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Xerox Phaser 6200, Service Manual

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48

Phaser 6200 Color Laser Printer - Service Manual

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.
Inspect the printer cavity for damage, 
foreign material and loose toner under the 
auger area which could prevent the 
Imaging Unit from being seated properly. 
Is there foreign material or damage?

Remove foreign 
materials.
Vacuum out loose 
toner if found.

Go to step [2].

2

Inspect and reseat the Imaging Unit 
checking for possible defects or damage.

Replace the Imaging 
Unit, PL 9.1.3.

Go to step [3].

3

Remove the left cover.
Check the Gear Slide and the Rack V for 
damage or misalignment. 
See "Toner Cartridge Holder Unit 
Assembly (PL 10.1)" on page 203 for 
more information, (RRP 10.1)

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 
reinstall the gear 
slide. 

Go to step [4].

4

Verify the CRUM connector is not 
damaged or improperly connected.

Replace the Plate 
Dispenser Left,
PL 10.1.9.

Go to step [5].

5

Check the CRUM Harness for continuity.
See "Laser Unit" on page 359

Go to step [6]

Replace CRUM 
Harness 
Assembly, 
PL 10.1.15.

6

Check the EEPROM Harness for 
continuity.
See  "Laser Unit" on page 359

Replace the Engine 
Control Board,
RRP 12.7.

Replace 
EEPROM 
Harness 
Assembly, 
PL 13.1.10.

Summary of Contents for Phaser 6200

Page 1: ......

Page 2: ......

Page 3: ...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 PHASER 6200 COLOR LASER PRINTER Service Manual ...

Page 4: ...a 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 MP RJ ...

Page 5: ...ific 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...

Page 6: ...tall a properly grounded outlet If the product loses its ground connection contact 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 tha...

Page 7: ...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 ...

Page 8: ...n 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 Interlock...

Page 9: ...ervicing 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 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 Compo...

Page 10: ... 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 a...

Page 11: ...t 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 Test Specificat...

Page 12: ...rror 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 cal...

Page 13: ...er s major assemblies switches and sensors drives and gears 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 ...

Page 14: ...xii Phaser 6200 Color Laser Printer Service Manual ...

Page 15: ...r Behavior 7 Front Panel Configuration 8 Image Processor Board 9 Printer Specifications 10 Functional Specifications 11 Electrical Specifications 12 Environmental Specifications 13 Media and Tray Specifications 14 Error Messages and Codes 17 Service Flowchart 20 Using the Troubleshooting Procedures 21 Service Diagnostics 23 Service Diagnostics Tests and Functions Table 24 Troubleshooting Procedure...

Page 16: ...Prints Adjustments and NVRAM 109 Service Test Prints 110 Analyizing the CMYK Sample Page 110 Analyizing the RGB Sample 110 Analyizing the Test Pattern Sample 111 Analyizing the 600 x 600 Service Test Print 112 Color Calibration 112 Color Registration 113 Margin Calibration 113 Resetting NVRAM 114 PostScript NVRAM Resets 114 Service Diagnostics PostScript NVRAM Resets 116 Cleaning and Maintenance 1...

Page 17: ...313 Paper Path of the Printer 314 Paper Path Route 315 Major Assemblies and Functions 316 Plug Jack Locator Maps 341 Print Engine Plug Jack Locator Table 341 High Capacity Feeder Plug Jack Locator Table 349 Wiring Diagrams 351 Main Wiring Diagram 352 Power Supply 353 Paper Tray 1 354 Drive Section 355 Developer Section 1 356 Developer 2 357 Fuser Assembly 358 Laser Unit 359 Xerographics 1 360 Xero...

Page 18: ...xvi Phaser 6200 Color Laser Printer Service Manual ...

Page 19: ...anual 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 Phaser 6200 Color Laser Printer shown with the optional High Capacity Feeder S6200 001 ...

Page 20: ...e 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...

Page 21: ...anel The customer assigns the password at the client workstation before printing The job is stored and printing is delayed until the password is entered 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 Sav...

Page 22: ...e Printer No Description 1 Top Cover Output Tray 2 Control Panel Front Panel 3 Front Cover 4 Multi Purpose Tray 5 Universal Paper Tray 1 6 High Capacity Feeder with Tray 2 and Tray 3 7 Door Latch B 8 Door Latch A 9 Power On Off Switch 1 2 3 4 5 6 7 8 9 S6200 005 ...

Page 23: ...General Information 5 No Description 1 Top Cover 2 Toner Cartridge 3 AC Power Cord Plug 4 Image Processor Board 5 Paper Tray Rear Cover 3 1 S6200 006 4 5 2 ...

Page 24: ...6 Phaser 6200 Color Laser Printer Service Manual No Description 1 Transfer Roller 2 Imaging Unit 3 Door C 4 Fuser Assembly 1 2 3 S6200 008a S6200 008b 4 3 ...

Page 25: ...ear 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 Black Toner Cartridge Standard Capacity is 4 000 High Capacity 8 000 B50 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 Fe...

Page 26: ...Warning Flashing Red Error 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 o...

Page 27: ...ge Processor Board in the printer See RRP 12 8 for information on replacing the Image Processor Board Rear Panel Configuration Interfaces IEEE 1284 Parallel Ethernet 10BaseT and 100BaseTx USB Top View No Description 1 Hard Drive optional 2 Configuration Upgrade Chip i Button 3 NVRAM 4 Memory RAM DIMM 1 and DIMM 2 1 2 3 4 S6200 270 pin 1 ...

Page 28: ...ions 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 lb no Paper Tray s installed Approximately 20 kg 44 lb 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 ...

Page 29: ...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 m2 Simplex Duplex 600 dpi Letter A4 65 105 16 ppm 10 ipm 100 159 8 ppm N A 160 216 8 ppm N A 1...

Page 30: ...f condition 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 W or less Ready Mode Fuser On 180 W or...

Page 31: ...7o to 26o C 10o C to 32o C 50o F to 90o F 30o C to 50o C 22o F to 122o F Normal 0o C to 35o C 32o F to 95o F Severe 20o C to 40o C 4o F to 104o F Humidity Operating Transportation Storage Optimal print quality range 35 to 70 10 85 30 85 5 95 Altitude Operating Transportation 0 2 500 meters 8 000 ft 0 6 092 meters 20 000 ft Acoustic Noise Idle Printing 35 0db or less 53 0db or less Full Speed 5 3 B...

Page 32: ...nd Phaser 6200 Transparency ONLY Thin Card Stock 100 163 g m2 26 60 lb Cover Thick Card Stock 160 216 g m2 59 80 lb Cover Labels N A Letterhead 85 105 g m2 22 28 lb Bond Glossy Coated Paper 120 163 g m2 81 110 lb Book Business and Greeting Card N A CD DVD Labels and Inserts N A Digital Photo Paper 120 163 g m2 81 110 lb All Trays All Trays MPT Tray 1 MPT Only MPT Only MPT Only All Trays MPT Only M...

Page 33: ...formation 15 Tray Capacity Universal Tray MPT Standard Paper 500 Sheets 100 Sheets Transparency 100 Sheets 50 Sheets Envelopes N A 10 each Tray 1 MPT only Media and Tray Specifications cont d Specification Trays ...

Page 34: ...16 Phaser 6200 Color Laser Printer Service Manual ...

Page 35: ...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 messa...

Page 36: ...nit 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...

Page 37: ...e 40 41 42 43 44 45 46 47 70 Fuser Fan Failure Code 50 73 Rear Fan Failure Code 51 74 Generic Fan Failure Code 52 75 Engine Firmware Failure Code 70 71 72 73 74 77 78 79 76 Imaging Unit Firmware Failure Code 75 77 Fuser Firmware Failure Code 76 72 Engine Firmware Failure Code 77 78 76 Controller to Engine Communications Failure Code 81 78 NVRAM Failure Code 83 78 Non Xerox Imaging Unit Code 95 79 ...

Page 38: ...isconnect the AC power cord from the wall outlet 3 Verify the power cord is free from damage or short circuit and is connected properly 4 Remove the Imaging Unit and protect it from light 5 Inspect the printer interior and remove any foreign matter such as paper clips staples pieces of paper dust or loose toner Do not use solvents or chemical cleaners to clean the printer interior Do not use any t...

Page 39: ...9 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 1 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 R...

Page 40: ...leshooting 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 Pl...

Page 41: ...d 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 Service 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 Func...

Page 42: ...f Hard Drive option Detects presence of High Capacity Feeder option Ambient Temperature Humidity Temperature XX o C Humidity Displays the current Temperature and Humidity for the printer Fuser Temperature Temperature XX o C Displays the printers current Fuser temperature Fault History Device Status Jams Hardware Errors Firmware Errors Fan Motors CTD Sensor Errors Fuser Failure Laser Failure Life O...

Page 43: ...rification 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 N...

Page 44: ...xit Sensor Sensor is OFF Sensor is ON Actuate de actuate the Exit Actuator PL8 1 7 located in the Fuser to toggle the sensor state Duplex Sensor Sensor is OFF Sensor is ON Actuate de actuate the Duplex Actuator PL6 1 13 located in the Fuser to toggle the sensor state Full Stack Sensor Sensor is OFF Sensor is ON Actuate de actuate the Output Tray Full Actuator PL6 1 4 at the output tray to toggle t...

Page 45: ...l Block the Toner Full Sensor PL5 1 13 to change the sensor state Image Unit Not Installed Sensor Image Unit is Not Present Open Door C to change the state of the Switch Fuser Fan Alarm Sensor Fuser Fan Alarm Sensor is OK Failure Status only Note Perform a test print immediately prior to performing this test Rear Fan Alarm Sensor Rear Fan Alarm Sensor is OK Failure Status only Note Perform a test ...

Page 46: ...olenoid is ON Solenoid is OFF Audible verification of the Solenoid function Maintenance Cleans the Intermediate Transfer Unit within the Imaging Unit Clean the Imaging Unit IDT 1 Clean the Imaging Unit IDT 2 Printing 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 NVRAM Access This menu le...

Page 47: ...er K Life Count XXX Record this value Displays the current CRU Life count Cyan Toner C Life Magenta Toner M Life Yellow Toner Y Life Transfer Roller Life Read Printer Page Count Count XXXX Reads engine printer life count Record this value before replacing the Engine Control Board CRU Life Restore The following options are available for CRU Life Restore Black Toner K Life Count XXXX Up Dn to Incr D...

Page 48: ... Passed Performs an extended memory test on the Image Processor Board Note Cycle power to the printer after executing this test Exit Exits service diagnostics and reboots the printer Service Diagnostics Tests and Functions Table cont d Test Front Panel Display and Test Definition ...

Page 49: ... 1 Transfer Roller PL 8 1 12 Imaging Unit PL 9 1 3 Replace the part s concerned Go to step 2 2 Remove the Fuser and check for broken or bent pins Replace the parts concerned Go to step 3 3 Use service diagnostics to test the Exit Sensor Does the sensor function correctly Go to step 8 Replace the Fuser Assembly Go to step 4 4 Does an error occur after the Fuser Assembly has been replaced Go to step...

Page 50: ...e voltage between P 52 1 P 60 2 on the Motor Driver Board is 24 VDC Go to step 11 Replace the Motor Driver Board RRP 12 3 11 Replace the Fuser Motor Does the Fuser Motor function correctly Complete Go to step 12 12 Check the DRV 1 Harness for continuity Replace the Engine Control Board RRP 12 7 Replace the DRV 1 Harness PL 13 1 2 Troubleshooting Procedure Table cont d Steps Actions and Questions Y...

Page 51: ...t Go to step 2 2 Use service diagnostics to test the Duplex Sensor Does the sensor function correctly Go to step 7 Replace the sensor and Go to step 3 3 Does the printer function correctly after the Duplex Sensor is replaced Complete Go to step 4 4 Block the Duplex Sensor and verify the voltage between J 139 3 J 139 2 is 0 VDC Go to step 6 Go to step 5 5 Check the Front 2 Harness for continuity Se...

Page 52: ...continuity See Drive Section on page 365 Got to step 11 Replace the Duplex Harness Assembly PL 6 1 23 11 Does the error recur after replacing the Duplex Motor Go to step 12 Complete 12 Check J 12 J 42 pins on the DRV 2 Harness for continuity See Drive Section on page 365 Replace the Engine Control Board RRP 12 7 Replace the Assembly Harness DRV2 PL 13 1 3 Troubleshooting Procedure Table cont d Ste...

Page 53: ... following for evidence of fault or damage Registration Actuator PL 9 1 9 Chute Assembly Registration PL 9 1 6 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Registration Sensor Does sensor function correctly Go to step 6 Go to step 3 3 Check that the connection between the Harness and the Registration Sensor is properly connected and seated Go to step 4 Reconnect p...

Page 54: ...tween P 18 4 P 18 2 on the Engine Control Board is 24 VDC Close the Interlock Switch while checking the voltage Replace the Chute Assembly Registration RRP 9 3 Replace the Engine Control Board RRP 12 7 Troubleshooting Procedure Table cont d Steps Action and Questions Yes No ...

Page 55: ...ing parts for fault or damage Multi Purpose Tray Remove any foriegn objects or debris in the paper path Registration Sensor PL 9 1 8 Main Drive Assembly PL 11 114 Replace any damaged or excessively worn parts Go to step 2 2 Use service diagnostics to test the Registration Sensor Does the sensor function normally Go to step 6 Go to step 3 3 Check that the connection between the Harness and the Regi...

Page 56: ...ge between P J61 8 P J61 7 on the Motor Driver Board is 5 VDC Go to step 13 Go to step 14 13 Check the power supply by verifing the voltage between P J61 6 P J61 5 on the Motor Driver Board is 3 3 VDC Go to step 15 Go to step 14 14 Check the LVNC Harness for continuity See Main Wiring Diagram on page 352 See DC Power Supply Troubleshooting on page 88 Replace the Harness LVNC PL 13 1 1 15 Check the...

Page 57: ...o to step 20 20 Use service diagnostics to test the MPT Feed Solenoid Does the solenoid actuate In the test actuate the Interlock Switch Check the spring and stopper of the Feed Solenoid Go to step 21 21 Remove the MPT Feed Solenoid connector J132 Is J132 1 J132 2 less than 100Ω Go to step 22 Replace the MPT Feed Solenoid 22 Check the Front 2 Harness for continuity Replace the Engine Control Board...

Page 58: ...ck for worn or damaged rollers and gears on the Paper Pick Assembly and 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 Replace any damaged or excessively worn parts Go to step 2 2 Use service diagnostics to test the Registration Sensor Does the sensor function normally Go to step 6...

Page 59: ... 8 P J61 7 on the Motor Driver Board is 5 VDC Go to step 13 Go to step 14 13 Check the power supply by verifing the voltage between P J61 6 P J61 5 on the Motor Driver Board is 3 3 VDC Go to step 15 Go to step 14 14 Check the LVNC Harness for continuity See Main Wiring Diagram on page 352 See DC Power Supply Troubleshooting on page 88 Replace the Harness LVNC PL 13 1 1 15 Check the DRV 1 Harness f...

Page 60: ... test the Tray 1 Feed Solenoid Does the solenoid actuate During the test actuate the Interlock Switch Check the spring and stopper on the Feed Solenoid Go to step 23 23 Verify the voltage between P J47 11 P J60 2 on the Motor Driver Board is 24 VDC Go to step 24 Replace the Motor Driver Board RRP 12 3 24 Check the Feeder Harness for continuity Go to step 25 Replace the Feeder Harness Assembly PL 3...

Page 61: ...to step 2 See Misfeed at Tray 1 Jam T1 on page 40 2 Does the HCF Motor run when printing one sheet Tray 2 Go to step 9 Go to step 3 3 Use service diagnostics to test the HCF Motor Does the HCF motor function correctly Replace the Engine Control Board RRP 12 7 Go to step 4 4 Verify the voltage between P J84 3 P J81 1 on the Lower Feeder Circuit Board is 24 VDC Go to step 7 Go to step 5 5 Verify the...

Page 62: ...nting one sheet of paper Check the Tray 2 Feed Solenoid for damage Go to step 14 14 Use service diagnostics to test the Tray 2 Clutch Solenoid Does the solenoid function correctly Check the stopper on the feed solenoid and replace if necessary Go to stop 15 15 Verify the voltage between P J82 11 P J81 1 on the Lower Feeder Circuit Board is 24 VDC Go to step 16 Replace the Lower Feeder Circuit Boar...

Page 63: ...oes the HCF Motor run when printing one sheet Go to step 10 Go to step 3 3 Use service diagnostics to test the HCF Motor Does the HCF motor function correctly Replace the Engine Control Board RRP 12 7 Go to step 4 4 Verify the voltage between P J84 3 P J81 1 on the Lower Feeder Circuit Board is 24 VDC Go to step 7 Go to step 5 5 Verify the voltage between P J81 2 P J81 1 on the Lower Feeder Circui...

Page 64: ...Gear in the Tray 3 Feeder turn when feeding 1 sheet of paper Check the Solenoid for damage Go to step 16 15 Use service diagnostics to test the Tray 3 Clutch Solenoid Does the solenoid function correctly Check the stopper on the feed solenoid and replace if necessary Go to step 17 16 Verify the voltage between P J83 11 P J81 1 on the Lower Feeder Circuit Board is 24 VDC Go to step 17 Replace the L...

Page 65: ...e Steps Actions and Questions Yes No 1 Check the following for evidence of fault or damage 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 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Interlock Switch Does the Interlock Switch function correctly Replac...

Page 66: ...e foreign materials Vacuum out loose toner if found Go to step 2 2 Inspect and reseat the Imaging Unit checking for possible defects or damage Replace the Imaging Unit PL 9 1 3 Go to step 3 3 Remove the left cover Check the Gear Slide and the Rack V for damage or misalignment See Toner Cartridge Holder Unit Assembly PL 10 1 on page 203 for more information RRP 10 1 Damage can occur if the Gear and...

Page 67: ...Table Steps Actions and Questions Yes No 1 Check the following parts for evidence of fault or damage Imaging Unit CRC PL 9 1 3 CRUM Connector on the Plate Dispenser Replace the parts concerned Go to step 2 2 Replace the Imaging Unit Does the error recur Go to step 3 Complete 3 Verify the CRUM Harness is properly connected See Laser Unit on page 359 Go to step 4 Replace the CRUM Harness Assembly PL...

Page 68: ...C PL 8 1 12 CTD ADC Sensor PL 5 1 11 Complete Go to step 2 2 Clean the CTD ADC Sensor to remove any toner build up Does this fix the problem Complete Go to step 3 3 Use service diagnostics to test the ADC Sensor Does the sensor function correctly Go to step 4 Go to step 5 4 Replace the Transfer Roller Does the error recur Go to step 5 Complete 5 Is the CTD ADC Harness connected to the CTD ADC Sens...

Page 69: ...cs 1 on page 360 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault or damage Transfer Roller PL 8 1 12 Toner Full Sensor PL 5 1 13 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Transfer Roller Toner Full Sensor Does the Transfer Roller Toner Full Sensor function correctly Replace the Engine Control Board ...

Page 70: ...ions Yes No 1 Cycle power to the printer Does the error recur Go to step 2 Complete 2 Check the Fuser Assembly for fault or damage Replace the Fuser Assembly CRC PL 8 1 1 Power cycle the printer after replacing the Fuser Go to step 3 3 Does the error recur after replacing the Fuser Assembly Go to step 4 Complete 4 Check the Fuser Harness FSR2 110V or Fuser 22 220V for continuity See Fuser Assembly...

Page 71: ...nd 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 Assembly for damage Connect properly or replace the parts concerned Power cycle the printer Go to step 2 2 Does the error recur after the Fuser has been replaced w...

Page 72: ...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 present switch of the problem color Does the Toner Present Switch YMCK function normally Replace the Engine Control Board RRP 12 7 Go to step 2 2 Check the following for evidence of fault or damage repl...

Page 73: ...acement of the of the problem color Does the error recur Go to step 2 Complete 2 Use service diagnostics to test the Toner 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 Go to step 3 Complete 3 Use service diagnostics to test the Toner Motor Caution Run this test for ONLY 5 seconds to avoid ...

Page 74: ... the wiring diagrams See Developer Section 1 on page 356 and See Drive Section on page 355 Replace any defective parts Does the error still appear Replace the Engine Control Board RRP 12 7 Complete Troubleshooting Procedure Table cont d Steps Actions and Questions Yes No ...

Page 75: ...amage Transfer Roller Assembly PL 8 1 12 CTD ADC Sensor Assembly PL 5 1 11 Replace the parts concerned Go to step 3 3 Is the CTD ADC Harness connected to the CTD ADC Sensor and functioning correctly Go to step 4 Replace the parts concerned 4 Replace the CTD ADC Sensor Does the error still appear after replacing the sensor Go to step 5 Complete 5 Check the CTD ADC Harness for continuity See Xerogra...

Page 76: ...or PL 6 1 4 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check the following for evidence of fault or damage Actuator Full Stack PL 6 1 Full Stack Sensor PL 6 1 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Full Stack Sensor Does the sensor function correctly Replace Engine Control Board RRP 12 7 Go to step 3 3 Replace the Full Stack Sensor ...

Page 77: ...es No 1 Check the following for evidence of fault or damage Paper Size Switch Assembly PL 3 2 4 Tray 1 PL 2 1 1 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the paper size switches using the table below Do the switches function normally Replace Engine Control Board RRP 12 7 Go to step 3 3 Troublshoot using the wiring diagram Paper Tray 1 on page 354 Replace any defect...

Page 78: ...he following for evidence of fault or damage Paper Size Switch Tray 2 3 PL 14 3 6 Actuators on the side of the Tray 2 3 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Tray 2 3 Paper Size Switches use the table below for reference Do the switches function correctly Replace Engine Control Board RRP 12 7 Go to step 3 3 Troubleshoot using the Paper Tray 2 3 wiring diagr...

Page 79: ...y with paper to the fill line Does the error still appear Go to step 2 Complete 2 Check the following for evidence of fault or damage Low Paper No Paper Sensor PL 3 3 4 No Paper Actuator PL 3 3 5 Replace the parts concerned Go to step 3 3 Use service diagnostics to test the Tray 1 Low Paper Sensor Do the sensor and actuator function properly Replace the Engine Control Board RRP 12 7 Go to step 4 4...

Page 80: ...e 367 Troubleshooting Procedures Table Steps Actions and Questions Yes No 1 Fill the tray with paper Does the error occur if the tray is full Go to step 2 Complete 2 Check the following for evidence of fault or damage Low Paper Sensor PL 14 5 7 Low Paper Lever PL 14 5 8 Replace the parts concerned Go to step 3 3 Use service diagnostics to test the Tray 2 3 Low Paper Sensor Do the sensor and actuat...

Page 81: ... Steps Actions and Questions Yes No 1 Fill the MPT with paper Does the error occur even if the MPT is full Go to step 2 Complete 2 Check the following for evidence of fault or damage MPT No Paper Sensor PL 6 1 4 MPT Actuator PL 6 1 37 Replace the parts concerned Go to step 3 3 Use service diagnostics to test the MPT No Paper Sensor Does the Sensor function correctly Replace Engine Control Board RR...

Page 82: ...Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Fill Tray 1 Does the error occur even if the tray is full Go to step 2 Complete 2 Check the following for evidence of fault or damage No Paper Sensor PL 3 3 4 No Paper Actuator PL 3 3 5 Replace the parts concerned Go to step 3 3 Use service diagnostics to test the Tray 1 No Paper Sensor Does the sensor function correctly Replace ...

Page 83: ...wing for evidence of fault or damage Paper Size Switch Assembly PL 3 2 4 Tray 1 PL 2 1 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Paper Size Switches using the table below Does the switch function normally Replace the Engine Control Board RRP 12 7 Go to step 3 3 Does the printer function correctly after replacing the Motor Driver Board Complete Go to step 4 4 Tr...

Page 84: ...ions Yes No 1 Check the following for evidence of fault or damage Paper Size Switch Tray 2 3 PL 14 3 6 Tray 2 3 PL 14 1 1 Replace the parts concerned Go to step 2 2 Use service diagnostics to test the Tray 2 3 switches using the table below for reference Does the sensor and actuator function properly Replace the Engine Control Board RRP 12 7 Go to step 3 3 Does the printer function correctly after...

Page 85: ...nd Questions Yes No 1 Check the following for evidence of fault or damage OHP Sensor and Harness PL 9 1 12 Chute Assembly Registration PL 9 1 6 Replace OHP Sensor and Harness RRP 9 5 Assembly Chute Registration RRP 9 3 Go to step 2 2 Using service diagnostics test the OHP Sensor Does the OHP Sensor function correctly Replace the Engine Control Board RRP 12 7 Go to step 3 3 Verify the voltage betwe...

Page 86: ...nd Plug Jack Map References Laser Unit PL 9 1 1 Laser Unit on page 359 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Check and reseat P J151 on the Laser Unit Does the printer function correctly if the harness is reseated Complete Go to step 2 2 Does the error recur after the Laser Unit has been replaced Go to step 3 Complete 3 Check the Laser ROSKA Harness ROSKA for continu...

Page 87: ... step 2 2 Use service diagnostics to test the ADC Sensor Does the sensor function correctly Go to step 4 Go to step 3 3 Does the error recur after the CTD ADC Sensor has been replaced Go to step 4 Complete 4 Check the following for evidence of fault or damage Transfer Roller Assembly PL 8 1 12 Imaging Unit PL 9 1 3 Replace the parts concerned Go to step 5 5 Does the error recur after the Laser win...

Page 88: ...lled in the printer verify against the label on the Fuser Assembly Check the Fuser Assembly for evidence of fault or damage Replace the parts concerned Go to step 2 2 Remove the Fuser Assembly and check for broken or bent pins Replace the parts concerned Go to step 3 3 Does the error recur after the Fuser Assembly has been replaced with a new one Go to step 4 Complete 4 Replace the Low Voltage Pow...

Page 89: ...cur after the Fuser Assembly has been replaced with a new one Go to step 4 Complete 4 Replace the Low Voltage Power Supply RRP 12 2 Does the error recur after the LVPS has been replaced Go to step 5 Complete 5 Troubleshoot using the wiring diagram Fuser Assembly on page 358 Does the printer function correctly after replacing any defective parts Complete Go to step 6 6 Verify the voltage of P J61 4...

Page 90: ...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 of fault or damage Replace the parts concerned Go to step 2 2 Remove the Fuser Assembly and check for broken or bent pins Replace the parts concerned Go to step 3 3 Does the error recur after the Fuser Assembly has been replaced ...

Page 91: ... Does an error recur after the Fuser Fan has been replaced Replace the Engine Control Board RRP 12 7 Go to step 3 3 Does the error recur after the Motor Driver Board has been replaced Go to step 4 Complete 4 Troubleshoot using the wiring diagram Drive Section on page 355 Replace any defective parts Does the printer function correctly after replacing any defective parts Complete Go to step 5 5 Prin...

Page 92: ... No 1 Check the Rear Fan for evidence of fault or damage Replace the Rear Fan RRP 12 4 Go to step 2 2 Does an error occur after the Rear Fan is replaced Go to step 3 Complete 3 Replace the Low Voltage Power Supply Board Does the error recur after the LVPS is replaced Go to step 4 Complete 4 Troubleshoot using the wiring diagram Main Wiring Diagram on page 352 Replace any defective parts Does the p...

Page 93: ... 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 or damage Rear Fan PL 12 1 2 Fuser Fan PL 1 1 7 Replace the defective fan Go to step 2 2 Isolate the problem fan by running service diagnostics testing both the Rear Fan and Fuser Fan Did one of the fans fail Go to the troubleshooting procedure for the sp...

Page 94: ...rmware Failure code fails to report to the controller properly 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 replace the Engine Control Board RRP 12 7 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Is the problem application related Forwar...

Page 95: ...rness connector damaged or improperly connected Replace the Plate Dispense Left PL 10 1 9 Go to step 4 4 Remove the left cover Check the Gear Slide and the Rack V for damage or misalignment Is the Rack V out of alignment See RRP 10 1 for more information 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 reinstall t...

Page 96: ...power to the printer Is the error cleared Complete Go to step 2 2 Is the error cleared by reseating the Image Processor Board to Engine Control Board Complete Go to step 3 3 Is the error cleared after replacing the Image Processor Board See note above Complete Replace the Engine Control Board RRP 12 7 Troubleshooting Procedure Table Steps Actions and Questions Yes No 1 Cycle power to the printer D...

Page 97: ...damage Replace the parts concerned Go to step 3 3 Does replacing the Imaging Unit fix the problem Complete Go to step 4 4 Verify the CRUM Harness is not damaged or improperly connected Go to step 4 Replace the Plate Dispense Left PL 10 1 9 5 Remove the left cover Check the Gear Slide and the Rack V for damage or misalignment Is the Rack V out of alignment See RRP 10 1 for more information Damage c...

Page 98: ... 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 Temperature Humidity Sensor Does the sensor function correctly Go to step 2 Replace the Temp Hum Sensor RRP 3 5 2 Troubleshoot using the wiring diagrams Xerographics 1 on page 360 and Xerographics 2 on page 36...

Page 99: ... 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 Probl...

Page 100: ...ing Edge 102 Missing Band Voids Or Streaks in a Single Color or All Colors in direction of paper travel 103 Repeating and Random Spots 104 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 Contents cont d Page ...

Page 101: ...tem 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 both the front panel and health LED blink the error code pattern see LED Blink Patterns on page 84 POST Startup indications At power on the hardware default is to turn on the IP board health LED The Image ...

Page 102: ...rtPage For hard faults The health LED flashes according to the fault code The front panel LED flashes in unison with the health LED 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 wort...

Page 103: ...ion chip is present If no chip is present the 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 R...

Page 104: ...DC 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 t...

Page 105: ...anel 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...

Page 106: ...heck the power cord for defects or a loose connection Replace or reseat the power cord Go to step 3 3 Disconnect the Power Cord and turn the AC switch ON Check the AC Switch Harness for continuity See Drive Section on page 355 Replace the Low Voltage Power Supply PL 12 1 12 Replace the AC Switch Harness Assembly PL 12 1 11 Troubleshooting Reference Table Triage Parts Wiring and Plug Jack Map Refer...

Page 107: ...eck the following parts for fault or damage LVRPG Harness Assembly for damage or if it is shorted to the frame Engine Control Board Replace if damaged or defective Go to step 6 6 Turn the AC power switch OFF Connect J165 to the LVPS then turn the AC power switch ON Verify P J165 1 P J165 2 5 VDC P J165 3 P J165 4 3 3 VDC Go to step 8 Go to step 7 7 Check the following parts for fault or damage LVN...

Page 108: ...humidiy 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 paper and then insert into the tray or flip existing paper over 5 Check the tray s retard roller for damage 6 Clean the pick rollers with a clean dry lint free wipe 7 Replace the paper pick rollers 8 Re...

Page 109: ...sizes and weights for each tray 2 Ensure only Phaser 6200 Transparency film is being used 3 Check that the printer is operating within its environmental specifications 4 Ensure that the loaded media matches the front panel settings 5 Are the margins on the page greater than 5 mm 6 Check the Fuser area for debris 7 Visually inspect the Fuser baffle for burrs 8 Test the fuser motor using service dia...

Page 110: ... 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 causi...

Page 111: ...s 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 1 Enter normal Customer Mode 2 From the main menu highlight Support Menu and press OK 3 Scro...

Page 112: ...nmental 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 ...

Page 113: ...y Voids Repeating Defects Transfer Roller Toner on the back side of the printed page simplex mode Light Prints Repeating Defects Fuser Hot or Cold Offsetting 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...

Page 114: ...oard cavity on the rear of the Engine Control Board locate jumper pins 1 and 2 on connector P31 5 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 remov...

Page 115: ...ove if the Imaging Unit is replaced Complete Go to step 3 3 Check the Heat Roll and NIP Belt for evidence of damage or contamination See Transfer Roller and Fuser Assembly on page 331 Replace the Fuser Assembly CRC PL 8 1 1 Go to step 4 4 Does the image quality improve if the Transfer Roller is replaced Complete Go to step 5 5 Check the Front 1A Harness for continuity P J5030 Transfer roller P J50...

Page 116: ...2 Is the affected color s toner supply empty Replace Toner Cartridge PL 10 1 Go to stop 3 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 4 Inspect the Developer Bias Plunger Stud of the effected color for proper spring pressure compare to the other colors Check for contamination...

Page 117: ...ion in the laser beam path between the Laser Unit and the Imaging Unit Remove the obstruction Go to step 3 3 Does the image quality improve if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 3 Go to step 4 4 Does the imaging quality improve if the Transfer Roller is replaced Replace the Transfer Roller CRC PL 8 1 12 Go to step 5 5 Does the image quality improve if the Laser Unit i...

Page 118: ...lace the Image Processor Board RRP 12 8 Go to step 2 2 Does the image improve if the laser beam path between the Laser Unit and the Imaging unit is blocked with a sheet of paper Replace the Engine Control Board RRP 12 7 Go to step 3 3 Does the image quality improve if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 3 Go to step 4 4 Does the image quality improve if the Laser Unit ...

Page 119: ...maging Unit IDT1 and IDT2 rollers from the Maintenance section of Service Diagnostics See Service Diagnostics Tests and Functions Table on page 24 Step Check Yes No 1 Is the problem resolved after replacing the Imaging Unit Complete Go to step 2 2 Inspect the Imaging Unit charge voltage contacts PL9 1 5 and the Bias Housing Assembly PL 9 1 4 in the printer for any damage or defects See Imaging Uni...

Page 120: ...ceable Unit See Repeating Defects Identification Chart on page 95 Replace the indicated CRU Go to step 4 4 Does the image quality improve if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 Go to step 5 5 Check the Heat Roller and NIP Belt in the Fuser Assembly for evidence of contamination or damage Replace the Fuser Assembly CRC PL 8 1 1 Go to step 6 6 Does the imaging quality im...

Page 121: ...Complete Go to step 3 3 Check for an obstruction in the laser beam path between the Laser Unit and the Imaging Unit Lay Imaging Unit on it s back with the IDT Rollers facing up and rotate the developer gears to remove any loose toner Remove the obstruction or debris Go to step 4 4 Does the image quality improve if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 3 Go to step 5 5 Ch...

Page 122: ...if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 3 Go to step 3 3 Check the Heat Roller and NIP Belt in the Fuser Assembly for evidence of contamination or damage See Transfer Roller and Fuser Assembly on page 331 Replace the Fuser Assembly PL 8 1 1 Go to step 4 4 Does the imaging quality improve if the Transfer Roller is replaced Replace the Transfer Roller CRC PL 8 1 12 Go to ...

Page 123: ...e quality improve if the Imaging Unit is replaced Replace the Imaging Unit CRC PL 9 1 3 Go to step 3 3 Check the Heat Roller and NIP Belt in the Fuser Assembly for evidence of contamination or damage See Transfer Roller and Fuser Assembly on page 331 Replace the Fuser Assembly CRC PL 8 1 1 Go to step 4 4 Does the imaging quality improve if the Transfer Roller is replaced Complete Go to step 5 5 Ch...

Page 124: ...o to step 3 3 Does the ghosting appear in only one or 2 colors Replace the Imaging Unit CRC PL 9 1 3 Go to step 4 4 Check the Heat Roller and NIP Belt in the Fuser Assembly for evidence of contamination or damage Replace the Fuser Assembly CRC PL 8 1 1 Go to step 5 5 Does the image quality improve after the Fuser has been replaced Complete Go to step 6 6 Does the imaging quality improve if the Tra...

Page 125: ...em 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 2 Replace the Fuser Assembly Does the problem recur after the Fuser is replaced Replace the LVPS RRP 12 2 Complete S6200 224 Xerox Phaser 6200DP Service Pr...

Page 126: ...er adjust the registration check to see if the problem still appears before using this procedure Step Check Yes No 1 Clean the CTD Sensor and cycle power to the printer Is the problem resolved Complete Go to step 2 2 Replace the CTD Sensor Is the problem resolved Go to step 3 Complete 3 Print the 600 x 600 Service Test Print Are all the colors aligned both vertically and horizontally Replace the I...

Page 127: ...rints 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...

Page 128: ... This page consists of four 25 tint primary color bands Things to look for Repeating defects Missing Color s Streaks Voids Banding Analyizing the RGB Sample This page consists of 80 solid fill in RGBK Bands Things to look for Wrinkling Creases Roller marks Scratches Cold Offset S6200 222 Xerox Phaser 6200DP Service Prints Page 1 3 Media Type Paper Letter S6200 224 Xerox Phaser 6200DP Service Print...

Page 129: ...Margins Should be 8mm from the edge of the paper to the line 6 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 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 S6200 223 Test Pattern A 600 x 600 Te...

Page 130: ...er 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 p...

Page 131: ...e printer s front panel Printable Pages Menu 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...

Page 132: ...ettings NOW and press the OK to reset the color settings to factory defaults Restore factory settings Color 1 You can reset settings for density and color balance to the factory default values 2 From the Main Menu highlight Support and press OK 3 Highlight Improve Print Quality and press OK 4 Highlight Calibrate Colors Menu and press OK 5 Highlight Restore Factory Settings and press OK to reset th...

Page 133: ...rint 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...

Page 134: ...etwork 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 From the Main Menu highlight Support and press OK 2 Highlight Service Tools Menu and press OK 3 Reset NVRAM is displayed press OK 4 Highlight Reset NVRAM and Reset Printer NOW and press OK to reset all the settings to...

Page 135: ... 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 1 Record number of sheets printed 2 Print several sheets of paper to check for problems or defects 3 Turn off the printer 4 Remove the Toner Cartridges the Imaging Unit and both side covers prior to cleaning 5 Remove the front cover and clean the Fuser Fan with a brus...

Page 136: ...118 Phaser 6200 Color Laser Printer Service Manual ...

Page 137: ...ne 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...

Page 138: ...P 4 3 Retard Roll Assembly PL4 1 5 164 RRP 5 Chute Assembly In RRP 5 1 Chute Assembly In PL 5 1 1 166 RRP 5 2 CTD ADC Sensor PL 5 1 11 167 RRP 5 3 Toner Full Sensor PL 5 1 14 168 RRP 5 4 Fuser Drive Assembly PL 5 1 18 169 RRP 5 5 Latch R Door A PL 5 1 21 170 RRP 5 6 Latch L PL 5 1 30 RRP 6 Chute Assembly Out RRP 6 1 Chute Assembly Out Duplex PL6 1 1 172 RRP 6 2 Output Tray Full Actuator PL 6 1 5 F...

Page 139: ...L 9 1 9 Registration Sensor PL 9 1 8 198 RRP 9 5 OHP Sensor and Harness Kit PL 9 1 12 200 RRP 10 Toner Cartridge Assemblies RRP 10 1 Toner Cartridge Holder Unit Assembly PL 10 1 203 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 4 206 RRP 10 3 Toner Present Switch PL 10 1 18 208 RRP 10 4 Toner Low Sensor PL 10 1 8 209 RRP 10 5 EEPROM Board PL 10 1 16 210 RRP...

Page 140: ...ty Feeder RRP 14 1 Cover Front PL14 2 4 234 RRP 14 2 Cover Right PL14 2 1 Cover Left PL14 2 3 235 RRP 14 3 Turn Chute Assembly PL14 3 7 236 RRP 14 4 Tray 2 Harness Assembly PL14 5 3 Tray 3 Harness Assembly PL14 5 4 HCF Plug Harness Assembly PL14 5 2 237 RRP 14 5 Circuit Board HCF PL14 5 1 239 RRP 14 6 Drive Feeder Assembly PL14 5 5 240 RRP 14 7 Indicator Assembly PL14 5 9 241 RRP 14 8 Right Tray G...

Page 141: ...FRU Disassembly Removal and Replacement Procedures 123 Orientation of the Printer S6200 063 ...

Page 142: ...in the Parts List For example a part called the Registration Chute Assembly in an RRP may 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...

Page 143: ...RP 1 1 Front Cover PL 1 1 2 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 Chute Assembly Out S6200 278 ...

Page 144: ...r 6200 Color Laser Printer Service Manual 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 S6200 065 1 ...

Page 145: ...ly Removal and Replacement Procedures 127 RRP 1 2 Front Panel PL 1 1 1 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 S6200 064 ...

Page 146: ...128 Phaser 6200 Color Laser Printer Service Manual RRP 1 3 Fuser Fan PL 1 1 7 S6200 066 1 2 1 ...

Page 147: ...em 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 ...

Page 148: ...rtridges 3 Open Door A 4 Open Door C Top Image Unit Cover PL1 1 10 5 Remove the 2 screws securing the Top Main Cover to the printer 6 Release the 4 tabs securing the Top Main Cover to the printer 7 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 S6200 067 ...

Page 149: ...Image Unit Top Cover Door C PL1 1 10 Removal 1 Remove the Top Main Cover RRP 1 4 2 Open Door A 3 Open Door C 4 Remove the Left Cover RRP 1 6 5 Remove the right and left Stud Top Hinge pins item 2 PL1 1 21 from the Image Unit Top Cover and remove the cover S6200 068 ...

Page 150: ...oval 1 Remove the Top Main Cover RRP 1 4 2 Remove 1 screw securing the Right Side Cover and or Left Side Cover to the printer 3 Release the tab at the front of the printer securing the Ride Side Cover and or Left Side Cover to the printer 4 Flex the cover slightly and slide off to remove from the printer R L S6200 071 ...

Page 151: ...Replacement Procedures 133 RRP 1 7 Rear Cover PL 1 1 20 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 S6200 069 2 ...

Page 152: ...om the printer 3 Open Door A 4 From inside the printer push out the Link Pin securing the Link to the printer 5 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 Note To disengage the links from the printer without removing the link only perform Steps 1 through 4 S6200 070 ...

Page 153: ...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 for...

Page 154: ...136 Phaser 6200 Color Laser Printer Service Manual RRP 1 10 Front Right Cover PL 1 1 25 Removal 1 Open Door A 2 Remove the 2 screws securing the Front Right Cover S6200 072 ...

Page 155: ...d open Door B 4 Pull the Front Right Cover slightly away from the Chute Assembly Out 5 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 6 Remove the Front Right Cover S6200 073 ...

Page 156: ...138 Phaser 6200 Color Laser Printer Service Manual RRP 1 11 Front Left Cover Assembly PL1 1 29 S6200 075 S6200 076 ...

Page 157: ...ver RRP 1 10 4 Open Door B 5 Spread apart both sides of the metal retaining clip with a flat blade screwdriver to disengage the Link holding the Front Left Cover 6 Remove the 2 screws securing the Front Left Cover to the Chute Assembly Out 7 Release the 2 tabs securing the Front Left Cover to the Chute Assembly Out and remove the Front Left Cover from the printer ...

Page 158: ...g the Feed Cover to the Paper Tray and open the Feed Cover 3 Carefully release the hook securing the Paper Feed Roller to the Retard Shaft 4 Slide the Paper Feed Roller off the shaft to remove 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 S6200 077 ...

Page 159: ...he printer 2 Push in on the Turn Chute Assembly to releae the 2 tabs 3 Rotate the Turn Chute Assembly 90 degrees downward from the Paper Feeder 4 Release the tabs securing the right and left shaft of the Turn Chute Assembly to the Paper Feeder 5 Pull out the Turn Chute Assembly from the Paper Feeder to remove S6200 080 S6200 081 ...

Page 160: ...RP 1 10 6 Remove the Right and Left Side Covers RRP 1 6 7 Remove the Turn Chute Assembly RRP 3 1 8 Remove the Link Actuator RRP 3 11 9 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 print...

Page 161: ...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 screwdri...

Page 162: ...144 Phaser 6200 Color Laser Printer Service Manual RRP 3 3 Paper Pick Assembly PL3 3 1 S6200 098 ...

Page 163: ...nnect 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 ...

Page 164: ...sing PL 3 2 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 RIGHT LEFT S6200 088 ...

Page 165: ...ve the Top Main Cover RRP 1 4 2 Remove the Left Side Cover RRP 1 6 3 Disconnect P J2361 gray from the printer 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 L S6200 083 ...

Page 166: ...acity Feeder Harness PL3 2 3 Removal 1 Remove the Printer Chassis RRP 3 2 2 Shift the HCF Harness from the Right Housing 3 Release the 2 tabs securing the harness to the Right Housing 4 Pull the HCF Harness down from the Housing Assembly to remove S6200 084 RIGHT REAR ...

Page 167: ...Size Switch Assembly PL3 2 4 Removal 1 Remove the Printer Chassis RRP 3 2 2 Disconnect P J471 from the Paper Size Switch 3 Remove 1 screw securing the Paper Size Switch to the Right Housing 4 Rotate the front of the Paper Size Switch to free the tab and remove S6200 085 ...

Page 168: ...r Right Housing RRP 3 4 3 Hold the tip of the Paper Level Indicator item 1 with needle nose pliers and pull the Indicator forward to remove from the Right Housing 4 Release the 2 tabs securing the Shaft Holder item 6 to the Right Housing 5 Pull the Guide Indicator item 3 together with the Indicator Spring item 5 and Shaft Indicator item 4 Note When reinstalling the guide ensure the flag is on top ...

Page 169: ...ight 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 S6200 ...

Page 170: ...al 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 S6200 090 ...

Page 171: ...FRU Disassembly Removal and Replacement Procedures 153 Blank Page ...

Page 172: ...154 Phaser 6200 Color Laser Printer Service Manual RRP 3 10 No Paper Actuator PL3 3 5 No Low Paper Sensor PL3 3 4 S6200 091 S6200 092 ...

Page 173: ...r 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 Removal Low Paper Sensor 8 Disconnect P J473 yellow on the Low Paper Sensor 9 Release 3 tab...

Page 174: ...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 the Link Actuator apart 4 Remove the link actuator from the bracket in the printer and remove S6200 093 ...

Page 175: ...emoval 1 Remove the Paper Feeder Assembly Unit RRP 3 2 2 Remove the Paper Pick Assembly RRP 3 3 3 Remove 1 screw securing the Feed Solenoid to the Paper Pick Assembly 4 Separate the Feed Solenoid slightly and shift the harness to disconnect P J474 gray 5 Remove the Feed Solenoid S6200 095 ...

Page 176: ... 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 S6200 096 1 2 P J 475 ...

Page 177: ...of the Paper Pick Assembly and pull out the Gear Feed 2 5 Pull out the Idler Gear item 2 and Idler Gear In item 3 from the Paper Pick Assembly 6 Remove the right and left E rings securing the shaft of the Roll Turn Assembly to the Paper Pick Assembly 7 Remove the metal bearing item 6 securing the right shaft of the Turn Roll Assembly 8 Remove the black bearing item 4 securing the left shaft of the...

Page 178: ...ut 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 S6200 176 ...

Page 179: ... 1 Retard Roller Housing Assembly PL4 1 1 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 S6200 099 ...

Page 180: ...162 Phaser 6200 Color Laser Printer Service Manual RRP 4 2 Turn Roll PL 4 1 2 Turn Clutch PL 4 1 9 Friction Clutch Assembly PL 4 1 4 S6200 100 S6200 103 ...

Page 181: ...Housing Assembly RRP 4 1 2 Remove the e ring securing the Turn Clutch to the shaft and remove the clutch 3 Remove the e ring securing the Turn Roll to the Retard Roller Housing Assembly 4 Remove the left and right bearings 5 Slide the shaft to the right and remove to the left of the assembly ...

Page 182: ...164 Phaser 6200 Color Laser Printer Service Manual RRP 4 3 Retard Roll Assembly PL4 1 5 1 S6200 183 S6200 184 1 ...

Page 183: ... 165 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 S6200 102 ...

Page 184: ...moval 1 Remove the Fuser Assembly 2 Remove the Transfer Roller 3 Remove the Imaging Unit 4 Remove all covers and the MPT RRP 1 7 and RRP 1 11 5 Remove the Chute Assembly Out RRP 6 1 6 Release latch A Door A and pull the Chute Assembly In forward to remove from the printer chassis S6200 105 ...

Page 185: ... 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 S6200 106 ...

Page 186: ...ll Sensor PL 5 1 14 Removal 1 Open Door A 2 Remove the Transfer Roll Assembly CRU 3 Disconnect P J142 from the Chute Assembly In 4 Release 2 tabs securing the Toner Full Sensor with a small screwdriver 5 Remove the Toner Full Sensor from the Chute Assembly In S6200 107 ...

Page 187: ...ove the Chute Assembly In RRP 5 1 5 Remove Latch A RRP 5 5 6 Remove the 1 screw securing the fuser ground wire to the Fuser Drive Assembly 7 Shift the harness attached to the Fuser Drive Assembly from its clamp and housing 8 Remove the 3 screws securing the Fuser Drive Assembly to the Chute Assembly In 9 Remove the Fuser Drive Assembly Note Note the routing of the wires for reassembly S6200 108 ...

Page 188: ...for Latch R 1 Remove the Fuser Assembly CRU 2 Remove the Front Right Cover RRP 1 10 3 Open Door A 4 Release the hook on the lower part of the spring item 4 securing it to the Chute Assembly In 5 Release the tab securing Latch R item 3 to the Chute Assembly In 6 Remove Latch R 1 2 3 S6200 109 4 ...

Page 189: ...nt Procedures 171 RRP 5 6 Latch L PL 5 1 30 Removal 1 Remove the Fuser Assembly 2 Remove the Front Left Cover RRP 1 6 3 Open Door A 4 Release the tab securing Latch L to the left side of the Chute Assembly In 5 Remove the Latch L S6200 110 ...

Page 190: ... steps you will need to latch the Chute Assembly Out Door B and the Chute 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 EEPRO...

Page 191: ...he 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 harnes...

Page 192: ...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 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 2 1 1 S6200 112 ...

Page 193: ...e 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 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 S6200 114 1 S6200 115 ...

Page 194: ...176 Phaser 6200 Color Laser Printer Service Manual RRP 6 3 Duplex Actuator PL 6 1 13 Duplex Sensor PL 6 1 4 S6200 119 S6200 118 ...

Page 195: ... 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 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...

Page 196: ...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 S6200 123 ...

Page 197: ...al and Replacement Procedures 179 Removal of the Sensor 1 Remove the MPT Actuator 2 Open Door B 3 From the back of the sensor release the 3 tabs securing the sensor and remove 4 Disconnect P J135 from the Sensor S6200 124 1 ...

Page 198: ...Manual RRP 6 5 Static Eliminator Assembly PL 6 1 9 Removal 1 Remove the Front Cover Assembly RRP 1 1 2 Remove 1 screw securing the Eliminator Assembly to the Chute Assembly Out 3 Raise the left end up and remove the Eliminator Assembly S6200 116 ...

Page 199: ...eft Cover RRP 1 11 2 Release the tab securing Gear 30 item 4 See Gear Layout Print Engine and Tray 1 on page 318 and remove the gear 3 Remove the bearing securing the left end of the shaft item 5 4 Raise the left end of the roller and shift the right bearing out item 3 then remove the Duplex Roller 1 3 4 5 S6200 117 ...

Page 200: ... PL 6 1 20 Removal 1 Remove the Front Right Cover RRP 1 10 1 Remove the Front Left Cover RRP 1 11 2 Remove the Spring Out item 3 from the Chute Assembly Out 3 Release the 2 tabs from the inside of the Chute Assembly Out 4 Slide the Holder Latch item 2 to the right and remove 5 Remove the Latch Out from the Holder item 1 1 2 3 S6200 120 TOP ...

Page 201: ...ssembly PL 6 1 27 Roll Feed Removal 1 Remove 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 S6200 122 ...

Page 202: ...e Chute Assembly Out RRP 6 1 2 Unhook the N F MPT spring from the Solenoid Stopper 3 Disconnect P J132 from the Solenoid 4 Remove 1 screw securing the Feed Solenoid to the Chute Assembly Out and remove Reassembly Note Make sure the solenoid seats properly on the aligning pins The pins are plastic S6200 125 ...

Page 203: ...enoid 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 CAMs 6 Slide the CAMs item 3 in 7 Slide the shaft to the right an...

Page 204: ...he 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 S6200 128 ...

Page 205: ...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 S6200 129 ...

Page 206: ...elease the tab securing the Gear Roll to the shaft and remove the Gear Roll 3 Remove the bearing from the left side of the shaft on the Roll Exit 4 Remove the e ring securing the right end of the shaft of the Roll Exit 5 Remove the bearing 6 Raise the right side of the shaft and pull the Roll Exit to the right and up to remove S6200 130 ...

Page 207: ... Remove the Chute Assembly Exit RRP 7 1 2 Release the tab securing the Gear Roll and remove the Gear 3 Remove the bearing from the left side of the shaft 4 Remove the e ring and bearing securing the right side of the shaft 5 Raise the right side of the shaft and pull out the Mid Roll S6200 131 ...

Page 208: ...r Assembly PL 7 1 8 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 G48 S6200 132 ...

Page 209: ...RRP 8 1 Exit Actuator Fuser PL 8 1 7 Removal 1 Remove the Fuser Assembly 2 Remove the bearing from the left side of the Fuser Exit Roller and move the exit roller slightly out of the way 3 Slide the Exit Actuator left 4 Remove the Actuator Spring S6200 137 ...

Page 210: ...192 Phaser 6200 Color Laser Printer Service Manual RRP 8 2 Strap PL 8 1 13 Removal 1 Open Door B 2 Turn the top of the strap 90 degrees and remove S6200 141 ...

Page 211: ...located on top of the power switch and move out of the way 5 Unhook the springs from the left and right ends of the shaft 6 Remove 1 screw securing the Laser Unit to the printer and remove the assembly Replacement 1 Align the Laser Unit with the printer 2 Secure the right and left shafts of the Laser Unit with the tabs on the top of the Spring Laser 3 Install the screw 4 Connect P J151 Note Perfor...

Page 212: ...194 Phaser 6200 Color Laser Printer Service Manual RRP 9 2 Bias Housing Assembly PL 9 1 4 S6200 143 ...

Page 213: ...onnect all the wires and remove from the channel 4 Remove the Link Left RRP 1 8 5 Remove the 5 screws securing the Bias Housing Assembly 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 bias...

Page 214: ...ng Electric Assembly PL 9 1 11 Removal 1 Open Door A and Door C 2 Remove the Imaging Unit 3 Release the 2 tabs securing the Electric Housing Assembly to the printer and remove straight up 4 Disconnect P J18 blue from the Registration Chute Assembly 5 Disconnect P J32 blue from the OHP Sensor S6200 144 ...

Page 215: ...gistration 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 S6200 145 1 ...

Page 216: ...9 1 9 Registration Sensor PL 9 1 8 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 S6200 146 ...

Page 217: ...emoval and Replacement Procedures 199 Removal of Sensor 1 Remove the Registration Actuator 2 Disconnect P J181 3 Release the 3 tabs securing the Sensor to the Chute Assembly Registration and remove the sensor S6200 147 ...

Page 218: ...emoval 1 Remove the Chute Assembly Registration RRP 9 3 2 Remove the 2 e rings securing the 2 Gears items 4 5 Note When removing the Springs use caution they spring off the shaft easily 3 Remove both springs item 1 6 4 Pull out the bearing on the left side of the shaft item 3 6 1 2 3 4 5 S6200 185 ...

Page 219: ...eft 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 7 Raise the left end of the shaft and remove with the right white plastic bearing attached 1 2 3 S6200 186 S6200 187 ...

Page 220: ...s 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 1 S6200 188 ...

Page 221: ...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 ...

Page 222: ...isconnect the third connector P J71 from the bracket on the left side printer 7 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 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 3 4 S6200 154 1 2 ...

Page 223: ...der Unit and remove the unit Note The 4 screws on the right side of the printer are below the toner motors 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 1 S6200 155 ...

Page 224: ...tall 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 In the 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 conn...

Page 225: ... P J442 and P J432 C P J513 P J443 and P J433 K 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 Assembly 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 S6200 150 8 6 7 ...

Page 226: ... 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 S6200 156 ...

Page 227: ...der 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 S6200 157 ...

Page 228: ...le 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 r...

Page 229: ...ge Power Supply Board PL 10 1 17 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 S6200 159 ...

Page 230: ... 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 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 S6200 160 ...

Page 231: ...eplacement Procedures 213 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 S6200 180 ...

Page 232: ...ith 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 Do not accidentally knock out the stud plungers bias contacts Note For reassembly ensure the drum levers are seated properly on the aligning posts S6200 178 3 4 ...

Page 233: ... Bracket PL 11 1 2 Lever Link PL 11 1 6 Lever Drum PL 11 1 4 Lever Spring PL 11 1 5 Removal 1 Remove the Right Cover RRP 1 6 2 Remove the Top Imaging Unit Cover Door C RRP 1 5 3 Remove the Right Link Spring PL1 1 24 4 Remove the Main Drive Assembly RRP 11 3 5 Remove the Motor Driver Board S6200 161 ...

Page 234: ...haser 6200 Color Laser Printer Service Manual 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 S6200 181 ...

Page 235: ...rinter 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 4 3 S6200 179 ...

Page 236: ...218 Phaser 6200 Color Laser Printer Service Manual RRP 11 3 Main Drive Assembly PL 11 1 14 1 S6200 164 ...

Page 237: ...t Right RRP 1 10 3 Remove the Cover Right RRP 1 6 4 Remove the Link Right RRP 1 8 5 Disconnect the P J48 from the Motor Driver Board 6 Free the harness from the clamp on the Main Drive Assembly 7 Remove the 4 screws securing the Main Drive Assembly to the printer 8 Remove the grounding screw 9 Remove the Main Drive item 1 ...

Page 238: ...RP 11 4 Developer Drive Assembly PL 11 1 13 Removal 1 Remove the Right Cover RRP 1 6 2 Remove the Motor Driver Board RRP 12 3 3 Disconnect P J52 from the Motor Driver Board 4 Remove the 4 screws securing the Developer Drive Assembly and remove S6200 163 ...

Page 239: ...P 11 5 Actuator I L PL 11 1 8 Spring I L PL 11 1 9 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 1 S6200 162 ...

Page 240: ...oard PL 11 1 16 Removal 1 Open Door A 2 Remove the Fuser Assembly 3 Remove the Transfer Roll Assembly 4 Remove the Chute Assembly Registration RRP 9 3 5 Remove the Housing Assembly Retard RRP 4 1 6 Remove the 2 screws securing the Ground Circuit Board and remove the board 1 S6200 177 ...

Page 241: ... 2 Remove the Front Right Cover RRP 1 10 3 Remove the Right Cover RRP 1 6 4 Remove the screw securing the ground wire to the LVPS 5 Release the tabs securing the harness cable guide to the AC Switch bracket and move aside 6 Disconnect P J161 from the LVPS 7 Press in on the tabs and remove the Harness Assembly AC Switch from the printer S6200 170 ...

Page 242: ...224 Phaser 6200 Color Laser Printer Service Manual RRP 12 2 Low Voltage Power Supply PL 12 1 10 1 S6200 168 2 3 S6200 169 ...

Page 243: ...way 3 Remove the 4 screws securing the Motor Driver Board and move out of the way 4 Remove the Harness Cable Guide Assembly items 1 2 3 5 Remove the Harness Assembly AC Switch RRP 12 1 6 Disconnect P J162 P J163 P J164 P J165 and P J166 from the Low Voltage Power Supply Board 7 Remove the 3 screws securing the board to the printer and remove the Low Voltage Power Supply board ...

Page 244: ... 12 1 12 Removal 1 Remove the Top Main Cover RRP 1 4 2 Remove the Front Right Cover RRP 1 10 3 Remove the Right Cover RRP 1 6 4 Disconnect all the connectors on the Motor Driver Board 5 Remove the 4 screws securing the Motor Driver Board to the printer and remove the board S6200 171 ...

Page 245: ...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 S6200 167 ...

Page 246: ...e removed prior to removing the Card Cage to prevent damaging the Bias Springs 1 Remove the Chute Assembly Registration RRP 9 3 2 Remove the Housing Assembly Bias RRP 9 2 3 Remove the Motor Driver Board RRP 12 3 4 Remove the LVPS RRP 12 2 5 Disconnect P J151 from the Laser Unit 6 Disconnect P J16 from the Paper Tray Feeder 7 Disconnect P J141 P J1361 P J138 P J221 and P J139 from the bracket 1 S62...

Page 247: ...move 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 ...

Page 248: ...r Printer Service Manual RRP 12 6 Housing Assembly Contact PL 12 1 14 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 S6200 172 ...

Page 249: ...it Board PL12 1 1 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 Contact RRP 12 6 3 Remove the 4 screws securing the Cover Engine Control Board from the Box Asssembly S6200 165 ...

Page 250: ... Board to the Card Cage and remove the board Caution Observe proper ESD procedures when removing any circuit board from the printer Replacement Note The NVRAM must be moved over to the new board Note Re install the Engine Control Board prior to installing the Chute Assembly Registration and the Housing Assembly Bias to prevent damaging the bias springs 1 NV RAM S6200 166 pin 1 ...

Page 251: ...e Processor board to the printer 4 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 Processor Board to the new board See Image Processor Board on page 9 for the exact locations of each component 1 Memory 2 Hard Drive if installed 3 Configuration Upgrade Chip i Button ...

Page 252: ...t PL14 2 4 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 S6200 191 ...

Page 253: ... 5 screws securing the Cover Right and the 5 screws securing the Cover Left 4 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 5 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 Right side shown S6200 193 ...

Page 254: ...moval 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 S6200 195 ...

Page 255: ...37 RRP 14 4 Tray 2 Harness Assembly PL14 5 3 Tray 3 Harness Assembly PL14 5 4 HCF Plug Harness Assembly PL14 5 2 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 S6200 197 RIGHT ...

Page 256: ... 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 7 Disconnect P J81 yellow from the Power Feeder Circuit Board 8 Remove J810 by lifting out of the hole in the top of the HCF frame 9 Lift the entire Harness Assembly Feeder Plug thr...

Page 257: ...J81 from the Harness Feeder Plug Assembly 5 Disconnect P J82 from the Harness Assembly Tray 2 6 Disconnect P J83 from the Harness Assembly Tray 3 7 Disconnect P J84 from the Drive Assembly 8 Remove the 3 screws securing the Power Feeder Circuit board to the HCF frame and remove the board Replacement Note When replacing the Power Feeder Circuit Board align the hole on the board and the two tabs on ...

Page 258: ...Removal 1 Remove both Paper Trays from the HCF 2 Remove the Front Covers RRP 14 1 3 Remove the Right Cover RRP 14 2 4 Release the Tray 2 Harness Assembly gray from the cable restraints 5 Disconnect P J84 6 Remove the 3 screws securing the Feeder Drive Assembly to the HCF and remove S6200 198 ...

Page 259: ...h Paper Trays from the HCF 2 Remove the Front Covers RRP 14 1 3 Remove the Right Cover RRP 14 2 4 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 Reassembly Note The Indicator Assembly has to be below the Low Paper Lever S6200 196 1 2 ...

Page 260: ...oth Paper Trays from the HCF 2 Remove the Front Covers RRP 14 1 3 Remove the Right Cover RRP 14 2 4 Remove the Chute Assembly Turn RRP 14 3 5 Remove the Feeder Drive Assembly RRP 14 6 6 Remove the Indicator Assembly RRP 14 7 7 Remove the HCF Circuit Board RRP 14 5 8 Remove the 1 screw securing the Low Paper Bracket to the HCF frame 9 Remove the Bracket S6200 199 ...

Page 261: ...RU Disassembly Removal and Replacement Procedures 243 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 S6200 200 ...

Page 262: ... Laser Printer Service Manual 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 S6200 201 ...

Page 263: ...ve both Paper Trays from the HCF 2 Remove the Front Covers RRP 14 1 3 Remove the Left Cover RRP 14 2 4 Remove the Chute Assembly Turn RRP 14 3 5 Remove the 5 screws securing the Left Tray Guide Assembly to the HCF frame 6 Release the 6 tabs securing the Left Tray Guide Assembly to the HCF frame S6200 203 ...

Page 264: ...246 Phaser 6200 Color Laser Printer Service Manual 7 Remove the Guide Assembly by rotating the top inward 8 Repeat Steps 1 7 to remove the lower guide S6200 204 ...

Page 265: ... Reach in through the rear of the printer and spread the tabs of the Link Actuator apart 4 Remove the link actuator from the bracket in the printer 5 Remove the actuator 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 S6200 207 ...

Page 266: ...248 Phaser 6200 Color Laser Printer Service Manual RRP 14 11 HCF Paper Pick Assembly PL14 4 1 S6200 208 S6200 209 ...

Page 267: ... 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 car...

Page 268: ... 5 6 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 S6200 210 ...

Page 269: ...emove the Cover Right RRP 14 2 4 Remove the Chute Assembly Turn 5 Remove the Indicator Assembly RRP 14 7 6 Remove the Bracket Low Paper upper and lower 7 Remove the HCF Circuit Board RRP 14 5 8 Remove the Right Tray Guide RRP 14 8 9 Release the 3 tabs securing the Sensor to the HCF frame and remove the sensor Note Use caution the Sensor tabs are easily broken S6200 211 ...

Page 270: ...nter Service Manual RRP 14 14 Paper Size Switch Assembly PL14 3 6 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 S6200 202 ...

Page 271: ...oller Fuser Assembly CRCs 274 PL 9 1 Xerographics 276 PL 10 1 Holder Toner Cartridge Assembly 278 PL 11 1 Frame and Drive Assemblies 280 PL 12 1 Electrical 282 PL 13 1 Harness Assemblies 284 Optional High Capacity Feeder PL 14 1 High Capacity Feeder Paper Trays 2 3 286 PL 14 2 High Capacity Feeder Covers 288 PL 14 3 High Capacity Feeder Guides and Turn Chute Assembly 290 PL 14 4 Paper Pick Assembl...

Page 272: ...f the printer produced on that day The serial number is coded as follows The text S N followed by the serial number in the barcode The barcode does not include a field identifier The nine digit serial number is based on the following format PPPRSSSSS 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...

Page 273: ...ade up of the individual parts called out in parentheses 7 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 8 An asterisk following a part name indicates the page contains a note about this part 9 The notation NS next to a part indicates that pariticular part is not s...

Page 274: ...256 Phaser 6200 Color Laser Printer Service Manual PL 1 1 Covers S6200 228 ...

Page 275: ...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 Cover Multi Purpo...

Page 276: ...258 Phaser 6200 Color Laser Printer Service Manual PL 2 1 Universal Paper Tray S6200 229 5 4 2 3 6 ...

Page 277: ...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 ...

Page 278: ...260 Phaser 6200 Color Laser Printer Service Manual PL 3 1 Paper Feed I S6200 230 1 2 4 4 4 5 5 5 5 3 ...

Page 279: ...ts 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 ...

Page 280: ...262 Phaser 6200 Color Laser Printer Service Manual PL 3 2 Paper Feed II S6200 231 ...

Page 281: ...ature 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 ...

Page 282: ...264 Phaser 6200 Color Laser Printer Service Manual PL 3 3 Paper Feed III S6200 247 ...

Page 283: ...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 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...

Page 284: ...266 Phaser 6200 Color Laser Printer Service Manual PL 4 1 Housing Assembly Retard S6200 232 ...

Page 285: ... 1 Assembly Housing Retard with 2 13 2 1 Roll Turn NS 3 1 Shaft Retard NS 4 116 1370 00 1 Assembly Friction Clutch 5 116 1371 00 1 Assembly RetardRoll 6 1 Holder Retard NS 7 1 Housing Retard NS 8 1 Bearing NS 9 116 1374 00 1 Turn Clutch 10 1 Stud Retard NS 11 1 Spring Retard 370 NS 12 1 Cap Retard NS 13 1 Bearing Ground NS ...

Page 286: ...268 Phaser 6200 Color Laser Printer Service Manual PL 5 1 Chute Assembly In S6200 233 ...

Page 287: ...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 1...

Page 288: ...Printer Service Manual PL 6 1 Chute Assembly Out 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 1 Assembly Harness Front 2 S6200 234 ...

Page 289: ...7 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 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...

Page 290: ...272 Phaser 6200 Color Laser Printer Service Manual PL 7 1 Chute Assembly Exit S6200 235 ...

Page 291: ...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 ...

Page 292: ...274 Phaser 6200 Color Laser Printer Service Manual PL 8 1 Transfer Roller Fuser Assembly CRCs S6200 236 ...

Page 293: ... 1a 1b 016 2014 00 016 2015 00 1 1 110 V Fuser Phaser 6200 with 7 and 8 220 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 ...

Page 294: ...276 Phaser 6200 Color Laser Printer Service Manual PL 9 1 Xerographics S6200 237 ...

Page 295: ...aging 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 ...

Page 296: ...278 Phaser 6200 Color Laser Printer Service Manual PL 10 1 Holder Toner Cartridge Assembly S6200 238 ...

Page 297: ...r Cartridge Standard Capacity Cyan Toner Cartridge High Capacity 4 016 2004 00 016 2008 00 1 1 Black Toner Cartridge Standard Capacity 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 Cartrid...

Page 298: ...280 Phaser 6200 Color Laser Printer Service Manual PL 11 1 Frame and Drive Assemblies S6200 239 ...

Page 299: ... 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 GRN...

Page 300: ...282 Phaser 6200 Color Laser Printer Service Manual PL 12 1 Electrical S6200 240 ...

Page 301: ...tion Chip i button IC Base Configuration Chip IC Network Configuration Upgrade Chip IC DP DX Configuration Upgrade Chip Internal Hard Drive FRU Memory 64 MB 8M x 64 PC133 Memory DIMM 128 MB 16M x 64 PC133 Memory DIMM 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 Cont...

Page 302: ...284 Phaser 6200 Color Laser Printer Service Manual PL 13 1 Harness Assemblies S6200 241 ...

Page 303: ... 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...

Page 304: ...286 Phaser 6200 Color Laser Printer Service Manual High Capacity Feeder FRU Parts List PL 14 1 High Capacity Feeder Paper Trays 2 3 S6200 246 5 4 2 3 6 ...

Page 305: ...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 ...

Page 306: ...288 Phaser 6200 Color Laser Printer Service Manual PL 14 2 High Capacity Feeder Covers S6200 242 ...

Page 307: ...er 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 ...

Page 308: ...290 Phaser 6200 Color Laser Printer Service Manual PL 14 3 High Capacity Feeder Guides and Turn Chute Assembly S6200 243 ...

Page 309: ...e 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 00 2 Paper Tray Stopper 1 per Tray ...

Page 310: ...292 Phaser 6200 Color Laser Printer Service Manual PL 14 4 Paper Pick Assembly Trays 2 3 S6200 244 ...

Page 311: ... 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 ...

Page 312: ...294 Phaser 6200 Color Laser Printer Service Manual PL 14 5 High Capacity Feeder Harness Board and Motor S6200 245 ...

Page 313: ...eder 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 ...

Page 314: ...llers 2 interchangeable Rollers per 116 1353 01 Main Shipping Box 004 5258 00 Lower Tray Deck Shipping Box 004 5278 00 Phaser 6200 World Kit Plus Standard Media Sample Pack 061 4462 00 Phaser 6200 World Kit Plus Metric Media Sample Pack 061 4463 00 Repackaging Kit Phaser 6200 065 0610 00 Repackaging Kit High Capacity Feeder Phaser 6200 065 0620 00 Cleaning Kit 5 Texwipes 016 1845 00 Power Cords De...

Page 315: ...omer Replaceable Consumables CRCs Description Part Number Toner Cartridges Phaser 6200 all Yellow Toner Cartridge Standard Capacity Yellow Toner Cartridge High Capacity 016 2003 00 016 2007 00 Magenta Toner Cartridge Standard Capacity Magenta Toner Cartridge High Capacity 016 2002 00 016 2006 00 Cyan Toner Cartridge Standard Capacity Cyan Toner Cartridge High Capacity 016 2001 00 016 2005 00 Black...

Page 316: ...ets 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 Applicator 1 Jewel Case 016 1885 00 CD DVD Labels and Inserts 1 Insert Sheet Letter 8 5 x 11 in 20 Sheets 2 Labels per Sheet 10 Sheets 016 2011 00 CD DVD Labels and Inserts A4 210 x 297mm 1 Insert She...

Page 317: ...ts List 299 Premium Greeting Card Media w Envelopes A4 50 sheets 016 1988 00 Digital Photo Paper A 50 Sheets 016 2009 00 Digital Photo Paper A4 50 Sheets 016 2010 00 Print Media cont d Description Part Number ...

Page 318: ...300 Phaser 6200 Color Laser Printer Service Manual Blank Page ...

Page 319: ...Paper Feed 320 HCF Trays 2 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 Assembly 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...

Page 320: ...individual drum surface is transferred 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 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 bo...

Page 321: ...4 Charged with electricity 1 Exposure 2 Develop ment 3 Charged with electricity 1 Exposure 2 Develop ment 3 Charged with electricity 1 Exposure 2 Develop ment 3 S6200 009 RTC 1 Charging with electricity RTC RTC Developer M Developer Y Developer C Developer K Drum K Drum C Drum Y Drum M IDT1 IDT1 IDT2 IDT2 Cleaner IDT1 Cleaner IDT1 Cleaner 1 Charging with electricity 3 Development 3 Development 3 D...

Page 322: ...n 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 Standard Draft mode Used for printing with a resolution of 600 dpi Enhanced mode Used for printing on plain paper with a resolution of 2400 X 600 dpi Photo mode Gloss is raised by setting half speed wit...

Page 323: ...he 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 la...

Page 324: ...control is made immediately before the start of printing if any of the following conditions is satisfied First print produced after the power on Accumulative print count exceeds 16 after power on 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 v...

Page 325: ...er 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 t...

Page 326: ...n 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 ...

Page 327: ...ent 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 ...

Page 328: ... process control This control is outlined below 1 With no toner on the Transfer Roller 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 patches are composed of 10mm lines of K C K M K and Y in this order by the amount of four dispense counts led by a black trigger 3 The density of...

Page 329: ...f 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 ...

Page 330: ...sor 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 T...

Page 331: ...ature 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 a...

Page 332: ...ICK ROLLER T3 PAPER FEED TRAY TURN ROLL ASSY TURN CHUTE ASSY T3 TURN CHUTE ASSY T2 PAPER FEED Tray PAPER FEED PAPER PICK ROLLER T2 EXIT ROLL MID ROLL DUPLEX ROLL TRANSFER ROLLER METAL ROLL REGISTRATION ROLL FEED ROLL ASSY RETARD ROLLER TURN ROLL TURN ROLL ASSY T1 TURN CHUTE ASSY T1 S6200 060 TURN ROLL ASSY T2 PAPER PICK ROLLER T1 PAPER FEED ROLLER T1 PAPER FEED ROLLER T2 PAPER FEED ROLLER T3 T3 ...

Page 333: ...t 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 Paper transfer by the Imaging Unit IDT2 and Transfer Roller Paper transfer by the Fuser Assembly Exit Roll and Pinch Roll Paper transfer by the Chute Assembly Exit and Chute Assembly Out Paper transfer by the Fuser Assembly Heat Roll and Fuser Belt...

Page 334: ... following areas based on the configuration of the printer and the optional High Capacity Feeder Frame and Drive Assemblies 1 Developer Drive Assembly Supplies the drive to the Imaging Unit Developer 2 Main Drive Assembly Supplies the drive to the following parts Paper Feeder Retard Housing Assembly Chute Assembly Out MPT position Chute Assembly Registration Imaging Unit IDT 1 IDT 2 Drum Transfer ...

Page 335: ...URN CLUTCH ASSY TURN ROLL ASSY GEAR IDLLER FEED GEAR FEED H1 PAPER FEED ROLLER PAPER TRAY REGI CHUTE Regi Clutch Regi Roll TURN CLUTCH TURN ROLL RETARD HOUSING ASSY MPT GEAR PAPER FEED R0LLER CHUTE ASSY OUT IMAGING UNIT IDT2 IDT1 2 Drum 4 TRANSFER ROLLER GEAR IDLER IN GEAR IDLLER GEAR FEED1 ...

Page 336: ...e and Tray 1 RETARD HOUSING ASSY TURN CLUTCH REGISTRATION CHUTE ASSY REGISTRATION CLUTCH IMAGING UNIT TRANSFER ROLLER MAIN DRIVE ASSY GEAR IDLER IN GEAR IDLER GEAR IDLER FEED GEAR FEED H1 GEAR FEED1 TURN CLUTCH ASSY PAPER PICK ASSY TRAY CHUTE ASSY OUT MPT GEAR FRONT 6200 037 ...

Page 337: ...per 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 S6200 040 1 2 3 2 ...

Page 338: ...nergizes 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 feed 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 d...

Page 339: ...n 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...

Page 340: ... and switches Controls the Feeder Drive Assembly Controls the paper pick process 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 pape...

Page 341: ... GEAR IDLER FEED GEAR FEED H1 GEAR FEED1 PAPER PICK ASSY T3 TURN CLUTCH FRONT S6200 058 LOWER FEEDER DRIVE ASSY PICK UP ASSY T2 GEAR IDLLER IN TURN CLUTCH ASSY TURN ROLL ASSY GEAR IDLLER FEED GEAR FEED H1 GEAR FEED 1 GEAR IDLER GEAR IDLLER PAPER FEED ROLL ASSY TURN CLUTCH ASSY TURN ROLL ASSY GEAR IDLLER FEED GEAR FEED H1 PAPER FEED ROLL ASSY PAPER PICK ASSY T3 GEAR IDLER IN GEAR IDLLER GEAR FEED1 ...

Page 342: ...urn 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 1 2 S6200 042 ...

Page 343: ...er 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 S6200 043 1 2 3 4 ...

Page 344: ...326 Phaser 6200 Color Laser Printer Service Manual Chute Assembly Out Duplex 1 2 4 5 6 7 8 3 S6200 007 ...

Page 345: ...sing 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 drive...

Page 346: ...roll mid roll and duplex roll 2 Mid Roll See Exit Roll 3 Exit Roll Rotates through the drive from the Duplex 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 S6200 044 1 2 3 ...

Page 347: ...SSY CHUTE ASSY EXIT CHUTE ASSY OUT GEAR 48 GEAR 40 42 GEAR 48 GEAR 40 42 GEAR 42 GEAR 30 GEAR ROLL GEAR ROLL FRONT S6200 050 DUPLEX MOTOR ASSY GEAR ROLL EXIT ROLL GEAR ROLL MID ROLL GEAR 30 DUPLEX ROLL CHUTE ASSY EXIT CHUTE ASSY OUT GEAR 48 GEAR 40 42 GEAR 48 GEAR 40 42 GEAR42 S6200 035 ...

Page 348: ...ading 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 Transparency 4 Registration Sensor Detects the print media leading edge has reached the Registration...

Page 349: ... 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 2 1 3 4 S6200 0...

Page 350: ...332 Phaser 6200 Color Laser Printer Service Manual Fuser Drive Assembly Transmission Route FUSER DRIVE ASSY Heat Roll FUSER ASSY Gear Exit Exit Roll Assy S6200 034 ...

Page 351: ... M C K RTC Y M C K Refresher Y M C K IDT 1 IDT 2 IDT 1 IDT 2 Cleaner IDT 1 Cleaner 2 Laser Unit The Laser 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 Registrati...

Page 352: ...nit Charge Voltage Contacts 1 Charge Voltage 2 Developer Voltage 3 IDT2 Voltage 4 IDT2 Refresher Cleaner 5 IDT1 Voltage 6 IDT1 Refresher Cleaner 7 Drum Refresher Cleaner 8 Drum Ground Contacts Printer shown with the Imaging Unit removed 1 2 3 4 5 6 7 8 S6200 290 ...

Page 353: ...Theory of Operation 335 1 IDT2 2 IDT2 Refresher Cleaner 3 IDT1 4 IDT1 Refresher Cleaner 5 Drum Refresher Cleaner 6 Developer 7 Charge Roll Imaging Unit Left Side View S6200 290 7 6 5 4 3 2 1 ...

Page 354: ...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 ...

Page 355: ...Theory of Operation 337 1 Agitator Assembly with film 2 Toner Motor 3 Auger Assembly 4 Auger Tube S6200 281 4 3 1 2 ...

Page 356: ...on Route Developer Assembly Transmission Route TONER CARTRIDGE Agitator TONER MOTOR ASSY GEAR IDLER1 GEAR IDLER2 GEAR AUGER AUGER ASSY GEAR TCRU GEAR AGITATOR AGITATOR ASSY Film PIPE AUGER S6200 279 DEVELOPER DRIVE ASSY IMAGING UNIT Developer Y Developer M Developer C Developer K S6200 033 ...

Page 357: ...om the sensors and switches Incorporates functions of the High Voltage Power Supply Major Functions Communicates with the Image Processor Board Receives information from the sensors and or switches Controls the Laser Unit Supplies high voltage to the Imagning Unit to perform charging development primary transfer and secondary transfer S6200 049 1 2 3 4 5 6 ...

Page 358: ...from the sensors and switches Controls the motor in the main drive assembly developer drive assembly fuser drive assembly duplex motor assembly and the holder toner cartridge motor assembly Distributes the low voltage DC power from the low voltage power supply to each component Controls the 24 VDC circuit through the interlock switch 4 Rear Fan Removes heat from the printer to prevent over heating...

Page 359: ...oard 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 ...

Page 360: ...ard 132 1 Chute Assembly Out MPT Feed Solenoid FRONT 1A Harness Assembly 133 1 Chute Assembly Out Duplex Jam Sensor FRONT 1A Harness Assembly 134 1 Chute Assembly Out Full Stack Sensor FRONT 1A Harness Assembly 135 1 Chute Assembly Out MPT No Paper Sensor FRONT 1A Harness Assembly 136 2 Assembly Front In Sensor CTD ADC Assembly FRONT 1A Harness Assembly 137 1 Front Cover Fan Fuser Motor Driver Boa...

Page 361: ...idity 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 Toner Present Sensor Motor Driver Board 432 1 Holder Assembly MQ M Toner Present Sensor Motor Driver Board 433 1 Holder Assembly MQ C Toner Present Sensor Motor Driver Board 434 1 Holder Assembly MQ K Toner Present Sensor Mo...

Page 362: ...iver Board 513 1 Holder Assembly MQ C Toner Motor Motor Driver Board 514 1 Holder Assembly MQ K Toner Motor Motor Driver Board 710 1 Plate Dispenser L EEPROM Harness Assembly 810 4 High Capacity Feeder Engine Control Board 1361 3 FRONT 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 Chut...

Page 363: ...Plug Jack Locator Maps 345 Map 1 S6200 264 ...

Page 364: ...346 Phaser 6200 Color Laser Printer Service Manual Map 2 S6200 265 ...

Page 365: ...Plug Jack Locator Maps 347 Map 3 S6200 266 ...

Page 366: ...348 Phaser 6200 Color Laser Printer Service Manual Map 4 S6200 267 ...

Page 367: ...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 Clutch 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 Boa...

Page 368: ...350 Phaser 6200 Color Laser Printer Service Manual Map 5 S6200 268 ...

Page 369: ...Wiring Diagrams 351 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 ...

Page 370: ...PL10 1 1 Toner Motor K PL10 1 1 P J514 LASER ASSY PL9 1 1 P J151 P J71 P J710 IMAGE UNIT PL9 1 3 CRUM EEPROM PL10 1 16 P J144 TONER FULL SENSOR PL5 1 13 P J141 P J142 P J24 HUM TEMP SENSOR PL3 2 2 P J2361 P J231 P J13 CTD SENSOR PL5 1 11 P J1361 P J136 TRANSFER ROLLER ASSY PL8 1 12 P J5011 P J5030 P J5020 Detack Saw BTR IMAGING UNIT PL9 1 3 IDT2 IDT2 CLEANER IDT1 IDT1CLEANER RFB HTC DEVE Y DEVE M ...

Page 371: ...DC P J41 24 5VDC P J11 17 5VDC 2 7 SG P J165 3 P J61 6 3 3VDC P J41 23 3 3VDC P J11 18 3 3VDC 4 5 SG 24VDC Supply 5VDC Supply 3 3VDC Supply 22 19 SG 21 20 SG P J165 8 6 7 P J61 1 3 2 P J42 13 12 29 P J12 18 19 2 FAN LOW FAN STOP P J166 2 1 3 Fan Control REAR FAN PL12 1 2 P J161 1 2 AC SW Heater Control P J162 2 1 P J164 4 3 2 1 P J311 4 3 2 1 GND_ESS 5VDC_ESS 3 3VDC_ESS GND_ESS REAR FAN ON H REAR ...

Page 372: ...7 PULL UP 3 3VDC SG TRAY1 NO PAPER SENSED H 3 3VDC P J42 19 P J12 12 P J473 3 2 1 P J47 8 9 10 PULL UP 3 3VDC SG TRAY1 LOW PAPER SENSED H 3 3VDC P J42 20 P J12 11 P J47 11 12 FEED SOLENOID Tray1 PL3 3 17 P474 2 J474 1 1 2 I L 24VDC TRAY1 FEED SOL ON L 24VDC P J42 21 P J12 10 P J47 13 14 TURN CLUTCH Tray1 PL3 3 18 P475 2 J475 1 1 2 I L 24VDC TRAY1 TURN CL ON L 24VDC P J42 22 P J12 9 3 3VDC Interloc...

Page 373: ...4 15 16 P J41 29 28 27 26 25 FSR TDB FSR A FSR TDA DA_FSRMOT P J52 1 2 3 4 5 6 Interlock 24VDC FUSER DRIVE ASSY PL5 1 18 I L 24VDC I L 24VDC FSR_A FSR_B FSR_XA FSR_XB M DUP A P J12 5 6 7 8 29 P J42 26 25 24 23 2 DUP B DUP TDA DUP TDB DA_DUPMOT P J50 1 2 3 4 5 6 Interlock 24VDC DUPLEX MOTOR ASSY PL7 1 8 I L 24VDC I L 24VDC DUP_A DUP_B DUP_XA DUP_XB M J131 6 5 P131 1 2 4 3 3 4 2 5 1 6 P J12 1 30 4 P...

Page 374: ... SW TCRU_K ON L 3 3VDC P J441 1 2 3 P J51 16 15 SG NOTNR_Y P J12 21 P J42 10 NOTNR_CHK_C P J442 1 2 3 P J51 18 17 SG NOTNR_M P J443 1 2 3 P J51 34 33 SG NOTNR_C P J444 1 2 3 P J51 36 35 SG NOTNR_K 22 9 NOTNR_CHK_M 23 8 NOTNR_CHK_Y 24 7 NOTNR_CHK_K Toner Sensor Control 28 3 NOTNR MOTOR DRIVER BOARD PL12 1 12 ENGINE CONTROL BOARD PL12 1 1 TONER PRESENT SWITCH M PL10 1 18 TONER PRESENT SWITCH C PL10 ...

Page 375: ...12 5 4 3 2 1 M TMOT_M_A TMOT_M_B TMOT_M_XA TMOT_M_XB P J11 33 34 35 36 P J41 8 7 6 5 P J51 19 20 21 22 23 Interlock 24VDC Toner Motor C Control TCRU HOLDER ASSY C PL10 1 3 I L 24VDC TMOT_C_A TMOT_C_B TMOT_C_XA TMOT_C_XB P J513 5 4 3 2 1 M TMOT_C_A TMOT_C_B TMOT_C_XA TMOT_C_XB P J11 37 38 39 40 P J41 4 3 2 1 P J51 24 25 26 27 28 Interlock 24VDC Toner Motor K Control TCRU HOLDER TCRU Toner Cartridge...

Page 376: ... J232 A5 A4 A3 J232 A2 P321 A1 A2 A3 P321 A4 18 19 P J13 20 21 3 3 J138 2 P138 4 1 5 A1 A5 Exit Sensor P323 3 2 1 P321 P144 PULL UP 3 3VDC SG EXIT PAPER SENSED L 3 3VDC Temp Sensor J322 2 1 SG FUSER_STS 3 3VDC J233 1 J235 1 J234 1 P J12 20 P J42 11 HEATER ON P J165 5 P J61 4 ENGINE CONTROL BOARD PL12 1 1 MOTOR DRIVER BOARD PL12 1 12 P J145 4 J138 4 3 P138 J232 B1 B2 B3 3 2 2 EEPROM DATA See laser ...

Page 377: ..._A_Y MO_D_K MO_C_C MO_B_M MO_A_Y XPDATA_D_K XPDATA_C_C XPDATA_B_M XPDATA_A_Y 5VDC Interlock 24VDC 4 3 2 P J140 1 5 6 10 9 8 P J140 7 P J152 1 2 3 4 5 6 7 Scanner Motor M P J153 1 2 3 SOS BOARD PLATE DISPENSER L PL10 1 9 CRUM P71 6 5 4 3 2 1 J71 1 2 3 4 5 6 3 4 5 P J710 6 2 1 EEPROM BOARD PL10 1 16 1 2 3 P J144 4 LD 5VDC CRUM DATA CRUM CLOCK 3 3VDC SG 5VDC EEPROM DATA EEPROM CLOCK 3 3VDC SG 3 3VDC ...

Page 378: ...ONER FULL PL5 1 13 5VDC TONER FULL SENSED H 3 3VDC SG P J13 12 13 14 15 16 P1361 5 J1361 1 4 2 3 3 2 4 1 5 P J136 5 4 3 2 1 CTD SENSOR ADC ASSY PL5 1 11 ADC VOUT 5VDC SG ADC MONITOR GLED 5VDC 5VDC SENSOR HUM TEMP PL3 2 2 J231 1 2 3 4 P2361 1 J2361 4 2 3 3 2 4 1 P J24 4 3 2 1 5VDC 5VDC ENV HUMI SG ENV TEMP ENGINE CONTROL BOARD PL12 1 1 ...

Page 379: ..._P ON L 24VDC BTR_M ON L 24VDC DTS ON L 24VDC HV_MONI_BTR_V P J702 1 P J802 1 IDT2 IDT2 CLEANER HTC P J701 1 P J801 1 IDT1 IDT1 CLEANER P J805 1 IDT1 IDT2 RFB P J804 1 P J601 1 P J602 1 P J603 1 P J604 1 DEVE M DEVE C DEVE K DEVE Y BTR P J5030 1 P J5020 1 Detack Saw DTS BTR IDT1 Interlock 24VDC ENGINE CONTROL BOARD PL12 1 1 TRANSFER ROLLER ASSY PL8 1 12 IMAGING UNIT PL9 1 3 NOTE BTR Transfer Rolle...

Page 380: ... 3VDC P J13 10 11 P139 2 J139 10 1 11 P132 2 J132 1 1 2 SOLENOID MPT FEED PL6 1 40 I L 24VDC MPT FEED SOL ON L 24VDC Interlock 24VDC P J18 1 2 3 PULL UP 3 3VDC 3 3VDC SG REGI PAPER SENSED L 3 3VDC P J181 3 2 1 P J18 4 5 I L 24VDC REGI CLUTCH ON L 24VDC Interlock 24VDC Regi Clutch REGI CHUTE PL9 1 7 P J19 1 2 I L 24VDC MPT TURN CLUTCH ON L 24VDC CLUTCH TURN MPT PL4 1 9 Interlock 24VDC P J32 3 2 1 5...

Page 381: ...14 15 16 17 18 19 20 P J221 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 P220 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J2211 P31 1 2 TEST PRINT ON L 3 3VDC SG ENGINE CONTROL BOARD PL12 1 1 FRONT PANEL PL1 1 1 SG FP RXD SG FP TXD SG FP STS SG FP RST 5 VDC 5 VDC SG 3 3 VDC SG 3 3 VDC SG 3 3 VDC SG 3 3 VDC SG 3 3 VDC ...

Page 382: ...ARD PL14 5 1 ENGINE CONTROL BOARD PL12 1 1 Low Paper Sensor T2 PL14 5 7 P J823 FEED SOLENOID T2 PL14 4 17 TURN CLUTCH ASSY T2 PL14 4 18 P J81 P J21 P J210 2 P J810 No Paper Sensor T3 PL14 4 4 PAPER SIZE SW T3 PL14 3 6 P J831 P J832 Low Paper Sensor T3 PL14 5 7 P J833 FEED SOLENOID T3 PL14 4 17 P J834 TURN CLUTCH ASSY T3 PL14 4 18 P J835 3 P J84 P J131 1 P J82 P J822 P J821 P J824 P J825 P J83 ...

Page 383: ...J810 B7 P810 B7 J210 A7 P210 A7 B8 B6 A8 A6 B9 B5 A9 A5 B10 B4 A10 A4 A13 A2 B13 B1 I L 24VDC P J21 2 P J81 25 J810 A2 P810 A13 J210 B2 P210 B12 25 2 I L 24VDC B12 B2 A12 A2 1 26 RTN A1 A14 B1 B13 26 1 RTN B13 B1 A13 A1 Interlock 24VDC 3 3VDC P J21 3 P J81 24 J810 A3 P810 A12 J210 B3 P210 B11 4 23 SG A4 A11 B4 B10 3 3VDC NO OPF L 3 3VDC P J21 24 P J81 3 J810 B11 P810 B3 J210 A11 P210 A3 ENGINE CON...

Page 384: ...DC SG TRAY2 LOW PAPER SENSED H 3 3VDC P J82 11 12 FEED SOLENOID Tray2 PL14 4 17 P824 2 J824 1 1 2 I L 24VDC TRAY2 FEED SOL ON L 24VDC P J81 20 P J21 7 P J82 13 14 TURN CLUTCH ASSY Tray2 PL14 4 18 P825 2 J825 1 1 2 I L 24VDC TRAY2 TURN CL ON L 24VDC 3 3VDC Interlock 24VDC Interlock 24VDC J810 B3 P810 B11 J210 A3 P210 A11 B2 B12 A2 A12 B1 B13 A1 A13 J810 A11 P810 A4 J210 B11 P210 B3 P J81 18 P J21 9...

Page 385: ...VDC TRAY3 FEED SOL ON L 24VDC P J81 19 P J21 8 P J83 13 14 P835 2 J835 1 1 2 I L 24VDC TRAY3 TURN CL ON L 24VDC 3 3VDC Interlock 24VDC Interlock 24VDC J810 B6 P810 B8 J210 A6 P210 A8 B5 B9 A5 A9 B4 B10 A4 A10 J810 A12 P810 A3 J210 B12 P210 B1 P J81 17 P J21 10 J810 A10 P810 A5 J210 B10 P210 B4 J810 A8 P810 A7 J210 B8 P210 B6 P J81 21 P J21 6 J810 A6 P810 A9 J210 B6 P210 B8 J8220 3 P8220 1 2 2 1 3 ...

Page 386: ...368 Phaser 6200 Color Laser Printer Service Manual Blank Page ...

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