window in the transfer roller CRU Life Read The following options are available for CRU Life Read Perform this operation lues prior to performing a CRU Life Res Do NOT attempt to extend the life of the CRU Doing so may cause print quality problems or premature failure of other internal printer components et Black Toner K Life Count XXX Cyan Toner C Life Record this value Magenta Toner M Life Yellow Toner Y Life Transfer Roller Life Displays the current CRU Life count Read Printer Page Count CRU Life Resto Count XXXX re The following options are available for CRU Life Restore Reads engine printer life count Record this value before replacing the Engine Control Board Black Toner K Life Count XXXX Cyan Toner C Life Up Dn to Incr Decr Help Back to Select Multiplier Magenta Toner
195. ontact RRP 12 6 3 Remove the 4 screws securing the Cover Engine Control Board from the Box Asssembly FRU Disassembly Removal and Replacement Procedures 231 S6200 166 4 Disconnect all 9 connectors on the Engine Control Board from the Card Cage 5 Remove the 6 screws securing the Engine Control Board to the Card Cage and remove the board Observe proper ESD procedures when removing any Caution circuit board from the printer Replacement Note The NVRAM must be moved over to the new board Re install the Engine Control Board prior to installing the Chute Assembly Registration and the Housing Assembly Bias to prevent damaging the bias springs Note 232 Phaser 6200 Color Laser Printer Service Manual RRP 12 8 Image Processor Board PL12 1 4 6200 189 Removal Caution Observe proper ESD procedures when removing any khOD circuit board from the printer Turn the printer power off Disconnect any cables attached to the Image Processor board Loosen the 2 thumb screws securing the Image Processor board to the printer Holding both knobs on the Image Processor board pull the board straight out from the printer to remove Replacing the Board The following items MUST be moved from the original Image
196. ot be reported to the controller Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Laser Unit PL 9 1 1 Laser Unit on page 359 Troubleshooting Procedure Table Does the printer function correctly if the harness is reseated Steps Actions and Questions Yes No 1 Check and reseat P J151 on the Laser Complete Go to step 2 Unit page 359 2 Does the error recur after the Laser Unit Go to step 3 Complete has been replaced 3 Check the Laser ROSKA Harness Replace the Replace the ROSKA for continuity or damage ROSKA Harness Engine Control See the wiring diagram Laser Unit on ae Board RRP 12 7 68 Phaser 6200 Color Laser Printer Service Manual Density Sensor Failure or Low Density Failure Code 12 An error was detected in the toner dispense system Code 13 14 15 An error was detected in the Density Sensor Code 16 This is a generic density sensor error that is generated when a code 12 13 14 or 15 is not specifically triggered Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References CTD ADC Sensor Assembly PL 5 1 11 Xerographics 1 on page 360 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Clean the CTD ADC Sensor to remove Complete Go to step 2 any toner build up Does this fix the problem 2 U
197. ove the Chute Assembly Exit RRP 7 1 Release the tab securing the Gear Roll and remove the Gear Remove the bearing from the left side of the shaft Remove the e ring and bearing securing the right side of the shaft Raise the right side of the shaft and pull out the Mid Roll akhwhd FRU Disassembly Removal and Replacement Procedures 189 RRP 7 4 Duplex Motor Assembly PL 7 1 8 G48 6200 132 Removal 1 Remove the Chute Assembly Exit RRP 7 1 2 Rotate Gear 48 to access 1 screw securing the Duplex Motor Assembly to the Chute Assembly Exit then remove the other screws 3 Remove the Duplex Motor Assembly from the Chute Assembly Exit 190 Phaser 6200 Color Laser Printer Service Manual RRP 8 1 Exit Actuator Fuser PL 8 1 7 6200 137 Removal 1 2 3 4 Remove the Fuser Assembly Remove the bearing from the left side of the Fuser Exit Roller and move the exit roller slightly out of the way Slide the Exit Actuator left Remove the Actuator Spring FRU Disassembly Removal and Replacement Procedures 191 RRP 8 2 Strap PL 8 1 13 6200 141 Removal 1 Open Door B 2 Turn the top of the strap 90 degrees and remove 192 Phaser 6200 Color Laser Printer Service Manual RRP 9 1 Laser Unit PL 9 1 1 6200 142 Removal 5 6 1 Remove the Toner Cartridge Holder Assembly Unit RRP 10 1 2 Remove the Rear Fan RRP 12 4
198. paper is in good condition and is the correct type for the printer See Media and Tray Specifications on page 14 for the correct media types sizes and weights for each tray Ensure the printer is within its operating environmental specifications Ensure that the loaded media matches the front panel settings Is the jam caused by a heavy stiff paper being used for two sided printing In such cases a lighter grade of paper should be used see the printer s Paper Tips Page Clean all exit locations in the Fuser and the Assembly Chute Exit with a clean dry lint free wipe if debris is visible Does the Exit Roller turn Test the Duplex Motor using service diagnostics For information on service diagnostics see Service Diagnostics on page 23 See Jam at Duplex Jam D on page 33 for troubleshooting duplex jams if the Duplex Motor test fails Troubleshooting 9 Operating System and Application Problems Print an internal test print from the printer s front panel to ensure the problem is not printer related See Using the Print Engine Only Test Print on page 96 Troubleshooting tips and more information are also available on the Xerox web site at www xerox com officeprinting support Macintosh printing problems Image never prints Printer acts as if it is receiving data but nothing comes out of the printer or it goes back to Ready mode without printing The most likely cause is a Po
199. part of 99 20 116 1363 00 1 Assembly Roll Turn 21 3 Bearing Black NS 22 1 Shaft Feed 2 NS 23 116 1331 00 2 Paper Feed Roller Kit 2 interchangeable rollers per order 24 116 1366 00 1 Assembly Harness Feeder J47 J471 J472 J473 P474 P475 99 116 1367 00 1 Paper Feed Gear Kit with 8 11 15 and 19 FRU Parts List 265 PL 4 1 Housing Assembly Retard V i with 2 13 Phaser 6200 Color Laser Printer Service Manual 266 PL 4 1 Assembly Housing Retard FRU Parts List Table ID No Part Number Qty Name Description 116 1368 00 1 Assembly Housing Retard with 2 13 1 Roll Turn NS Shaft Retard NS 116 1370 00 Assembly Friction Clutch 116 1371 00 Assembly RetardRoll Holder Retard NS Housing Retard NS Bearing NS OO CO NI OD oO A WwW N 116 1374 00 Turn Clutch oO Stud Retard NS Spring Retard 370 NS N Cap Retard NS wo Bearing Ground NS FRU Parts List 267 PL 5 1 Chute Assembly In P5030 V 1 with 2 30 3 2 y P5020 Ss wap Fi Hey Toe yyy ee r BiG TE Ly a Dr TE Eg 2 6200 233 268 Phaser 6200 Color Laser Printer Service Manual PL 5 1 Chute Assembly In FRU Parts List Table
200. per and then insert into the tray or ONOvW flip existing paper over Check the tray s retard roller for damage Clean the pick rollers with a clean dry lint free wipe Replace the paper pick rollers Replace the paper tray Mis pick 1 Check that the correct type of media is being used 2 3 4 5 Ensure that the tray has not been over filled Try loading paper from a fresh ream fan the paper and then insert into the tray or flip existing paper over Clean the pick rollers with a clean dry lint free wipe Troubleshoot the paper pick roller assembly Skewed image The image area is not parallel with the sides of the page but the printer neither jams nor displays an error code ONnd ou Remove the tray and ensure the paper guides are set correctly Check that the correct type of media is being used Ensure that the tray has not been over filled Skewed images are a common defect when the MPT is filled too high Verify the paper pick rollers are installed correctly Clean the pick rollers with a clean dry lint free wipe Troubleshoot the paper pick roller assembly Phaser 6200 Color Laser Printer Service Manual Damaged prints The printed page exits the printer either wrinkled creased or torn The printer neither jams nor displays an error code 1 2 5 Stop the page at various points in the paper path to determine where the media becomes damaged See Pape
201. r Service Manual Blank Page FRU Disassembly Removal and Replacement Procedures 153 RRP 3 10 No Paper Actuator PL3 3 5 No Low Paper Sensor PL3 3 4 REAR 6200 091 6200 092 154 Phaser 6200 Color Laser Printer Service Manual Removal Actuator 1 Remove the Paper Feeder Unit Assembly RRP 3 2 2 Remove the Paper Pick Assembly RRP 3 3 and turn it upside down 3 Release the hook securing the No Paper Actuator to the Paper Pick Assembly and extract the left end of the shaft 4 Pull the No Paper Actuator out and up to remove Removal No Paper Sensor 5 Remove the right Paper Pick Roller to gain access to the P J472 blue 6 Disconnect P J472 blue from the No Paper Sensor 7 Lift up on the clear plastic lock to release 3 tabs securing the No Paper Sensor to the Paper Pick Assembly and remove the No Paper Sensor 6200 094 Removal Low Paper Sensor 8 Disconnect P J473 yellow on the Low Paper Sensor 9 Release 3 tabs securing the Low Paper Sensor to the Paper Pick Assembly and remove the sensor Note The sensors are interchangeable FRU Disassembly Removal and Replacement Procedures 155 RRP 3 11 Link Actuator PL3 3 6 6200 093 Note Perform this procedure from the rear of the printer Removal 1 Pull the paper tray out of the printer 2 Remove the paper tray Rear Cover 3 Reach in through the rear of the printer and spread the tabs of t
202. r Top Stopper NS 99 116 1329 00 1 Tray MPT with 26 and 27 FRU Parts List 257 PL 2 1 Universal Paper Tray N s 2 gt 6200 229 Phaser 6200 Color Laser Printer Service Manual 258 PL 2 1 Tray Univeral Paper FRU Parts List Table ID No Part Number Qty Name Description 1 116 1330 00 1 Universal Paper Tray with 2 6 2 116 1331 00 2 Paper Feed Roller Kit 2 interchangeable rollers per order 3 116 1332 00 1 Assembly Friction Clutch 4 1 Holder Retard NS 5 116 1334 00 1 Spring Retard 6 1 Cover Front Tray NS FRU Parts List 259 PL 3 1 Paper Feed 6200 230 260 Phaser 6200 Color Laser Printer Service Manual PL 3 1 Paper Feed FRU Parts List Table ID No Part Number Qty Name Description 1 116 1335 00 1 Cover Feeder Front 2 116 1336 00 1 Assembly Turn Chute 3 116 1337 00 1 Cover Paper Tray Rear 4 116 1338 00 3 Block 1 per order 5 212 0237 00 4 Long Screw M3 x 85 Kit 2 per order FRU Parts List 261 PL 3 2 Paper Feed Il P2361 12 P810 7 6200 231 262 Phaser 6200 Color Laser Printer Service Manual PL 3 2 Paper Feed Il FRU Parts List Table ID No Part Number Qty Name Description 1 116 1340 00 1 Assembly Harness Temperature Humidity J231 J2361 2 116 1341 00
203. r Laser Printer Service Manual Missing Band Voids or Streaks in a Single Color or All Colors in Direction of Paper Travel There are areas of the image that are extremely light or missing entirely These missing areas form bands 6200 274 that run along the paper from the leading edge to the trailing edge in the direction of paper travel Step Check Yes No 1 Print the 600 x 600 test print and Replace the Image Go to step 2 evaluate the print Processor Board Are there defects in the print nae 2 Is the paper wrinkled dimpled or Complete Go to step 3 show any signs of having a high moisture content Is the problem resolved by loading fresh dry paper 3 Check for an obstruction in the laser Remove the Go to step 4 beam path between the Laser Unit obstruction or and the Imaging Unit debris Lay Imaging Unit on it s back with the IDT Rollers facing up and rotate the developer gears to remove any loose toner 4 Does the image quality improve if Replace the Go to step 5 the Imaging Unit is replaced Imaging Unit CRC PL 9 1 3 5 Check the Heat Roller and NIP Belt Replace the Fuser Go to step 6 in the Fuser Assembly for evidence Assembly PL 8 1 1 of contamination or damage 6 Does the imaging quality improve if Replace the Go to step 7 the Transfer Roller is replaced Transfer Roller CRC PL 8 1 12 7 Does the image quality improve if Replace the L
204. r Path Route on page 315 for more information Try using the next heaviest type of paper For more information print the Paper Tips Page from the printer s Printable Pages Menu Feed paper through the printer from each of the available trays Is the paper damaged when fed out of one tray but not when fed out of the others If so inspect the tray for damage ensure that the media guides are set correctly and verify that the proper media is being used Feed paper from the MPT Is the paper damaged when fed out of MPT Inspect the MPT for debris or obviously broken components that could be damaging the paper as it feeds out of the assembly and into the printer Inspect the paper tray for debris or broken components Fuser jams 1 OONOaRW ND Ensure the paper is in good condition and is the correct type for the printer See Media and Tray Specifications on page 14 for the correct media types sizes and weights for each tray Ensure only Phaser 6200 Transparency film is being used Check that the printer is operating within its environmental specifications Ensure that the loaded media matches the front panel settings Are the margins on the page greater than 5 mm Check the Fuser area for debris Visually inspect the Fuser baffle for burrs Test the fuser motor using service diagnostics See Jam at Fuser Jam F on page 31 for troubleshooting Fuser Jams Exit jams 1 AON Ensure the
205. r Replace or reinstall Go to step 2 Assembly and Transfer Roller for the affected correct installation damage or component contamination and life remaining 2 Does the image quality improve if Complete Go to step 3 the Imaging Unit is replaced 3 Check the Heat Roll and NIP Belt for Replace the Fuser Go to step 4 evidence of damage or Assembly CRC contamination See Transfer Roller PL 8 1 1 and Fuser Assembly on page 331 4 Does the image quality improve if Complete Go to step 5 the Transfer Roller is replaced 5 Check the Front 1A Harness for Go to step 6 Replace the defective continuity wire P J5030 lt gt Transfer roller P J5020 lt gt Transfer roller 6 Does the image quality improve if Complete Go to step 7 the Laser Unit is replaced 7 Does the image quality improve if Complete Go to step 8 the SUB HVPS is replaced 8 Check the FRONT 1A Harness for Replace the Engine Replace the Front 1A continuity Control Board RRP 12 7 Harness Assembly PL 13 1 7 Troubleshooting 97 Light Print in Only One Color Only one color yellow magenta cyan or black is too light on the printed image The test print 6200 272 is 80 coverage Verify the media used is supported by this printer See Media and Tray Specifications on page 14 for the correct media types sizes and weights for each tray Verify the media settings are correct at the front panel a
206. r Unit is an exposure unit that generates the laser beams to form an electrostatic latent image on the surface of the drum The Laser Unit Assembly consists of the following parts LD Assembly Scanner Assembly SOS Board Lens Mirror Window 3 Chute Assembly Registration See Chute Assembly Registration REGI on page 330 Theory of Operation 333 Imaging Unit Charge Voltage Contacts 8 6200 290 Printer shown with the Imaging Unit removed Charge Voltage Developer Voltage IDT2 Voltage IDT2 Refresher Cleaner IDT1 Voltage IDT1 Refresher Cleaner Drum Refresher Cleaner oN O aA Fk WO N Drum Ground Contacts 334 Phaser 6200 Color Laser Printer Service Manual Gir 7 g e EDIPE N CU TEES i OC Ee Se H DA SO SA De Cd 2 H 7 6 5 i 6200 290 Imaging Unit Left Side View IDT2 IDT2 Refresher Cleaner IDT1 IDT1 Refresher Cleaner Drum Refresher Cleaner Developer N Own BP WRN Charge Roll Theory of Operation 335 Toner Cartridge Assembly 6200 047 1 Sub High Voltage Power Supply Board Supplies high voltage to the Transfer Roller and the Detack Saw for the tertiary transfer and static elimination part of the printing process 2 3 4 5 Toner Cartridge Present Switch CTG In Y M C K Detects if the Toner Cartridge
207. re of this manual Chapter 1 General Information This chapter contains a general overview of the printer and basic information regarding printer specifications Chapter 2 Error Messages and Codes Information regarding front panel error codes and image processor diagnostics and fatal messages in tabular form Chapter 3 Troubleshooting This chapter discusses the most common troubleshooting problems encountered with Printer Performance Problems Image Quality Problems and Electrical Problems Chapter 4 Tests Adjustments and NVRAM This chapter provides information on how to use the service test prints color registration margin calibrations and resetting NVRAM to assist in analyzing and fine tuning printer performance Chapter 5 Cleaning and Maintenance A quick guide to routine cleaning and maintenance for the printer Chapter 6 FRU Disassembly Removal and Replacement Procedures RRPs This large chapter provides many procedures and illustrations for removing and replacing key Field Replaceable Units FRUs within the print engine Chapter 7 FRU Parts List This is the parts list for the Field Replaceable Units This chapter contains exploded views of the FRUs as well as part numbers for items available as FRUs x Phaser 6200 Color Laser Printer Service Manual Chapter 8 Theory of Operation This chapter covers the detailed processes for the printer s major assemblies switches and sensors drives and ge
208. rn ON the PostScript error handler through the front panel PostScript Error Info in the Support menu or CWIS and print the document again Take note of the information on the error page that just printed akhoND 92 Phaser 6200 Color Laser Printer Service Manual Network Problems The Phaser 6200 printer maintains 4 logs in memory detailing network functions The logs contain TCP IP NetWare and AppleTalk initialization events The logs can also be accessed remotely via CentreWare The logs list events chronologically The log is limited in length when the log is full the printer stops recording data to the log The logs are stored on the Hard Drive so only new data is stored each time the printer s power is cycled There is a Connection Setup Page Configuration Page and a network reset available for troubleshooting Network problems To print an Event Log Runtime Log or Configuration Page Enter normal Customer Mode From the main menu highlight Support Menu and press OK Scroll and highlight Network Questions and press OK Highlight the appropriate menu item from the list and select OK The page should now print akhoOND Troubleshooting 93 Print Quality Problems Print quality defects can be attributed to printer components consumables media internal software external software applications and environmental conditions To successfully troubleshoot print quality problems as many variables as po
209. rotate drive assemblies to inspect sprockets and gears Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running Servicing Fuser Components Warning This printer uses heat to fuse the toner image to a sheet of paper The Fuser Assembly is very hot Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components vii Regulatory Specifications Federal Communications Commission Compliance The equipment described in this manual generates and uses radio frequency energy If it is not installed properly in strict accordance with Xerox instructions it may cause interference with radio and television reception or may not function properly due to interference from another device However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiver device being interfered with m Increase the separation between the printer and the receiver Connect the printer into an outlet on a circuit different from that which the receiver is connected m Route the interface cables on the printer away from the
210. roubleshooting Reference Table Triage Parts Wiring and Plug Jack Map References Low Voltage Power Supply PL 12 1 10 Power Supply on page 353 AC Switch Harness Assembly PL 12 1 11 Drive Section on page 355 Troubleshooting Procedure Table Steps Action and Questions Yes No 1 Check the voltage at the AC wall outlet Go to step 2 Notify the Is there approximately 110VAC or Senate 220VAC if the printer is a 220V model at i be ee ih the AC wall outlet Ou Put mom ene outlet 2 Check the power cord for defects or a Replace or reseat Go to step 3 loose connection the power cord 3 Disconnect the Power Cord and turn the Replace the Replace the AC AC switch ON Low Voltage Switch Harness Check the AC Switch Harness for cee a continuity io eet See Drive Section on page 355 DC Power Supply Troubleshooting Troubleshooting Reference Table Triage Parts Wiring and Plug Jack Map References Low Voltage Power Supply PL 12 1 10 Power Supply on page 353 Troubleshooting Procedure Table Steps Action and Questions Yes No 1 Perform the AC power supply troubleshooting procedure first if this does not fix the problem go to step 2 2 Turn the AC power Switch OFF Replace the Go to step 3 Is the fuse F001 on the low voltage S power supply board open Board upPIy RRP 12 2 88 Phaser 6200 Color Laser Printer Service Manual
211. rrors Jam at Fuser Code Jam F 31 Jam at Duplex Code Jam D 33 Jam at Registration Roller Code Jam RR 35 Misfeed at MPT Code Jam TO 37 Misfeed at Tray 1 Code Jam T1 40 Misfeed at Tray 2 Code Jam T2 43 Misfeed at Tray 3 Code Jam T3 Door and Cover Errors Close Front Door 47 Consumable Errors Install or Reseat Imaging Unit 48 Replace Imaging Unit or Imaging Unit is at End of Life 49 Install or Reseat Transfer Roller 50 Replace Transfer Roller or Transfer Roller is at End of Life 51 Install or Reseat Fuser 52 Replace Fuser or Fuser is at End of Life 53 Install or Lock Y M C K Toner Cartridge 54 Replace Y M C K Toner Cartridge or Y M C K Toner Cartridge Empty 55 Dusty Density Sensor 57 Tray and Media Errors Output Tray is Full Unload Paper 58 Insert Tray 1 or Tray 1 missing 59 Insert Tray 2 3 or Tray 2 3 missing 60 Tray 1 Paper is Low 61 Tray 2 3 Paper is Low 62 MPT Empty Load Paper 63 Tray 1 2 3 Empty Load Paper 64 18 Phaser 6200 Color Laser Printer Service Manual Contents cont d Front Panel Message Media Mismatch Errors Load Tray 1 with size type Load Tray 2 3 with size type Front Panel Fatal Error Messages and Codes Laser Failure Density Sensor Failure or Low Density Failure Fuser Failure Fuser Fan Failure Rear Fan Failure Generic Fan Failure Engine Firmware Failure Imaging Unit Firmware Failure Fuser Firmware Failure Engine Firm
212. rs for During the test close the Interlock damage Switch Replace if necessary 18 Verify the voltage between P J47 13 lt gt Go to step 19 Replace the P J60 2 on the Motor Driver Board is 24 VDC Motor Driver Board RRP 12 3 Error Messages and Codes 41 19 Check the Feeder Harness for continuity Go to step 20 Replace the Feeder Harness Assembly PL 3 3 24 20 Remove the clutch connector J475 Go to step 21 Replace the gt Paper Pick 1 lt f Is J475 1 lt gt J475 2 less than 20097 Assembly PL 3 3 1 21 If possible print one sheet of paper Check parts for Go to step 22 Did the paper attempt to feed damage or i obstructions in the paper path 22 Use service diagnostics to test the Tray 1 Check the spring Go to step 23 Feed Solenoid and stopper on the Does the solenoid actuate Feed Solenoid During the test actuate the Interlock Switch 23 Verify the voltage between P J47 11 lt gt Go to step 24 Replace the P J60 2 on the Motor Driver Board is Motor Driver 24 VDC Board RRP 12 3 24 Check the Feeder Harness for continuity Go to step 25 Replace the Feeder Harness Assembly PL 3 3 24 25 Remove the Solenoid connector J474 Go to step 26 Replace Feed 2 Solenoid PL Is J474 1 lt gt J474 2 less than 1009 3 3 17 26 Check the DRV2 Harness for continuity Replace the Replace the Engine Control DRV2 Harness Board RR
213. s assemblies drain the electrostatic charge from your body This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source Wearing a wrist strap will also prevent accumulation of additional bodily static charges Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surface If the anti static bag is conductive you may ground the bag and use it as a conductive surface Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices Do not remove a replacement component or electrical sub assembly from its protective package until you are ready to install it Immediately before removing the protective material from the leads of a replacement device touch the protective material to the chassis or circuit assembly into which the device will be installed Minimize body motions when handling unpackaged replacement devices Motion such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro statically sensitive device Handle IC s and EPROM s carefully to avoid bending pins m Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards PCB s Service
214. s lower than the specified value If the output of the CTD sensor is greater than the specified value then the controller senses installation If the output is less than the specified value the controller senses the transfer roller is not installed Detecting the Life of the Transfer Roller Assembly The Transfer Roller Assembly consists of a bias transfer roller and a waste toner recovery system End of life of the Transfer Roller is detected when the toner recovery space becomes full The full toner recovery space is detected by the Toner Full Sensor 1 Timing check for a full waste toner recovery space is m When the power is turned on m When the front cover is opened and closed m When paper exits the print engine 2 Transfer Roller is at End of Life error message is received when the toner full sensor detects the toner recovery space is full 3 Replace Transfer Roller warning message is received if the print count and the toner dispense time are counted and the total count exceeds 15 000 prints Theory of Operation 311 Toner Control Toner Cartridge installation is detected by the Toner Present CTG In Switch and the presence of toner is detected by the Toner Low Sensor These switches and sensors are provided for each respective color CMYK and detection is made for each individually Toner Low Sensor The toner low sensor checks one color every 3 5 seconds requiring 14 seconds to detect all four colors
215. sage Profile Report if the printer is able to print View the fault history under the Service Tools Menu Verify the AC input power supply is within proper specifications by measuring the voltage at the electric outlet while the printer is running Step 2 Inspect and Clean the Printer IAUN 7 8 Switch OFF printer power Disconnect the AC power cord from the wall outlet Verify the power cord is free from damage or short circuit and is connected properly Remove the Imaging Unit and protect it from light Inspect the printer interior and remove any foreign matter such as paper clips staples pieces of paper dust or loose toner E Do not use solvents or chemical cleaners to clean the printer interior E Do not use any type of oil or lubricant on printer parts E Use only an approved toner vacuum Clean all rubber rollers with a lint free cloth dampened slightly with cold water and mild detergent Inspect the interior of the printer for damaged wires loose connections toner leakage and damaged or obviously worn parts If a toner cartridge appears obviously damaged replace with a new one Step 3 Find the Cause of the Problem 1 oa AON Use the Error Messages and Codes and troubleshooting procedures to find the cause of the problem Use Diagnostics to check printer and optional components Use the Wiring Diagrams and Plug Jack Locator to locate test points Take voltage readings at various test points
216. sage still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References CTD ADC Sensor Assembly PL 5 1 11 Xerographics 1 on page 360 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Clean the CTD Sensor to remove any Complete Go to step 2 toner build up Does this fix the problem 2 Check the following for evidence of fault Replace the parts Go to step 3 or damage concerned Transfer Roller Assembly PL 8 1 12 CTD ADC Sensor Assembly PL 5 1 11 3 Is the CTD ADC Harness connected to Go to step 4 Replace the the CTD ADC Sensor and functioning parts correctly concerned 4 Replace the CTD ADC Sensor Go to step 5 Complete Does the error still appear after replacing the sensor 5 Check the CTD ADC Harness for Go to step 6 Replace the continuity CTD Harness Assembly See Xerographics 1 on page 360 PL 5 1 10 6 Check the Front 1A Harness for Go to step 7 Replace Front continuity 1A Harness See Xerographics 1 on page 360 Ree 7 Verify the voltage between P J1361 1 Replace the CTD Replace Engine lt gt P J1361 3 on the CTD Harness is ADC Sensor Control Board 0 VDC Assembly PL RRP 12 7 5 1 11 Error Messages and Codes 37 Output Tray is Full Unload Paper The printer s front panel displays Output Tray is Full Unload Paper The output tray has be
217. se service diagnostics to test the ADC Go to step 4 Go to step 3 Sensor Does the sensor function correctly 3 Does the error recur after the CTD ADC Go to step 4 Complete Sensor has been replaced 4 Check the following for evidence of fault Replace the parts Go to step 5 or damage concerned Transfer Roller Assembly PL 8 1 12 Imaging Unit PL 9 1 3 5 Does the error recur after the Laser Go to step 6 Complete windows have been cleaned with a dry lint free cloth 6 Replace the Laser Unit Go to step 7 Complete Does the error still occur 7 Troubleshoot using the wiring diagram Complete Go to step 8 Xerographics 1 on page 360 Does the printer function correctly after replacing any defective parts 8 Replace the Transfer Roller Assembly Replace the Complete Engine Control Does the error still occur Board RRP 12 7 Error Messages and Codes 69 Fuser Failure Code 40 The temperature sensor sensed an overheat condition Code 41 The temperature sensor sensed a low temperature condition Code 43 Warm up failure the temperature sensor does not detect the correct temperature within 60 4 seconds after the fuser lamp has been turned on Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Low Voltage Power Supply PL 12 1 10 Fuser Assembly on page 358 FSR 2 Harness Assembly PL 5 1 9 Troubleshooting Procedure Table
218. sembly RRP 3 1 Remove the Link Actuator RRP 3 11 On the right side of the printer disconnect P J2361 gray from the Printer Chassis 10 On the left side of the printer disconnect P J210 yellow from the Printer Chassis 11 Disconnect P J47 yellow blue from the Motor Driver Circuit Board on the right side of the printer OONOARWD 142 Phaser 6200 Color Laser Printer Service Manual 12 Remove the 8 short screws securing the Printer Chassis item 1 to the Paper Feeder Assembly item 2 Note It is easy to strip the long screws use caution when removing and replacing 13 Using a PZ1 Posi bit remove the 4 long screws securing the Printer Chassis to the Paper Feeder Unit Assembly 14 Using a large screwdriver handle prop up the right side of the printer chassis in order to clear the wiring harnesses in the following steps 15 Shift the harness P J24 gray from the square hole on the bottom plate 16 Shift the harness P J210 yellow and P J47 yellow blue through the square hole on the bottom plate Caution Lift the printer chassis unit off the Paper Feeder Assembly by placing your hands into the front and back cavity of the paper tray The right and left sides of the printer chassis are extremely sharp 17 Remove the screwdriver being careful not to pinch the wires and lift the entire printer chassis off the Paper Feeder Unit Assembly Replacement 1 Replace in reverse order of removal Note Whe
219. sembly item 7 7 Release the tab securing the Toner Cartridge Holder Assembly Y M C K to the Plate Dispenser item 8 and slide the Toner Cartridge Holder to the right to remove 6200 150 FRU Disassembly Removal and Replacement Procedures 207 RRP 10 3 Toner Present Switch PL 10 1 18 I LEFT lt S6200 156 Removal 1 Remove the Toner Holder Cartridge Unit RRP 10 1 2 Remove the Holder Toner Cartridge Assembly of the relevant color RRP 10 2 3 Remove the Toner Cartridge for the relevant color Note Rotate the Toner Holder Assembly with the switch facing up before removing the switch to prevent toner spills 4 Carefully pry the tabs securing the Toner Present Switch Assembly with a small screwdriver and remove the switch 208 Phaser 6200 Color Laser Printer Service Manual RRP 10 4 Toner Low Sensor PL 10 1 8 ZS 1 0029S Removal 1 Remove the Toner Holder Cartridge Assembly Unit RRP 10 1 2 Remove the Holder Toner Cartridge Assembly of the relevant color RRP 10 2 Note Rotate the Toner Holder Assembly with the sensor face up before removing the sensor to prevent toner spills 3 Remove the 2 screws securing the Low Toner Sensor to the holder and remove the sensor FRU Disassembly Removal and Replacement Procedures 209 RRP 10 5 EEPROM Board PL 10 1 16 LEFT 6200 158 Removal 1 Remove the Left Side Cover RRP 1 6
220. sferred onto the surface of the IDT1 intermediate Drum Transfer 1 intermediate transfer roll 1 There are two IDT1 s one for yellow and magenta and one for cyan and black 5 Secondary Transfer IDT 1 gt IDT 2 The toner image formed on both IDT 1 surfaces are then transferred onto the surface of IDT 2 to create a 4 color toner complete image 6 Cleaning Toner remaining on both IDT 1 s after the image transfer to IDT 2 is temporarily stored in the IDT 1 cleaner 7 Tertiary Transfer The finished toner image on IDT 2 is transferred onto the print media using the voltage supplied by the transfer roller 8 Cleaning Toner remaining on IDT 2 after transfer is temporarily stored in the IDT 2 cleaner 9 Static Elimination Negative DC voltage is applied to the back side of the print media by the Detack Saw located on the Transfer Roller Assembly to neutralize and eliminate the charge to the print media 10 Fixing Toner is fused onto the print media by the Fuser Assembly using heat and pressure 11 Cleaning During the general cleaning process the voltage from the IDT rollers and drums go through a cycle of changes to move the negative and positive charged toner from IDT1 then IDT2 and then the transfer roller The toner stored in the IDT 1 cleaner the IDT 2 cleaner and on the transfer roller is removed and deposited into the transfer roller waste recovery bin 302 Phaser 6200 Color Laser Printer Service Manual
221. ssembly and pans the Feed Roller on Tray 1 Check Tray 1 for damage Remove any foriegn objects or debris in the paper path Registration Sensor PL 9 1 8 Main Drive Assembly PL 11 1 14 2 Use service diagnostics to test the Go to step 6 Go to step 3 Registration Sensor Does the sensor function normally 3 Check that the connection between the Go to step 4 Connect or Harness and the Registration Sensor is replace the properly connected and seated faulty part 4 Check the Registration Clutch Harness Go to step 5 Replace the for continuity Registration Chute See Paper Feed on page 362 Assembly RRP 9 3 5 Is the voltage between P J18 3 lt gt Replace Go to step 6 P J18 2 located under the electric Registration housing assembly see RRP 9 3 on the Sensor RRP 9 4 Engine Control Board is 0 VDC 6 If possible print a sheet of paper from Go to step 16 Go to step 7 Tray 1 Does the Main Drive Motor function properly 40 Phaser 6200 Color Laser Printer Service Manual 7 Use service diagnostics to test the Main Replace the Go to step 8 Drive Motor Engine control Does the Main Drive Motor turn Board RRP 12 7 8 Verify the voltage between P J48 1 lt gt Go to step 12 Go to step 9 P J60 2 on the Motor Driver Board is 24 VDC 9 Use service diagnostics to test the Go to step 10 Replace the Interlock Switch Motor Driver Does the Inter
222. ssembly heater Generates and supplies stable low voltage DC power to be used for the logic circuits etc 6 AC Switch Harness Assembly Consists of the main switch and harness Controls the supply of AC power from the power source to the low voltage power supply 340 Phaser 6200 Color Laser Printer Service Manual Plug Jack Locator Maps Use the table and maps in this section to locate specific plug jack P J connectors within the printer To find the location of a P J within the printer 1 Locate the P J connector number in the first column of the P J Location table 2 Locate the corresponding map and location number such as M2 5 in the second column 3 With this information go to the appropriate map in this case Map 2 and locate item number 5 Plug Jack Locator Table P J Map Connected to Other end connected to No 11 3 Engine Control Board Motor Driver Board 12 3 Engine Control Board Motor Driver Board 13 3 Connects Engine Control Board Sub HVPS Fuser Harness Assembly Harness Assembly FRONT 1A and the CTD ADC Harness Assembly 14 3 Engine Control Board Image Processor Board 15 3 Engine Control Board Laser Unit 18 3 Engine Control Board Chute Assembly Registration Clutch and Sensor 19 3 Engine Control Board Retard Housing Assembly Turn Clutch 21 3 Engine Control Board HCF Main Harness Assembly 22 3 Engine Control Board Front Panel
223. ssible must be eliminated The first step is to generate prints using printable pages embedded in the printer on laser paper from the approved media list The paper should be from an unopened ream that has been acclimated to room temperature See the approved media list Xerox Supplies and Accessories on page 296 for media that has been tested and approved for use in the Phaser 6200 printer If the print quality defect is still present when printing on approved media from an unopened ream of paper then media software applications and environmental conditions need to be researched Print the Usage Profile Report to determine the temperature and humidity the printer has been operating under Compare this to the environmental specifications for the printer found in Environmental Specifications on page 13 of this manual Temperature and humidity extremes can adversely effect the Xerographic and fusing characteristics of the printer The Phaser 6200 printer uses an Imaging Unit that contains all the imaging drums and developers for all four colors in one Customer Replaceable Consumable Print quality defects can be isolated to one particular component in the print engine See Repeating Defects Identification Chart on page 95 or print the Repeating Defects Page from the front panel When a single component of the Imaging Unit is causing a print quality defect the entire Imaging Unit must be replaced When analyzing a print quality defect f
224. stScript error occurred in the printer 1 Power cycle the printer and try printing again 2 Make sure that the correct Phaser 6200 printer icon was selected in the Chooser Try printing the job again 3 In the Chooser or the print dialog switch background printing to off Try printing the job again 4 If the error returns turn ON the PostScript error handler through the front panel PostScript Error Info in the Support menu or CWIS and print the document again Take note of the information on the error page that just printed 5 Select the appropriate Phaser 6200 PPD with the LaserWriter Driver or application Not selecting the appropriate PPD can cause PostScript errors 6 Select a different document from the application and try to print If the PostScript error does not occur then the original document may be causing the problem Image prints in black and white 1 Ensure the driver setting for TekColor tab is not set to Black amp White Image is rotated 90 degrees 1 In the application s Page Setup make sure that the image is selected to print in portrait or landscape orientation to match the document Also ensure the selected paper size is correct Windows printing problems Image never prints Try printing a test page from the printer driver s properties dialog box Try printing from another application Try printing to another printer Try printing from another computer If the error returns tu
225. stics to test the MPT Check the spring Go to step 21 Feed Solenoid and stopper of the Does the solenoid actuate Feed Solenoid In the test actuate the Interlock Switch 21 Remove the MPT Feed Solenoid Go to step 22 Replace the connector J132 MPT Feed Is J132 1 lt gt J132 2 less than 1000 Solenoid 22 Check the Front 2 Harness for continuity Replace the Replace Front 2 Engine Control Harness Board RRP 12 7 Assembly PL 6 1 2 Error Messages and Codes 39 Misfeed at Tray 1 Jam T1 The printers front panel displays Misfeed at Tray 1 indicating a paper misfeed has occurred in the printer Tray 1 is free from defects and installed properly Any obstruction media and debris has been removed from the paper path and there is adequate paper in the paper tray Printer power has been cycled and the error still displays Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Paper Pick Roller Kit PL 3 3 3 Paper Tray 1 on page 354 Paper Feed Roller Kit PL 3 3 23 Paper Feed on page 362 Paper Pick Assembly PL 3 3 1 Drive Section on page 355 Chute Assembly Registration PL 9 1 6 Main Wiring Diagram on page 352 Steps Actions and Questions Yes No 1 Check the following parts for fault or Replace any Go to step 2 damage damaged or Check for worn or damaged rollers and TA worn gears on the Paper Pick A
226. stments and NVRAM 109 Service Test Prints From the printers front panel Main Menu select Printable Pages Menu select Service Pages Menu and then select Service Test Prints Analyizing the CMYK Sample Page This page consists of four 25 tint primary color bands Things to look for E Repeating defects E Missing Color s E Streaks E Voids m Banding 6200 222 Analyizing the RGB Sample This page consists of 80 solid fill in RGBK Bands Things to look for m Wrinkling E Creases E Roller marks E Scratches m Cold Offset 6200 224 110 Phaser 6200 Color Laser Printer Service Manual Analyizing the Test Pattern Sample 9 d P 6200 P 6200 5 o T P 6200 P 620 P 6200 P 620d E E P6 6200 P 6200 P 6200k P 6200 P 620 P 6200 P 6200 P 6200 P 6200 Test Pattern A 600 x 600 Test Pattern A 600 x 600 Abe DefgHijk Lmnop Qrstuvw XYZ 123456789 4 56200 223 Things to look for 1 Color Registration Horizontal The colored lines should match up Perform the color registration procedure See Color Calibration on page 112 2 Color Registration Vertical The colored lines should match up Clean the CTD sensor and cycle power to the printer to correct Uniform RGB The secondary color squares should be uniformly colored with no mottling Density The color bars should have even density from top to bottom Margins Should be 8mm from the edge of the paper to th
227. t Shaft Pivots securing the bottom of the Chute Assembly Out to the printer 15 Rotate the MPT roller until the lower plate assembly raises up Caution The Plate Assembly Bottom has sharp burrs be careful when performing the following steps 2 6200 112 16 Using needle nose pliers remove the left and right Shaft Pivots item 2 pulling them inward to remove 17 Release the latch at Door B and pull the Chute Assembly Out forward to remove 174 Phaser 6200 Color Laser Printer Service Manual RRP 6 2 Output Tray Full Actuator PL 6 1 5 Full Stack Sensor PL 6 1 4 6200 114 Removal Actuator 1 Remove the Front Cover RRP 1 1 2 Deflect the shaft of the Actuator Full from the top portion of the Chute Assembly Out and remove the shaft from the left side 86200 115 Removal Full Stack Sensor 1 Remove the Actuator Output Tray Full 2 Disconnect P J134 from the Full Stack Sensor 3 Release the 3 tabs securing the Full Stack Sensor and remove FRU Disassembly Removal and Replacement Procedures 175 RRP 6 3 Duplex Actuator PL 6 1 13 Duplex Sensor PL 6 1 4 176 Phaser 6200 Color Laser Printer Service Manual Removing the Duplex Actuator 1 Remove the Front Left Cover RRP 1 11 2 Release the 2 tabs securing the Actuator Cover push in and remove the cover 3 Release the tab on
228. t Specification Electrostatic Discharge IEC61000 4 2 1995 6kV Contact 10kV Air Radio Frequency Electromagnetic Field radiated IEC61000 4 3 1995 80 1000 MHz 3V m 80 AM 1KHz Fast Burst Transients IEC61000 4 4 1995 5 50 Tr Th ns 5kHz Rep Freq 0 5kV on Signal Lines 1kV on AC Mains Line Surge IEC61000 4 5 1995 Combination wave 2 0kV Common mode 2 0kV Differential mode Radio Frequency Electromagnetic Field Conducted IEC61000 4 6 1996 0 15 80 MHz 3V 80 AM 1kHz Line voltage dips IEC61000 4 11 1994 gt 95 dip for cycle 50 Hz 30 dip for 25 cycles 50 Hz Line voltage drop out IEC61000 4 11 1994 gt 95 dropout for 250 cycles 50 Hz This product if used properly in accordance with the user s instructions is neither dangerous for the consumer nor for the environment A signed copy of the Declaration of Conformity for this product can be obtained from Xerox Manual Organization This Service Manual contains technical information for the Phaser 6200 Color Laser Printer as well as complete Error Messages and Codes Diagnostics Disassembly Reassembly RRPs procedures and a complete Field Replaceable Units FRU Parts List Frontis Introductory Safety and Regulatory Information This is the section you are reading at this moment It contains important safety information regarding technical components regulatory agency requirements and information about the structu
229. tch Turn T2 Circuit Board HCF 831 Switch Paper Size T3 Tray 3 Harness Assembly 832 Sensor No Paper Tray 3 Tray 3 Harness Assembly 833 Sensor Low Paper T2 Tray 3 Harness Assembly 834 Solenoid Feed Tray 3 Circuit Board Lower Feeder 835 Assembly Clutch Turn T3 Circuit Board Lower Feeder 8220 Assembly Harness No Paper Circuit Board Lower Feeder Sensor 8220 Assembly Harness No Paper Circuit Board Lower Feeder Sensor Plug Jack Locator Maps 349 Map 5 832 822 824 8220 810 81 83 821 834 833 823 835 825 6200 268 350 Phaser 6200 Color Laser Printer Service Manual Wiring Diagrams This section of the manual contains all the wiring diagrams for the Phaser 6200 Color Laser Printer and the optional trays 2 and 3 Wiring Diagrams 351 Main Wiring Diagram PL8 1 1 IMAGE UNIT PL9 1 3 10 332 ROLLER ASSY PL8 1 12 ITCRUM PL3 2 2 PL5 1 11 Dup Jam Sensor PL6 1 4 H H i i a 8 MPT No Paper Sensor PL6 1 4 MPT FEED SOLENOID PL6 1 40 FUSER ASSY es FULL SENSOR 7 PL5 1 13 Tne HUM TEMP SENSOR CTD SENSOR PAT P J162 P J232 ENGINE CONTROL BOARD PL12 1 1 P J138 eee PITS Pms LVPS PIJAT P3471 PL9 1 1 PL12 1 10 P J163 P J60 PATIO PATA P s140_ I I P J472 Paes P J61 Puan
230. te Assembly In Door A while disconnecting wiring harnesses to avoid damaging the printer 6 On left side of the printer disconnect P J5030 Red and P J5020 Red from the Sub High Voltage Supply Board 7 Disconnect the top 2 connectors P J141 P J1361 and the 4th connector P J138 from the bracket and P J145 bottom gray from the EEPROM Circuit Board 8 Remove 1 screw securing the ground wire left side and move out of the way 172 Phaser 6200 Color Laser Printer Service Manual Caution The yellow and gray harnesses on the EEPROM Board contain the same number of pins but are NOT interchangeable Make sure P J144 yellow is connected on the top and the P J145 gray is connected to the bottom 9 Free the harness in step 6 from the bottom portion of the Housing Assembly Bias 10 On the right side of the printer disconnect P J52 and P J50 from the Motor Driver Board and disconnect P J162 from the Low Voltage Power Supply 11 Remove 1 screw securing the Fuser ground wire right side and move out of the way 12 Free the wiring harness on the Fuser Drive Assembly from the clamp on the Main Drive Assembly 13 Free the wiring harness on the Fuser 2 Harness Assembly from the hook of the housing on the right side of the printer CA y MTA S Tf Bi ur 7 Any 6200 113 FRU Disassembly Removal and Replacement Procedures 173 14 Remove the e rings item 1 from the right and lef
231. ter Service Manual J Catt O SE ANN A Cat O 5 2 A BKC ASS Q O y N S6200 180 4 Remove the Housing Assembly Bias RRP 9 2 5 Remove the 4 screws securing the Left Plate Assembly 6 Press on the aligning posts from inside the cavity of the printer to remove the Plate Assembly FRU Disassembly Removal and Replacement Procedures 213 D g S6200 178 7 Carefully remove the Left Link lever item 4 from the printer chassis together with the springs and the drum levers item 3 Note Lay the asssembly on a flat surface pressing down to remove the spring from the drum lever 8 Remove the spring levers Caution Note 214 Do not accidentally knock out the stud plungers bias contacts For reassembly ensure the drum levers are seated properly on the aligning posts Phaser 6200 Color Laser Printer Service Manual RRP 11 2 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 Lever Spring PL 11 1 5 Removal Remove the Right Cover RRP 1 6 Remove the Top Imaging Unit Cover Door C RRP 1 5 Remove the Right Link Spring PL1 1 24 Remove the Main Drive Assembly RRP 11
232. ter Service Manual Color Registration This procedure must be performed whenever the Laser Unit has been removed or replaced i HkoOwWLOLSAL l l against black to ensure that the colors are properly aligned The Color Registration Menu allows you to adjust the printer s cyan magenta and yellow You can adjust the settings from 7 to 7 units left to right See the images on the left 0 is always the printer s current color registration setting Print the Color Registration page from the printer s front panel Printable Pages Menu ee Nodskomsottakagsa Margin Calibration The Calibrate Margins Menu allows you to adjust the printer s imaging area relative to the edges of the paper The imaging area is shown as a dashed rectangle on the front side of the print the printer will not print outside this rectangle The dashed rectangle should line up with the solid rectangle printed on the back side of the page Hold up to strong light for verification Print the Calibrate Margins Page from the printer s front panel Improve Print Quality Menu and follow the instructions detailed on the page Test Prints Adjustments and NVRAM 113 Resetting NVRAM Resetting NVRAM returns all the Image Processor Board NVRAM stored parameters to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset Yo
233. terial part number used to order specific parts Qty This number represents the parts per printer not the number of parts supplied in the actual part order Name Description Details the name of the part to be ordered and the number of parts supplied per order Parts identified throughout this manual are referenced PL For example PL3 1 10 means the part is item 10 of Parts List 3 1 A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly made up of the individual parts called out in parentheses The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 An asterisk following a part name indicates the page contains a note about this part The notation NS next to a part indicates that pariticular part is not spared but contained in a kit or major assembly 10 The notation J1 lt gt J2 and P2 is attached to a wire harness It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2 Note Only parts showing part numbers are available for support Parts not showing part numbers are available on the parent assembly Legend Identifier Meaning C C ring E E ring KL K clip S S
234. the Tray 3 Feed Solenoid connector Go to step 18 Replace the J834 Tray 3 Feed Solenoid a 2 7 Is J834 1 lt gt J834 2 less than 100 ohms PL 14 417 18 Check the OPT Feeder Plug Assembly to the Replace the Replace the HCF Main Assembly to the Tray 3 Harness Engine Control open Harness Assembly for continuity Board Assembly See Paper Tray 3 on page 367 BRR 46 Phaser 6200 Color Laser Printer Service Manual Close Front Door The printer s front panel displays Close Front Door The front door is free of obstructions and is fully closed Printer power has been cycled and the message still appears Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Map References Front Cover PL 1 1 2 Main Wiring Diagram on page 352 Motor Driver Board PL 12 1 12 Drive Section on page 355 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to step 2 or damage concerned Motor Driver Board PL 12 1 12 Interlock Switch on Motor Driver Board Actuator tab on the Front Cover CAM I R on the Top Imaging Unit Cover Acutator I L PL 11 1 8 2 Use service diagnostics to test the Replace Engine Go to step 3 Interlock Switch Control Board Does the Interlock Switch function RRP12 7 correctly 3 Verify the voltage between P J41 35 lt gt Replace Engine Repl
235. tics to test the Duplex Go to step 7 Replace the Sensor sensor and Does the sensor function correctly Go to step 3 3 Does the printer function correctly after Complete Go to step 4 the Duplex Sensor is replaced 4 Block the Duplex Sensor and verify the Go to step 6 Go to step 5 voltage between J 139 3 lt gt J 139 2 is 0 VDC 5 Check the Front 2 Harness for continuity Go to step 6 Replace the Front 2 Harness See Paper Feed on page 362 Assembly PL 6 1 2 6 Check P 139 lt gt J 13 on the Front 1A Replace the Replace the Harness for continuity Engine Control Assembly Front See Paper Feed on page 362 Board RRP 12 7 1A PL 13 1 7 7 If possible print 1 sheet of paper in Replace the Chute Go to step 8 Duplex Mode and check to see if the Assembly Exit sheet has reversed in the printer RRP 7 1 8 Use service diagnostics to test the Duplex Replace the Chute Go to step 9 Motor Assembly Exit Actuate the Interlock Switch during the RRP 7 1 test Error Messages and Codes 33 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 9 Verify the voltage between Go to step 10 Replace the P 50 1 lt gt P 60 2 on the Motor Driver Motor Driver Board is 24 VDC Board RRP 12 3 10 Check J 131 lt gt J 50 on the Duplex Got to step 11 Replace the Harness for continuity Duplex Harness Dri inn Assembly See Drive Section on p
236. tion Actuator 2 Disconnect P J181 3 Release the 3 tabs securing the Sensor to the Chute Assembly Registration and remove the sensor FRU Disassembly Removal and Replacement Procedures 199 RRP 9 5 OHP Sensor and Harness Kit PL 9 1 12 4 6200 185 Removal 1 Remove the Chute Assembly Registration RRP 9 3 2 Remove the 2 e rings securing the 2 Gears items 4 amp 5 Note When removing the Springs use caution they spring off the shaft easily 3 Remove both springs item 1 amp 6 4 Pull out the bearing on the left side of the shaft item 3 200 Phaser 6200 Color Laser Printer Service Manual 6200 186 5 Remove 1 screw from the left side of the Chute Assembly securing the Bracket Assembly item 3 6 Pull off the black plastic bearing item 2 securing the left side of the metal registration roller 6200 187 7 Raise the left end of the shaft and remove with the right white plastic bearing attached FRU Disassembly Removal and Replacement Procedures 201 6200 188 8 Pull back on the tabs item 1 to remove the OHP Sensor Cover 9 Remove the OHP Sensor from the cover 10 Disconnect P J321 Reassembly Note When reassembling item 5 the white gear goes on the metal roller and the black gear item 4 goes on the rubber roller Note Install the springs last 202 Phaser 6200 Color Laser Printer Service Manual RRP 10 1 Toner Cartridge Holder Unit Assembly PL
237. top of the HCF frame oon 238 Phaser 6200 Color Laser Printer Service Manual RRP 14 5 Circuit Board HCF PL14 5 1 E Zoe 6200 277 Removal Remove both Paper Trays from the HCF Remove the Front Covers RRP 14 1 Remove the Cover Right RRP 14 2 Disconnect P J81 from the Harness Feeder Plug Assembly Disconnect P J82 from the Harness Assembly Tray 2 Disconnect P J83 from the Harness Assembly Tray 3 Disconnect P J84 from the Drive Assembly Remove the 3 screws securing the Power Feeder Circuit board to the HCF frame and remove the board ONOORWND Replacement Note When replacing the Power Feeder Circuit Board align the hole on the board and the two tabs on the HCF Frame FRU Disassembly Removal and Replacement Procedures 239 RRP 14 6 Drive Feeder Assembly PL14 5 5 6200 198 Removal Remove both Paper Trays from the HCF Remove the Front Covers RRP 14 1 Remove the Right Cover RRP 14 2 Release the Tray 2 Harness Assembly gray from the cable restraints Disconnect P J84 Remove the 3 screws securing the Feeder Drive Assembly to the HCF and remove oahwhd 240 Phaser 6200 Color Laser Printer Service Manual RRP 14 7 Indicator Assembly PL14 5 9 R OZ A HA HN RS U Removal Remove both Paper Trays from the HCF Remove the Front Covers RRP 14 1 Remove the
238. tration accessed under the electric housing RRP 9 4 assembly See RRP 9 3 on the Engine Control Board isO VDC 6 If possible print a sheet of paper from the Go to step 16 Go to step 7 MPT Does the Main Drive motor function properly Error Messages and Codes 37 Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No 7 Use service diagnostics to test the Main Replace the Go to step 8 Drive Motor Engine control Does the Main Drive Motor turn Board RRP 12 7 8 Verify the voltage between P J48 1 lt gt Go to step 12 Go to step 9 P J60 2 on the Motor Driver Board is 24 VDC 9 Use service diagnostics to test the Go to step 10 Replace the Interlock Switch Motor Driver Does the Interlock switch function oes 3 correctly ER 10 Verify the voltage between SW 1 lt gt Replace the Go to step 11 P J60 2 and SW 2 lt gt P J60 2 on the Motor Driver Motor Driver Board is 24 VDC Board Close the Interlock Switch BREA 11 Check the power supply by verifing the Replace the Motor See DC Power voltage between P J60 1 lt gt P J60 2 on Driver Board Supply the Motor Driver Board is 24 VDC RRP 12 3 Troubleshooting on page 88 12 Check the power supply by verifing the Go to step 13 Go to step 14 voltage between P J61 8 lt gt P J61 7 on the Motor Driver Board is 5 VDC 13 Check the power supply by verifing the Go to step 15 G
239. u can reset the PostScript NVRAM using the Customer Menu or the Service Diagnostics Menu PostScript NVRAM Resets Restore factory settings Registration You can reset settings for color registration to the factory default values From the Main Menu highlight Support and press OK Highlight Improve Print Quality and press OK Highlight Color Registration Menu and press OK Highlight Restore Factory Settings and press OK Highlight Restore Factory Settings NOW and press the OK to reset the color settings to factory defaults oOuahwhd Restore factory settings Color You can reset settings for density and color balance to the factory default values From the Main Menu highlight Support and press OK Highlight Improve Print Quality and press OK Highlight Calibrate Colors Menu and press OK Highlight Restore Factory Settings and press OK to reset the color settings to factory defaults akhoND Restore previous settings color You can return the color settings to the ones that existed before you saved the last color balance adjustments 1 From the Main Menu highlight Support and press OK 2 Highlight Improve Print Quality and press OK 3 Highlight Calibrate Colors Menu and press OK 4 Highlight Restore Previous Settings and press OK to restore the previous color settings 5 Highlight Restore Previous Settings NOW and press the OK to reset the color settings to factory defaults 114
240. ulti Purpose Tray Paper feed by Paper Pick Assy T3 Paper feed by Paper Pick Assy T2 y Paper feed by Paper Pick Assy T1 Paper feed by MPT Feed Roller and Paper Feed Retard Roller Paper feed by Paper feed by Paper Feed Rollers Nudge and Retard Tray 3 Paper Feed Rollers Nudge and Retard Tray 2 y Paper transfer by Tray 3 Turn Roll and Tray 3 Turn Chute Assy v Paper transfer by Tray 2 Turn Roll and Tray 2 Turn Chute Assy Paper feed by Paper Feed Rollers Nudge and Retard Tray 2 Paper transfer by Turn Roll and Pinch Roll y Paper transfer by the Tray 1 Turn Roll and Tray 1 Turn Chute Assy Paper transfer by the Chute Assembly Registration REGI Metal and Registration Rolls y Paper transfer by the Imaging Unit IDT2 and Transfer Roller y Paper transfer by the Fuser Assembly Heat Roll and Fuser Belt y Paper transfer by the Fuser Assembly Exit Roll and Pinch Roll y Paper transfer by the Chute Assembly Exit and Chute Assembly Out v v Theory of Operation Print output Paper transfer to duplex path by reversing Exit Roll and Mid Roll y Paper transfer by Duplex Rollers to Print Output S6200 059 315 Major Assemblies and Functions The following se
241. ve the grounding screw Remove the Main Drive item 1 OWMNOORWN FRU Disassembly Removal and Replacement Procedures Remove the 4 screws securing the Main Drive Assembly to the printer 219 RRP 11 4 Developer Drive Assembly PL 11 1 13 Ry Y W S6200 163 Removal Remove the Right Cover RRP 1 6 Remove the Motor Driver Board RRP 12 3 Disconnect P J52 from the Motor Driver Board Remove the 4 screws securing the Developer Drive Assembly and remove khOD 220 Phaser 6200 Color Laser Printer Service Manual RRP 11 5 Actuator I L PL 11 1 8 Spring I L PL 11 1 9 6200 162 Removal 1 Remove the 4 screws on the Motor Driver Board and set the board to the side 2 Remove the spring from the actuator 3 Release the hook securing the actuator to the shaft and remove item 1 FRU Disassembly Removal and Replacement Procedures 221 RRP 11 6 Earth Ground Circuit Board PL 11 1 16 6200 177 Removal Open Door A Remove the Fuser Assembly Remove the Transfer Roll Assembly Remove the Chute Assembly Registration RRP 9 3 Remove the Housing Assembly Retard RRP 4 1 Remove the 2 screws securing the Ground Circuit Board and remove the board oOuahwhd 222 Phaser 6200 Color Laser Printer Service Manual RRP 12 1 AC Switch Harness Assembly PL 12 1 11 6200 170 Removal Remove the Top Mai
242. ware Failure Controller to Engine Communications Failure NVRAM Failure Non Xerox Imaging Unit Environment Sensor Failure Error Messages and Codes Code Code Code Code Code Code Code Code Code Code Code Code Code Code 07 08 09 10 11 12 13 14 15 16 40 41 42 43 44 45 46 47 50 51 52 70 71 72 73 74 77 78 79 75 76 77 78 81 83 95 102 Page 65 66 68 69 73 74 75 76 77 72 76 78 78 79 80 19 Service Flowchart The Service Flowchart outlines one possible approach to troubleshooting and repair of the printer The Service Flowchart is an overview of the path a service technician could take using this technical manual to service the print engine and options If you choose not to use the Service Flowchart it is recommended that you start at the appropriate troubleshooting table and proceed from there Always follow the safety measures detailed in the front of the manual when servicing the printer See Service Safety Summary on page vi of this manual Step 1 Identify the Problem OONDARWNH Verify the reported problem does exist Check for any error codes and write them down Print normal customer prints and service test prints Make note of any print quality problems in the test prints Make note of any mechanical or electrical abnormalities present Make note of any unusual noise or smell coming from the printer Print a U
243. with needle nose pliers and Remove the Feeder Right Housing RRP 3 4 pull the Indicator forward to remove from the Right Housing Release the 2 tabs securing the Shaft Holder item 6 to the Right Housing Shaft Indicator item 4 Note When reinstalling the guide ensure the flag is on top of the 150 guide Phaser 6200 Color Laser Printer Service Manual aa NA S6200 086 Removal Low Paper Lever 1 Deflect the shaft in the Right Housing securing the right axis of the Lever Low Paper from the bottom surface and shift the right axis 2 Push the actuator on the Low Paper Lever toward the inside of the Right Housing then raise the Low Paper Lever up and out of the feeder Replacement 1 Replace in reverse order of removal Note Put the leading end of the lever low paper on the left convex portion of the Guide Indicator when replacing the Guide Indicator Hold the Guide Indicator securely when replacing the Indicator FRU Disassembly Removal and Replacement Procedures 151 RRP 3 9 Paper Pick Rollers PL3 3 3 6200 090 Removal 1 Pull the paper tray out of the printer Note Remove and replace the Paper Pick Rollers one at a time to maintain their orientation 2 Remove the Turn Chute Assembly RRP 3 1 3 Rotate the Feed Shaft so that the Paper Pick Rollers face down 4 Pull the Paper Pick Roller off the shaft 152 Phaser 6200 Color Laser Printe
244. x Motor and drives the fused print media partially into the output tray where it then reverses in duplex mode and feeds the print media fused on one side in the direction of the Registration Chute 328 Phaser 6200 Color Laser Printer Service Manual Duplex Motor Drive and Gear Transmission Route DUPLEX MOTOR ASSY GEAR 48 GEAR 48 i GEAR 40 42 GEAR 40 42 l l y l l l l l GEAR ROLL GEAR ROLL GEAR42 EXIT ROLL MID ROLL CHUTE ASSY EXIT j Cy GEAR 30 l l l Y l DUPLEX ROLL l i l CHUTEASSYOUT N GEAR ROLL GEAR ROLL DUPLEX MOTOR ASSY GEAR 40 42 GEAR 48 1 GEAR 42 CHUTE ASSY EXIT gt I GEAR 30 CHUTE ASSY OUT FRONT 6200 050 Theory of Operation 329 Chute Assembly Registration REGI 4 5 6200 280 1 Registration Rubber Roll Receives drive energy from the main drive assembly through the registration clutch transporting the paper from the paper tray or MPT 2 Registration Metal Roll Works in conjuction with the rubber roller When the leading edge of the paper arrives at the registration rubber roll metal roll it buckles the paper to correct the skew at the leading edge 3 OHP Sensor The OHP sensor can sense reflected light detecting the print media If the OHP sensor cannot sense reflected light it identifies the print media as OHP
245. y Full Sensor Detects a full output tray over accumulation of print media by the position of the actuator This is only checked when the paper is feeding into the exit 2 Duplex Jam Sensor Detects when print media has reached and passed through the duplex roll based on the position of the actuator 3 Duplex Roll The duplex roller rotates under drive from the duplex motor and feeds the print media returned from the chute assembly exit to the turn roll in the retard housing assembly 4 Gear Main Drive See Roll Feed Assembly 5 MPT Gear See Roll Feed Assembly 6 Feed Roll Assembly When the MPT feed soleniod energizes the MPT gear and the gear idler are engaged by the force of the spring solenoid The roll feed rotates from the drive of the Main Drive Assembly and feeds paper from the MPT After rotating one turn the MPT gear and the gear idler are disengaged the drives and roll feed stop allowing one sheet of paper to be fed through at a time 7 MPT No Paper Sensor Actuator detects whether print media is present or not No paper sensor beam is intercepted 8 MPT Feed Solenoid Controls the operation rotation stop of the Assembly Roll Feed by controlling the rotations of the Gear MPT Theory of Operation 327 Chute Assembly Exit 6200 044 1 Duplex Motor Supplies the drive to the exit roll mid roll and duplex roll 2 Mid Roll See Exit Roll 3 Exit Roll Rotates through the drive from the Duple

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