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Publication Information for Xerox,
Phaser 6110
Service Documentation
Product : Xerox Phaser 6110TM Service Documentation
Title: Xerox Phaser 6110 Service Documentation
Part number: 701P28450
January 29, 2007
Precautions
In order to prevent accidents and to prevent damage to the equipment please read the precautions listed
below carefully before servicing the printer and follow them closely.
Safety Warning
(1) Only to be serviced by appropriately qualified service engineers.
High voltages and lasers inside this product are dangerous. This printer should only be serviced by a suitably
trained and qualified service engineer.
(2) Use only Xerox replacement parts
There are no user serviceable parts inside the printer. Do not make any unauthorized changes or
additions to the printer, these could cause the printer to malfunction and create electric shock or fire haz-ards.
(3) Laser Safety Statement
The Printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, chapter 1 Subchapter J for
Class 1(1) laser products, and elsewhere, it is certified as a Class I laser product
con-forming to the requirements of IEC 825. Class I laser products are not considered to be hazardous. The
laser system and printer are designed so there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed service condition.
Warning >> Never operate or service the printer with the protective cover removed from Laser/Scanner assembly. The
reflected beam, although invisible, can damage your eyes. When using this product, these basic safety
pre-cautions should always be followed to reduce risk of fire, electric shock, and injury to persons.
CAUTION - INVISIBLE LASER RADIATION
WHEN THIS COVER OPEN.
DO NOT OPEN THIS COVER.
VORSICHT - UNSICHTBARE LASERSTRAHLUNG,
WENN ABDECKUNG GEÖFFNET.
NICHT DEM STRAHL AUSSETZEN.
ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS
D'OUVERTURE. EXPOSITION DANGEREUSE
AU FAISCEAU.
ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI
APERTURA. EVITARE L'ESPOSIZIONE AL
FASCIO.
PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.
EVITAR EXPONERSE AL RAYO.
ADVARSEL. - USYNLIG LASERSTRÅLNING VED ÅBNING, NÅR
SIKKERHEDSBRYDERE ER UDE AF FUNKTION.
UNDGÅ UDSAETTELSE FOR STRÅLNING.
ADVARSEL. - USYNLIG LASERSTRÅLNING NÅR DEKSEL
ÅPNES. STIRR IKKE INN I STRÅLEN.
UNNGÅ EKSPONERING FOR STRÅLEN.
VARNING - OSYNLIG LASERSTRÅLNING NÄR DENNA DEL
ÄR ÖPPNAD OCH SPÄRREN ÄR URKOPPLAD.
BETRAKTA EJ STRÅLEN. STRÅLEN ÄR FARLIG.
VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA
OLET ALTTIINA NÄKYMÄTTÖMÄLLE LASER-
SÄTEILYLLE ÄLÄ KATSO SÄTEESEEN.
Caution for safety
Toxic material
This product contains toxic materials that could cause illness if ingested.
(1) Please keep toner cartridges away from children. The toner powder contained in the toner cartridge may be harmful
and if swallowed you should contact a doctor.
Electric Shock and Fire Safety Precautions
Failure to follow the following instructions could cause electric shock or potentially cause a fire.
(1) Use only the correct voltage, failure to do so could damage the printer and potentially cause a fire or electric
shock.
(2) Use only the power cable supplied with the printer. Use of an incorrectly specified cable could cause the cable
to overheat and potentially cause a fire.
(3) Do not overload the power socket, this could lead to overheating of the cables inside the wall and could lead to
a fire.
(4) Do not allow water or other liquids to spill into the printer, this can cause electric shock. Do not allow paper
clips, pins or other foreign objects to fall into the printer these could cause a short circuit leading to an electric
shock or fire hazard..
(5) Never touch the plugs on either end of the power cable with wet hands, this can cause electric shock. When
servicing the printer remove the power plug from the wall socket.
(6) Use caution when inserting or removing the power connector. The power connector must be inserted com-
pletely otherwise a poor contact could cause overheating possibly leading to a fire. When removing the power
connector grip it firmly and pull.
(7) Take care of the power cable. Do not allow it to become twisted, bent sharply round corners or other wise
damaged. Do not place objects on top of the power cable. If the power cable is damaged it could overheat and
cause a fire or exposed cables could cause an electric shock. Replace a damaged power cable immediately,
do not reuse or repair the damaged cable. Some chemicals can attack the coating on the power cable,
weakening the cover or exposing cables causing fire and shock risks.
(8) Ensure that the power sockets and plugs are not cracked or broken in any way. Any such defects should be
repaired immediately. Take care not to cut or damage the power cable or plugs when moving the machine.
(9) Use caution during thunder or lightening storms. Xerox recommend that this machine be disconnected from
the power source when such weather conditions are expected. Do not touch the machine or the power cord if it
is still connected to the wall socket in these weather conditions.
(10) Avoid damp or dusty areas, install the printer in a clean well ventilated location. Do not position the machine
near a humidifier. Damp and dust build up inside the machine can lead to overheating and cause a fire.
(11) Do not position the printer in direct sunlight. This will cause the temperature inside the printer to rise possibly
leading to the printer failing to work properly and in extreme conditions could lead to a fire.
(12) Do not insert any metal objects into the machine through the ventilator fan or other part of the casing, it could
make contact with a high voltage conductor inside the machine and cause an electric shock.
Handling Precautions
The following instructions are for your own personal safety, to avoid injury and so as not to damage the printer
(1) Ensure the printer is installed on a level surface, capable of supporting its weight. Failure to do so could cause
the printer to tip or fall.
(2) The printer contains many rollers, gears and fans. Take great care to ensure that you do not catch your fingers,
hair or clothing in any of these rotating devices.
(3) Do not place any small metal objects, containers of water, chemicals or other liquids close to the printer which if
spilled could get into the machine and cause damage or a shock or fire hazard.
(4) Do not install the machine in areas with high dust or moisture levels, beside on open window or close to a
humidifier or heater. Damage could be caused to the printer in such areas.
(5) Do not place candles, burning cigarettes, etc on the printer, These could cause a fire.
Assembly / Disassembly Precautions
Replace parts carefully, always use approved parts. Take care to note the exact location of parts and also
cable routing before dismantling any part of the machine. Ensure all parts and cables are replaced correctly.
Please carry out the following procedures before dismantling the printer or replacing any parts.
(1) Check the contents of the machine memory and make a note of any user settings. These will be erased if the
mainboard or network card is replaced.
(2) Ensure that power is disconnected before servicing or replacing any electrical parts.
(3) Disconnect printer interface cables and power cables.
(4) Only use approved spare parts. Ensure that part number, product name, any voltage, current or temperature
rating are correct.
(5) When removing or re-fitting any parts do not use excessive force, especially when fitting screws into plastic.
(6) Take care not to drop any small parts into the machine.
(7) Handling of the OPC Drum
- The OPC Drum can be irreparably damaged if it exposed to light.
Take care not to expose the OPC Drum either to direct sunlight or to fluorescent or incandescent room
lighting. Exposure for as little as 5 mins can damage the surface's photoconductive properties and will result
in print quality degradation. Take extra care when servicing the printer. Remove the OPC Drum and store it in
a black bag or other lightproof container. Take care when working with the covers(especially the top cover)
open as light is admitted to the OPC area and can damage the OPC Drum.
- Take care not to scratch the green surface of OPC Drum Unit.
If the green surface of the Drum Cartridge is scratched or touched the print quality will be compromised.
1-3
Disregarding this warning may cause bodily injury
(1) Be careful with the high temperature part.
The fuser unit works at a high temperature. Use caution when working on the printer. Wait for the fuser to cool
down before disassembly.
(2) Do not put finger or hair into the rotating parts.
When operating a printer, do not put hand or hair into the rotating parts (Paper feeding entrance, motor, fan,
etc.). If do, you can get harm.
(3) When you move the printer.
This printer weighs 19.95kg including toner cartridge and cassette. Use safe lifting and handling techniques.
Use the lifting handles located on each side of the machine. Back injury could be caused if you do not lift care-
fully.
(4) Ensure the printer is installed safely.
The printer weighs 19.95Kg, ensure the printer is installed on a level surface, capable of supporting its weight.
Failure to do so could cause the printer to tip or fall possibly causing personal injury or damaging the printer.
(5) Do not install the printer on a sloping or unstable surface. After installation, double check that the printer is stable.
Section 1 Service Call Procedures
There is a smell, or smoke, or the printer is hot. NOTE: the top cover, above
the Fuser, is normally very warm to the touch when printer is ready.
No Yes
Remove the Fuser (5.4.2) and check it for signs of overheating such as
discoloration, deformed frames, or a thermostat with high electrical
resistance. Remove the Covers (5.4.1). Check the PWB's and wiring for
signs of overheating. Check the drives for signs of damage (5.4.7).
Replace or repair any part as required.
Switch on the power. The LED panel indicates ready.
Yes No
Remove the Covers (5.4.1). Go to the Block Diagram, lower right corner,
and check input power, switch, SMPS, and Main PWB power distribution
voltages.
Refer to the Control Panel wiring diagram (Section 7, Level 2 Block
Schematic Diagram).
Refer to Control Panel LEDs (Section 10 Product Technical Overview).
Replace or repair any part as required.
Print a Demonstration Print (Section 6 General Procedures). The
Demonstration Print is output.
Yes No
Go to 7.3 Solving General Printing Problems (Section 3 User Declared
Errors)
The Demonstration Print image quality is good.
Yes No
Go to Image Quality Problems (Section 3 User Declared Errors)
There is still a problem with the printer.
No Yes
Go to Section 3 User Declared Errors and attempt to find a solution.
Verify that Routine Maintenance is complete (Section 1, 5.2 Parts for
Maintenance and Repair).
Ensure Printer is ready for customer service (clean covers)
Place Demonstration Print in output tray.
Disassembly and Reassembly
Parts for Maintenance and Repair
Replacement interval for parts with a limited life
Some of the parts in this printer have a limited life, shorter than that of the whole machine. These parts
must be replaced periodically.
The table below shows the interval at which these parts should be replaced.
The table shows the life of each part, and is measured when using A4 paper. When servicing a machine
always check the status of these parts using the control panel and ensure that parts are replaced at the
appropriate times otherwise a general degradation in print quality will occur.
COMPONENT REPLACEMENT CYCLE REMARK
Toner Cartridge (Black) intial (1,500 pages@5% coverage) User replace
replacement (2,000 pages@5% coverage)
Toner Cartridge (Color: C/M/Y) intial (700 pages@5% coverage) User replace
replacement (1,000 pages@5% coverage)
Waste toner container 5K image or 1.25K pages User replace
(Full color 5% image)
T2 Roller 100K pages
Imaging Unit 20K pages (Black)
12.5K pages (Color)
ITB Unit(Image Transfer Unit) Black : (60K pages@5% coverage) User replaceCo,
Color : (15K pages@5% coverage)
Pick-Up Roller 100,000 pages Engineer
- MP Pick-Up Roller,
- Cassette Tray1 Pick-Up Roller
Fuser Unit 100,000 pages (B/W) Color(50,000 pages) User replace
The life span of each of these parts is stored in memory. The amount of each 'life' used can be checked at
any time using the control panel.
When a part is replaced it is necessary to reset the 'life used' that is stored in memory.
* How to initialize a the value of part's life span:
From the control panel, select the following items in order:
Menu-Setup - Maintenance - Check other - (Select a desired part) - Reset
Service Manual
Section 2 Machine Declared Faults
Alignment and Adjustmens
Error Message
When the printer experiences an error, the control panel will indicate an error message with the indicator
lights. Find the light pattern below that matches the printer light pattern and follow the solutions to clear the error.
LED status legend
LED pattern Possible Problem and Solution
The blinking toner cartridge is low. Order a new toner cartridge. You can temporar-
ily improve print quality by redistributing the toner.
The lighting toner cartridge is empty.
Remove the old toner cartridge and install a new one.
The blinking toner cartridge is totally exhausted. Remove the old toner cartridge
and install a new one.
The blinking toner cartridge is wrong. Only install a Xerox toner
cartridge, designed for your printer.
A paper jam has occurred. To solve the problem.
The front cover is open. Close the front cover.
There is no paper in the tray. Load paper in the tray.
The waste toner container is open or full. Check the container.
Your system has some problems. If this problem occurs, contact your service
representative.
Service Manual
Troubleshooting
JAM 0
Service Manual
Troubleshooting
JAM 1
Multi-Feeding
No Fuser drive due to overheated gear(s)
Service Manual
Troubleshooting
Paper Empty
Cover Open
Defective motor operation
Service Manual
Section 3 User Declared Faults
Troubleshooting
Solving Print Quality Problems
Dirt inside of the printer or improper paper loading may reduce print quality. See the table below to troubleshoot
problems.
Problem Solution
Light or faded print If a vertical white streak or faded area appears on the page:
The toner supply is low. You may be able to temporarily extend the toner cartridge life.
If this does not improve print quality, install a new toner cartridge.
AaBbCc The paper may not meet paper specifications (for example, the paper is too moist or too
AaBbCc rough).
AaBbCc A combination of faded or smeared defects may indicate that the printer needs cleaning.
AaBbCc
AaBbCc
Toner specks The paper may not meet specifications (for example, the paper is too moist or too rough).
AaBbCc
AaBbCc
AaBbCc
AaBbCc
AaBbCc
Dropouts If generally rounded, faded areas occur randomly on the page:
A single sheet of paper may be defective. Try reprinting the job.
The moisture content of the paper is uneven or the paper has moist spots on its sur-
AaBbCc face. Try a different brand of paper.
AaBbCc The paper lot is bad. The manufacturing process can cause some areas to reject toner.
AaBbCc Try a different kind or brand of paper.
The toner cartridge may be defective. See "Vertical repetitive defects" on the next page.
AaBbCc If these steps do not correct the problems, contact a service representative.
AaBbCc
Vertical lines If black vertical streaks appear on the page:
A imaging unit has probably been scratched.
Remove the imaging unit and install a new one.
AaBbCc
AaBbCc If white vertical lines appear on the page:
AaBbCc Clean the inside of the printer. If you still have the same problems, replace the imaging
unit with a new one.
AaBbCc
AaBbCc
Service Manual
Troubleshooting
Problem Solution
Color or Black If the amount of background shading becomes unacceptable, the procedures below may
background fix the problem.
Change to lighter weight paper.
AaBbCc heck the printer's environment; very dry (low humidity) or high humidity (higher than
AaBbCc 80% RH) conditions can increase the amount of background shading.
Remove one of the old toner cartridges and install a new one.
AaBbCc
AaBbCc
AaBbCc
Toner smear Clean the inside of the printer.
Check the paper type and quality.
Remove the imaging unit and install a new one.
Vertical repetitive If marks repeatedly appear on the printed side of the page at even intervals:
defects Clean the inside of the printer. After cleaning the inside of the printer, if you still have the
same problems, install a new toner cartridge of the problem color.
AaBbCc Parts of the printer may have toner on them. If the defects occur on the back of the
AaBbCc page, the problem will likely correct itself after a few more pages.
The fusing assembly may be damaged. Contact a service representative.
AaBbCc
AaBbCc
AaBbCc
Background scatter Background scatter results from bits of toner distributed on the printed page.
The paper may be too damp. Try printing with a different batch of paper. Do not open
packages of paper until necessary so that the paper does not absorb too much mois-
A
ture.
If background scatter occurs on an envelope, change the printing layout to avoid print-
ing over areas that have overlapping seams on the reverse side. Printing on seams can
cause problems.
If background scatter covers the entire surface area of a printed page, adjust the print
resolution through your software application or via the printer properties window.
Misformed If characters are improperly formed and producing hollowed images, the paper stock
characters may be too slick. Try a different paper.
If characters are improperly formed and producing a wavy effect, the printer may need
service. Verify that it also occurs on a demo page.
Service Manual
Troubleshooting
Problem Solution
Page skew Ensure that the paper is loaded properly.
Check the paper type and quality.
AaBbCc Ensure that the paper or other material is loaded correctly and the guides are not too
tight or too loose against the paper stack.
AaBbCc
AaBbCc
AaBbCc
AaBbCc
Curl or wave Ensure that the paper is loaded properly.
Check the paper type and quality. Both high temperature and high humidity can cause
paper curl.
Turn the stack of paper over in the tray. Also try rotating the paper 180° in the tray.
Wrinkles or creases Ensure that the paper is loaded properly.
Check the paper type and quality.
Turn the stack of paper over in the paper tray. Also try rotating the paper 180° in the
tray.
Back of printouts Check for leaking toner. Clean the inside of the printer.
aredirty
Solid Color or The toner cartridge may not be installed properly.
Black pages Remove the toner cartridge and reinsert.
The toner cartridge may be defective and need replacing. Install a new toner cartridge.
The printer may require repair. Contact a service representative.
A
Service Manual
Troubleshooting
Problem Solution
Loose toner Clean the inside of the printer.
Check the paper type and quality.
Install a new toner cartridge.
If the problem persists, the printer may require repair. Contact a service representative.
Character Voids Character voids are white areas within characters that should be solid black:
You may be printing on the wrong surface of the paper. Remove the paper and turn it
over.
The paper may not meet paper specifications.
A
Horizontal stripes If horizontally aligned color or black streaks or smears appear:
A toner cartridge may be installed improperly.
Remove the toner cartridge and reinsert.
AaBbCc A toner cartridge may be defective. Install a new toner cartridge.
AaBbCc If the problem persists, the printer may require repair. Contact a service representative.
AaBbCc
AaBbCc
AaBbCc
Curl If the printed paper is curled or paper does not feed into the printer:
Turn the stack of paper over in the paper tray. Also try rotating the paper 180° in the
tray.
Service Manual
Troubleshooting
Major Problems Trouble shooting
Vertical Line and Band
Vertical White Line
Service Manual
Troubleshooting
Light Image
Dark Image or black
Service Manual
Troubleshooting
Background
Service Manual
Troubleshooting
Major Problems Trouble shooting
Vertical Line and Band
Vertical White Line
Service Manual
Troubleshooting
Light Image
Dark Image or black
Service Manual
Troubleshooting
Background
JAM 0
Service Manual
Alignment and Adjustmens
Periodic Defective Image
If an image defects appears at regular intervals on the printed-paper, it is due to a faulty or damaged roller.
Refer to the table below and check the condition of the appropriate roller.
No Roller Period Phenomenon
1 OPC Drum 188.5 mm White and Black Spots
2 Charge Roller 37.7mm Black Spot and line and Periodic Band
3 Supply Roller 47.5mm Periodic Band by little difference of density
4 Developing Roller 26.0mm White Spot, Horizontal black band
5 1 st Transfer Roller 32.7mm Ghost, Damaged Image by abnormal tranfer
6 2 nd Transfer Roller 57.5mm Ghost, Damaged Image by abnormal tranfer
7 Heat Roller 86.6mm Black Spots or Vertical Black Band
8 Pressure Roller 86.6mm Background
Service Manual
Troubleshooting
Solving General Printing Problems
For problems with the operation of your printer, refer to the table for suggested solutions.
Service Manual
Troubleshooting
Service Manual
Troubleshooting
Service Manual
Troubleshooting
Service Manual
Troubleshooting
Common Windows Problems
Problem Possible Cause and Solution
"File in Use" message appears Exit all software applications. Remove all software from the StartUp Group,
during installation. then restart Windows. Reinstall the printer driver.
"Error Writing to LPTx" message Ensure that all cables are connected correctly and the printer is on.
appears. If bi-directional communication is not turned on in the driver, it will also
cause this message.
"General Protection Fault", Close all other applications, reboot Windows and try printing again.
"Exception OE", "Spool32", or
"Illegal Operation" messages
appear.
"Fail To Print", "A printer timeout These messages may appear during printing. Just keep waiting until the
error occurred." messages appear. printer finishes printing. If the message appears in standby mode or after
printing has been completed, check the connection and/or whether an error
has occurred.
NOTE: Refer to the Microsoft Windows 98/Me/NT 4.0/2000/2003/XP User's Guide that came with your PC for further
information on Windows error messages.
Common Macintosh Problems
Problem Possible Cause and Solution
The printer does not print a You should change the Print Method option to Print as Image when you print
document from Acrobat Reader. from Acrobat Reader.
The document has printed, but the Update your Mac OS to OS 10.3.3 or higher.
print job has not disappeared from
the spooler in Mac OS 10.3.2.
Service Manual
Troubleshooting
Common Linux Problems
Problem Possible Cause and Solution
I can't change settings in the You need to have administrator privileges to be able to change global
configuration tool. settings.
I am using the KDE desktop but You may not have the GTK libraries installed. These usually come with most
the configuration tool and LLPR Linux distributions, but you may have to install them manually. Refer to your
won't start. distribution's installation manual for more details about installing additional
packages.
I just installed this package but Some versions of the KDE or GNOME desktop environments may require
can't find entries in the KDE/ that you restart your session for the changes to take effect.
Gnome menus.
I get a "Some options are not Some printers have conflicting settings, meaning that some settings for two
selected" error message while options can't be selected at the same time. When you change a setting and
editing the printer settings. the Printer Package detects such a conflict, the conflicting option is changed
to a "No Choice" value. You have to choose an option that does not conflict
before being able to submit the changes.
I can't make a printer the system In some conditions, it may not be possible to change the default queue. This
default. happens with some variants of LPRng, especially on recent RedHat systems
that use the "printconf" database of queues.
When using printconf, the /etc./printcap file is automatically refreshed from
the database of printers managed by the system (usually through the "print-
tool" command), and the queues in /etc./printcap.local are appended to the
resulting file. The default queue in LPRng is defined as the first queue in
/etc./printcap, and therefore it is not possible for the Linux Printer Package to
change the default when some queues have otherwise been defined using
printtool.
LPD systems identify the default queue as the one named "lp". Thus, if there
is already a queue by this name, and if it doesn't have an alias, then you
won't be able to change the default. To work around this, you can either
delete the queue or rename it by manually editing the /etc./printcap file.
The N-up setting does not work The N-up feature is achieved through post-processing of the PostScript data
correctly for some of my that is sent to the printing system. However, such post-processing can
documents. only be adequately achieved if the PostScript data conforms to the Adobe
Document Structing Conventions. Problems may arise when using N-up
and other features that rely on post-processing if the document being printed
isn't compliant.
I am using BSD lpr (Slackware, Legacy BSD lpr systems have a hard limitation on the length of the option
Debian, older distributions) and string that can be passed to the printing system. As such, if you selected a
some options chosen in LLPR number of different options, you may have exceeded the length of the
don't seem to take effect. options and some of your choices won't be passed to the programs
responsible for implementing them. Try to select fewer options that deviate
from the defaults, to save on memory usage.
Service Manual
Troubleshooting
Problem Possible Cause and Solution
I am trying to print a document in Most Unix applications that offer a Landscape orientation option in their print-
Landscape mode, but it prints ing options will generate correct PostScript code that should be printed as is.
rotated and cropped. In that case, you need to make sure that you leave the LLPR option set to its
default Portrait setting, to avoid unwanted rotations of the page that would
result in cropped output.
Some pages come out all white If the data being sent is in Encapsulated PostScript (EPS) format, some earli-
(nothing is printed), and I am using er versions of CUPS (1.1.10 and before) have a bug preventing them from
CUPS. being processed correctly. When going through LLPR to print, the Printer
Package will work around this issue by converting the data to regular
PostScript.
However, if your application bypasses LLPR and feeds EPS data to CUPS,
the document may not print correctly.
I can't print to an SMB (Windows) To be able to configure and use SMB-shared printers (such as printers
printer. shared on a Windows printer), you need to have a correct installation of the
SAMBA package that enables that feature. The "smbclient" command should
be available and usable on your system.
My application seems to be frozen Most Unix applications will expect a command like the regular "lpr" command
while LLPR is running. to be non-interactive and thus return immediately. Since LLPR is waiting
for user input before passing the job on to the print spooler, very often the
application will wait for the process to return, and thus will appear to be
frozen (its windows won't refresh). This is normal and the application should
resume functioning correctly after the user exits LLPR.
How do I specify the IP address of It can be specified in the "Add Printer" dialogue of the configuration tool, if
my SMB server? you don't use the CUPS printing system. Unfortunately, CUPS currently
doesn't allow you to specify the IP address of SMB printers, so you will have
to be able to browse the resource with SAMBA in order to be able to print.
Some documents come out as Some versions of CUPS, especially those shipped with Mandrake Linux
white pages when printing. before the 8.1 release, have some known bugs when processing PostScript
output from some applications. Try upgrading to the latest version of CUPS
(at least 1.1.14). Some RPM packages for the most popular distributions are
provided as a convenience with this Linux Printing Package.
I have CUPS and some options There may be some local options defined in your ~/ .lpoptions file, which are
(such as N-up) seem to be always manipulated by the lpoptions command. These options are always used
enabled even though I don't if not overridden by LLPR settings. To get rid of all options for a printer, run
choose them in LLPR. the following command, replacing "printer" with the name of the queue:
lpoptions -x printer
I configured a printer to print to a Most printing systems will not run as the super-user but as a special user
file, but I get "Permission denied" (usually "lp"). Therefore, make sure that the file you have chosen to print to is
errors. accessible to the user owning the spooler daemon.
Service Manual
Troubleshooting
Problem Possible Cause and Solution
On my PCL (or GDI) printer, I Unfortunately, some Unix applications may generate non-compliant
sometimes get error messages PostScript output that may not be supported by Ghostscript, or even the
printing instead of my document. printer itself in PostScript mode. You can try to capture the output to a file and
view the results with Ghostscript (gv or ghostview will allow you to do so
interactively) and see if you get error messages.
However, since the application is probably at fault, contact your software ven-
dor to inform them of the issue.
Some color images come out all This is a known bug in Ghostscript (until GNU Ghostscript version 7.05)
black. when the base color space of the document is indexed color space and it is
converted through CIE color space. Because Postscript uses CIE color
space for Color Matching System, you should upgrade Ghostscript on your
system to at least GNU Ghostscript version 7.06 or later. You can find recent
Ghostscript versions at www.ghostscript.com.
Service Manual
Alignment and Adjustmens
LED Diagnostics:
Remove the Covers (5.4.1). Go to the Block Diagram, lower right corner, and
check input power, switch, SMPS, and Main PWB power distribution voltages.
Refer to the Control Panel wiring diagram (Section 7, Level 2 Block Schematic
Diagram). Refer to Control Panel LEDs (Section 10 Product Technical Overview).
Replace or repair any part as required.
LED Operation:
Go to next page.
Alignment and Adjustmens
LED Function
There are six LEDs present. Status led indicate the error/online status of the printer in idle mode. In error
mode, the status LED glows by red color and in ready mode, it glows by green color. The other four LEDs
indicate the toner status. If the black toner needs to change, the toner-low (black) LED glows and if the
color (yellow, magenta, cyan) toners need to change, the toner-low (yellow, magenta, cyan) LED glows.
Functions
LED function is made up of
- Ready/Printing status display
- Error status display
- Toner low status display
Detail Description
LED control order
1) Control LED according to current printer state
: After the panel task is received each event, the LED operation is controlled by current printer status.
2) Write LED value to GOP (General Output Port)
Service Manual
Alignment and Adjustmens
LED behavior
Status LED Black-only Toner-low Status
(Green/Red) LED (CMYK)LEDs
Green LED ON N/A N/A Ready to receive the data.
Green LEDS N/A N/A Receiving the data from the host.
LOWLY BLINK
Green LED N/A N/A Printing the page.
FAST BLINK
Red LED BLINK N/A N/A Paper source is set to MANUAL .
Need to push the button to start the
printing
Red LED ON N/A N/A Out of paper
Red LED ON N/A N/A Cover open
Red LED ON N/A N/A Paper jam
Green/Red N/A CM Service error ( LSU or Fuser error)
N/A N/A Toner-low(black) ON Black toner needs to change
N/A N/A Toner-low(cyan) ON Cyan toner needs to change
N/A N/A Toner-low(magenta) ON Magenta toner needs to change
N/A N/A Toner-low(yellow) ON Yellow toner needs to change
N/A ON N/A Black only key is pressed
Service Error LED Operation
All LEDs blink the each time interval.
Service Error LED operation
Fuser Error Open Fuser Error All LEDs (Toner low LEDs, Status (Red) LED) blink
a time interval of 1 second.
No Heat Error All LEDs (Toner low LEDs, Status (Red) LED) blink
a time interval of 4 seconds.
Over Heat Error All LEDs (Toner low LEDs, Status (Green/Red) LED)
blink a time interval of 1 second.
Scanner Error P Motor Error All LEDs (Toner low LEDs, Status (Green) LED)
(=LSU Error) blink a time interval of 1 second.
H Sync Error All LEDs (Toner low LEDs, Status(Green) LED)
blink a time interval of 4 seconds.
Service Manual
Alignment and Adjustmens
Assert Error LED Operation
The panel LED operation display the line number of assert error occurrence.
Line number LED operation
start & end All LEDs(Toner low LEDs, Status(Red) LED, turn ON for approximately 2 sec-
onds and then All LEDs turn OFF for approximately 3 seconds.
1 After Status (Red) LED blinks one time, Toner low LEDs blink one time.
2 After Status (Red) LED blinks two times, Toner low LEDs blink one time.
3 After Status (Red) LED blinks three times, Toner low LEDs blink one time.
4 After Status (Red) LED blinks four times, Toner low LEDs blink one time.
5 After Status (Red) LED blinks five times, Toner low LEDs blink one time.
6 After Status (Red) LED blinks six times, Toner low LEDs blink one time.
7 After Status (Red) LED blinks seven times, Toner low LEDs blink one time.
8 After Status (Red) LED blinks eight times, Toner low LEDs blink one time.
9 After Status (Red) LED blinks nine times, Toner low LEDs blink one time.
Service Manual
Section 4 Repairs and Adjustments
Precautions
Precautions
In order to prevent accidents and to prevent damage to the equipment please read the precautions listed
below carefully before servicing the printer and follow them closely.
Safety Warning
(1) Only to be serviced by appropriately qualified service engineers.
High voltages and lasers inside this product are dangerous. This printer should only be serviced by a suitably
trained and qualified service engineer.
(2) Use only approved replacement parts
There are no user serviceable parts inside the printer. Do not make any unauthorized changes or
additions to the printer, these could cause the printer to malfunction and create electric shock or fire hazards.
(3) Laser Safety Statement
The Printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, chapter 1 Subchapter J for
Class 1(1) laser products, and elsewhere, it is certified as a Class I laser product
conforming to the requirements of IEC 825. Class I laser products are not considered to be hazardous. The
laser system and printer are designed so there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed service condition.
Warning >> Never operate or service the printer with the protective cover removed from Laser/Scanner assembly. The
reflected beam, although invisible, can damage your eyes. When using this product, these basic safety
pre-cautions should always be followed to reduce risk of fire, electric shock, and injury to persons.
CAUTION - INVISIBLE LASER RADIATION
WHEN THIS COVER OPEN.
DO NOT OPEN THIS COVER.
VORSICHT - UNSICHTBARE LASERSTRAHLUNG,
WENN ABDECKUNG GE FFNET.
NICHT DEM STRAHL AUSSETZEN.
ATTENTION - RAYONNEMENT LASER INVISIBLE EN CAS
D OUVERTURE. EXPOSITION DANGEREUSE
AU FAISCEAU.
ATTENZIONE - RADIAZIONE LASER INVISIBILE IN CASO DI
APERTURA. EVITARE L ESPOSIZIONE AL
FASCIO.
PRECAUCION - RADIACION LASER IVISIBLE CUANDO SE ABRE.
EVITAR EXPONERSE AL RAYO.
ADVARSEL. - USYNLIG LASERSTR LNING VED BNING, N R
SIKKERHEDSBRYDERE ER UDE AF FUNKTION.
UNDG UDSAETTELSE FOR STR LNING.
ADVARSEL. - USYNLIG LASERSTR LNING N R DEKSEL
PNES. STIRR IKKE INN I STR LEN.
UNNG EKSPONERING FOR STR LEN.
VARNING - OSYNLIG LASERSTR LNING N R DENNA DEL
R PPNAD OCH SP RREN R URKOPPLAD.
BETRAKTA EJ STR LEN. STR LEN R FARLIG.
VARO! - AVATTAESSA JA SUOJALUKITUS OHITETTAESSA
OLET ALTTIINA N KYM TT M LLE LASER-
S TEILYLLE L KATSO S TEESEEN.
Service Manual
Precautions
Caution for safety
Toxic material
This product contains toxic materials that could cause illness if ingested.
(1) Please keep toner cartridges away from children. The toner powder contained in the toner cartridge may be harmful
and if swallowed you should contact a doctor.
Electric Shock and Fire Safety Precautions
Failure to follow the following instructions could cause electric shock or potentially cause a fire.
(1) Use only the correct voltage, failure to do so could damage the printer and potentially cause a fire or electric
shock.
(2) Use only the power cable supplied with the printer. Use of an incorrectly specified cable could cause the cable
to overheat and potentially cause a fire.
(3) Do not overload the power socket, this could lead to overheating of the cables inside the wall and could lead to
a fire.
(4) Do not allow water or other liquids to spill into the printer, this can cause electric shock. Do not allow paper
clips, pins or other foreign objects to fall into the printer these could cause a short circuit leading to an electric
shock or fire hazard..
(5) Never touch the plugs on either end of the power cable with wet hands, this can cause electric shock. When
servicing the printer remove the power plug from the wall socket.
(6) Use caution when inserting or removing the power connector. The power connector must be inserted com-
pletely otherwise a poor contact could cause overheating possibly leading to a fire. When removing the power
connector grip it firmly and pull.
(7) Take care of the power cable. Do not allow it to become twisted, bent sharply round corners or otherwise
damaged. Do not place objects on top of the power cable. If the power cable is damaged it could overheat and
cause a fire or exposed cables could cause an electric shock. Replace a damaged power cable immediately,
do not reuse or repair the damaged cable. Some chemicals can attack the coating on the power cable,
weakening the cover or exposing cables causing fire and shock risks.
(8) Ensure that the power sockets and plugs are not cracked or broken in any way. Any such defects should be
repaired immediately. Take care not to cut or damage the power cable or plugs when moving the machine.
(9) Use caution during thunder or lightening storms. Xerox recommend that this machine be disconnected from
the power source when such weather conditions are expected. Do not touch the machine or the power cord if it
is still connected to the wall socket in these weather conditions.
(10) Avoid damp or dusty areas, install the printer in a clean well ventilated location. Do not position the machine
near a humidifier. Damp and dust build up inside the machine can lead to overheating and cause a fire.
(11) Do not position the printer in direct sunlight. This will cause the temperature inside the printer to rise possibly
leading to the printer failing to work properly and in extreme conditions could lead to a fire.
(12) Do not insert any metal objects into the machine through the ventilator fan or other part of the casing, it could
make contact with a high voltage conductor inside the machine and cause an electric shock.
Service Manual
Precautions
Handling Precautions
The following instructions are for your own personal safety, to avoid injury and so as not to damage the printer
(1) Ensure the printer is installed on a level surface, capable of supporting its weight. Failure to do so could cause
the printer to tip or fall.
(2) The printer contains many rollers, gears and fans. Take great care to ensure that you do not catch your fingers,
hair or clothing in any of these rotating devices.
(3) Do not place any small metal objects, containers of water, chemicals or other liquids close to the printer which if
spilled could get into the machine and cause damage or a shock or fire hazard.
(4) Do not install the machine in areas with high dust or moisture levels, beside on open window or close to a
humidifier or heater. Damage could be caused to the printer in such areas.
(5) Do not place candles, burning cigarettes, etc. on the printer, these could cause a fire.
Assembly / Disassembly Precautions
Replace parts carefully, always use approved parts. Take care to note the exact location of parts and also
cable routing before dismantling any part of the machine. Ensure all parts and cables are replaced correctly.
Please carry out the following procedures before dismantling the printer or replacing any parts.
(1) Check the contents of the machine memory and make a note of any user settings. These will be erased if the
mainboard is replaced.
(2) Ensure that power is disconnected before servicing or replacing any electrical parts.
(3) Disconnect printer interface cables and power cables.
(4) Only use approved spare parts. Ensure that part number, product name, any voltage, current or temperature
rating are correct.
(5) When removing or re-fitting any parts do not use excessive force, especially when fitting screws into plastic.
(6) Take care not to drop any small parts into the machine.
(7) Handling of the OPC Drum
- The OPC Drum can be irreparably damaged if it exposed to light.
Take care not to expose the OPC Drum either to direct sunlight or to fluorescent or incandescent room
lighting. Exposure for as little as 5 mins can damage the surface's photoconductive properties and will result
in print quality degradation. Take extra care when servicing the printer. Remove the OPC Drum and store it in
a black bag or other lightproof container. Take care when working with the covers(especially the top cover)
open as light is admitted to the OPC area and can damage the OPC Drum.
- Take care not to scratch the green surface of OPC Drum Unit.
If the green surface of the Drum Cartridge is scratched or touched the print quality will be compromised.
Service Manual
Precautions
Disregarding this warning may cause bodily injury
(1) Be careful with the high temperature part.
The fuser unit works at a high temperature. Use caution when working on the printer. Wait for the fuser to cool
down before disassembly.
(2) Do not put finger or hair into the rotating parts.
When operating a printer, do not put hand or hair into the rotating parts (Paper feeding entrance, motor, fan,
etc.). If do, you can get harm.
(3) When you move the printer.
This printer weighs 13.6kg including Consumables. Use safe lifting and handling techniques. Back injury could
be caused if you do not lift carefully.
(4) Ensure the printer is installed safely.
The printer weighs 13.6Kg, ensure the printer is installed on a level surface, capable of supporting its weight.
Failure to do so could cause the printer to tip or fall possibly causing personal injury or damaging the printer.
(5) Do not install the printer on a sloping or unstable surface. After installation, double check that the printer is stable.
Service Manual
Disassembly and Reassembly
Precautions when replacing parts
Precautions when assembling and disassembling
* Use only approved apporved spare parts. Ensure that part number, product name, any voltage, current or
temperature rating are correct. Failure to do so could result in damage to the machine, circuit overload,
fire or electric shock.
* Do not make any unauthorized changes or additions to the printer, these could cause the printer to mal-
function and create electric shock or fire hazards.
* Take care when dismantling the unit to note where each screw goes. There are 19 different screws. Use of
the wrong screw could lead to system failure, short circuit or electric shock.
* Do not disassemble the LSU unit. Once it is disassembled dust is admitted to the mirror chamber and will
seriously degrade print quality. There are no serviceable parts inside.
* Regularly check the condition of the power cord, plug and socket. Bad contacts could lead to overheating
and fire. Damaged cables could lead to electric shock or unit malfunction.
Preautions when handling PBA
Static electricity can damage a PBA, always used approved anti-static precautions when
handling or storing a PBA.
>> Precautions when moving and storing PBA
1. Please keep PBA in a conductive case, anti-static bag.
2. Do not store a PBA where it is exposed to direct sunlight.
>> Precautions when replacing PBA
1. Disconnect power connectors first, before disconnecting other cables
2. Do not touch any soldered connections, connector terminals or other electronic parts when handling
insulated parts.
>> Precautions when checking PBA
1. Before touching a PBA, please touch other grounded areas of the chassis to discharge any static elec-
trical charge on the body.
2. Take care not to touch the PBA with your bare hands or metal objects as you could create a short cir-
cuit or get an electric shock. Take extra care when handling PBAs with moving parts fitted such as sen-
sors, motors or lamps as they may get hot.
3. Take care when fitting, or removing, screws. Look out for hidden screws. Always ensure that the correct
screw is used and always ensure that when toothed washers are removed they are refitted in their orig-
inal positions.
Releasing Plastic Latches
Many of the parts are held in place with plastic latches. The latches break easi-
ly; release them carefully.
To remove such parts, press the hook end of the latch away from the part to
which it is latched.
Service Manual
Disassembly and Reassembly
Parts for Maintenance and Repair
Replacement interval for parts with a limited life
Some of the parts in this printer have a limited life, shorter than that of the whole machine. These parts
must be replaced periodically.
The table below shows the interval at which these parts should be replaced.
The table shows the life of each part, and is measured when using A4 paper. When servicing a machine
always check the status of these parts using the control panel and ensure that parts are replaced at the
appropriate times otherwise a general degradation in print quality will occur.
COMPONENT REPLACEMENT CYCLE REMARK
Toner Cartridge (Black) intial (1,500 pages@5% coverage) User replace
replacement (2,000 pages@5% coverage)
Toner Cartridge (Color: C/M/Y) intial (700 pages@5% coverage) User replace
replacement (1,000 pages@5% coverage)
Waste toner container 5K image or 1.25K pages User replace
(Full color 5% image)
T2 Roller 100K pages
Imaging Unit 20K pages (Black)
12.5K pages (Color)
ITB Unit(Image Transfer Unit) Black : (60K pages@5% coverage) User replace
Color : (15K pages@5% coverage)
Pick-Up Roller 100,000 pages Engineer
- MP Pick-Up Roller,
- Cassette Tray1 Pick-Up Roller
Fuser Unit 100,000 pages (B/W) Color(50,000 pages) User replace
The life span of each of these parts is stored in memory. The amount of each 'life' used can be checked at
any time using the control panel.
When a part is replaced it is necessary to reset the 'life used' that is stored in memory.
* How to initialize a the value of part's life span:
From the control panel, select the following items in order:
Menu-Setup - Maintenance - Check other - (Select a desired part) - Reset
Service Manual
Disassembly and Reassembly
Critical Service Information
Warnings, Cautions, and Notes
Warnings
Personal injury or death may occur if
service personnel come into contact with
AC operating voltages.
Disconnect the power cord when removing
or replacing parts.
When diagnosing electrical problems
use care to avoid contact with AC voltages.
Cautions
Damage to the printer can occur if service
procedures aren't followed or careless service
methods are practiced. To avoid damage to the
printer review the intended action or procedure
before actually woorking on the printer.
Notes
Notes are used to communicate helpful tips
or relate conditions that may affect the
service action.
Service Manual
Disassembly and Reassembly
Information Related to Disassembly and Assembly
Special service parts
Never disassemble or adjust the items listed on this page except the Fuser.
1) Disassembly of the Laser Scan Unit 4) Disassembly of DEVE drive ass'y
There are no serviceable parts inside the and the main drive ass'y
LSU. Alignment of the mirrors is critical. The alignment of the drive mechanism is
Opening the LSU will allow dust into the critical and it has been set up in factory
laser and significantly reduce print quality. using a jig and a driving gear. It is adjust-
It is very dangerous to operate or service ed for the best gearing alignment. If the
a machine with the LSU open or system motor is disassembled alignment would
interlocks disabled. Exposure to laser not be maintained and this could cause
radiation can cause blindness. operational noise and image problems:
image alignment and toner distribution
may be affected.
2) Disassembly of the ITB unit
Do not disassemble the ITB. The align-
ment of the home sensor is critical and is 5) Disassembly of terminal parts
set up in the factory on a special jig. Do not adjust the variable resistors on the
Incorrect re-assembly will cause print PBA. They have been already adjusted in
quality degra