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Phaser 6180MFP
Xerox Phaser 6180MFP Service Manual
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Phaser 6180MFP Mu
l
tifuncti
on Printer Service Manual
8-51
Service Parts Disassembly
T
urn Clutch (PL3
.2.25)
1.
Remov
e
the Feeder Unit (pa
ge
8-47)
.
2.
Release t
he T
ur
n Clutc
h wirin
g har
ness f
rom the Cl
amps.
3.
Remov
e
the E-
ring s
ecur
ing the T
u
rn
Clutc
h.
4.
Remov
e
the T
ur
n Clutc
h from th
e F
e
eder Unit
.
s6180mfp-274
668
670
Table of Contents
Default Chapter
3
Service Manual
3
Service Terms
5
Symbols Marked on the Product
6
Power Safety Precautions
7
Electrostatic Discharge Precautions
8
Service Safety Summary
9
General Guidelines
9
Servicing Electrical Components
10
Servicing Mechanical Components
10
Regulatory Information
11
Copy Regulations
13
Fax Regulations
16
Manual Organization
19
Table of Contents
21
1 General Information
33
Printer Introduction and Overview
34
Technical Support Information
34
Printer Configurations
35
Parts of the Printer
36
Front and Side Views
36
Rear View
37
Internal View
38
Scanner
39
Control Panel
40
Printer Options
43
Additional Memory
43
Duplex Unit
43
Multi-Protocol Network Card
44
Optional 550-Sheet Feeder (Tray 3)
45
Maintenance Items
46
Consumables
48
Specifications
49
Printer Specifications
49
Scanning Specifications
50
Copy Specifications
52
Fax Specifications
53
Memory Specifications
54
Environment Specifications
54
Electrical Specifications
55
Print Speed
56
Operating Mode
57
Warm-Up Time
60
First Print Output Time
60
First Copy Output Time
60
Image Specifications
61
Alignment Specifications
62
Physical Dimensions and Clearances
63
Mounting Surface Specifications
64
Media and Tray Specifications
66
Controller Functions
68
Job Control
68
ID Print
70
Toner Remaining Amount
71
Maintenance Function
71
Diagnostics
72
Information Pages
72
Admin Reports
79
2 Theory of Operation
83
Phaser 6180MFP Operational Overview
84
System Overview
84
Print Process Block Diagram
86
Printing Process
87
Charging
88
Exposure
89
Development
91
Transfer (Drum
93
Cleaning (Print Cartridge)
95
Neutralization
96
Fusing
97
Cleaning
97
Paper Path of the Printer
98
Paper Path Route
98
Paper Path Components
99
Major Assemblies and Functions
100
Tray 2
100
Paper Feeder
104
Tray 1 (MPT) & Registration
107
Fuser Unit
113
Transfer Unit
115
Laser Unit
116
Print Cartridge
118
Main Drive
120
Electrical
122
Duplex Unit
130
Tray 3 - Optional 550-Sheet Feeder
131
Printer Modes
137
Operational Modes
137
Printer Control
138
Paper Size Detection
138
Selective Control on Paper Tray
139
Laser Unit Light Quantity Control
139
Process Control
139
Color Registration Control
142
Fuser Control
143
Drive Transmission
144
Mechanical Components
144
Main Drive
147
Front View
148
Dispenser (C) (M) (Y) (K)
153
Drive Assembly
155
Duplex Drive
157
Optional 550-Sheet Feeder Drive
159
Optional 550-Sheet Feeder
159
Scanner Assembly
161
Scanning on Document Glass
161
Scanning at Automatic Document Feeder
162
Preregistration
164
Drive Torque Transfer
166
Functions of Components
168
Control
170
CCD Image Sensor Overview
171
Fax System
172
Telephone System Overview
172
Telephone Call Connection Mechanism
176
Fax (Facsimile) System Overview
179
Protocol Monitor
183
Fax Standards (ITU-T Recommendations)
187
3 Error Messages and Codes
189
Introduction
190
Accessing Error History Report
190
Error History Report
190
Servicing Instructions
192
Messages, Chain Link Codes, and Procedures
193
Error Messages Abbreviations
193
Chain Link Definition
194
Error Message and Chain Link Code Summary
195
Jam Errors
207
Jam at Tray 2 (Illegal Settings)
207
Jam at Scanner
210
Jam at Tray 2 (IOT Feed Jam)
212
Jam at Tray 3 (Illegal Settings)
214
Jam at Tray 1 (MPT)
218
Jam at Tray 2 (Feed Jam)
222
Jam at Exit/Jam at Registration Roll
224
Jam at Duplexer
230
Consumable/Routine Maintenance Errors
234
Insert Fuser
234
Fuser Error (IOT Fuser Life Over)
236
Fuser CRUM ID Error
237
Fuser Error
238
Check Print Cartridge Error (Yellow/Magenta/Cyan/Black)
240
Remove Print Cartridge Tape (Yellow/Magenta/Cyan/Black)
241
Replace Print Cartridge (Yellow/Magenta/Cyan/Black)
243
Empty Print Cartridge (Yellow/Magenta/Cyan/Black)
244
Print Cartridge CRUM Error (Yellow/Magenta/Cyan/Black)
245
Applicable Chain Link
245
Initial Actions
245
Non-Xerox Print Cartridge Error (Yellow/Magenta/Cyan/Black)
247
Insert Print Cartridge (Yellow/Cyan/Magenta/Black)
248
Non-Xerox Print Cartridge Installed
251
Insert Transfer Unit
253
Transfer Unit CRUM Error
255
Ready Transfer Unit Life
256
Replace Transfer Unit
257
Tray and Paper Errors
258
Load Tray 1 (MPT) (Paper Mismatch)
258
Load Tray 2 (Paper Size Mismatch)
260
Load Tray 3 (Paper Mismatch)
262
Insert Tray 2
264
Insert Tray 3
266
Load Tray 1 (MPT) (no Suitable Paper)
268
Load Tray 2 (no Suitable Paper)
270
Load Tray 3 (no Suitable Paper)
272
Multiple Feed
275
Options Errors
277
Feeder Error (Optional 550-Sheet Feeder)
277
Motor Error (Optional 550-Sheet Feeder)
279
Duplexer Error
281
Configuration, Memory, and Firmware Errors
283
Incorrect Pagepack Password
283
Flash Error
284
Control Panel Language Set Unsupported
285
Engine Model Mismatch
286
Out of Memory/Hard Drive Full
287
PDL Error
288
Format Error
289
MPC Error
290
Reseat MPC Error
292
MPC Communication Error
294
Protection Error
296
Invalid ID
297
Range Check Error
298
Check Sum Error
299
Header Error
300
Invalid Job
301
MPC Error
302
Network Error
304
MCU Firmware Error
305
Download Mode
306
MCU Communication Error
307
MCU NVRAM Error
308
Fan Motor Error (Duplex Fan)
310
Printer too Hot
312
Main Motor Error
314
Sub Motor Error
316
Fan Motor Error (Main Fan)
318
Laser Error
320
Deve Motor Error
322
Motor Error (Tray 2)
324
Door a Open
326
ADC Sensor Error (Error Code 01)
327
ADC Sensor Error (Error Code 02)
329
Environmental (Humidity/Temperature) Sensor Error
332
Font ROM Error
334
Mac Address Error
335
RAM Error
336
NVRAM Error
338
Controller Error
339
ASIC Error
340
Parallel Port Error
341
MACPHY Chip Test Error
342
MACPHY Internal Loop Test Error
343
MACPHY External Loop Test Error
344
Controller Error
345
Task Error
347
E-Mail Errors
349
Email Error
349
Email Login Error
351
Invalid Email Address
353
Scanner and Copier Errors
355
Scanner ADF Cover Open
355
Network Scan Error
356
Network Not Ready Error
358
Network Not Ready, Scan Aborted Error
360
File Size Limit
361
PC Scan Time out
362
Scan Codec Error
364
Scanner Error
365
Scanner Error
367
Copier Error
368
Scan Error
369
Controller Error
370
Control Panel Error
371
Fax Errors
372
Memory Full
372
Fax Codec Error
374
Memory Full
375
Controller Error
376
NVM Error
378
Task Error
379
Fax Error
381
Report Error
383
Fax Communication Error
384
Target Fax Busy Error
386
Fax Communication Error
388
Fax Communication Error
390
Fax Communication Error
391
Fax Codec Error
392
Fax Codec Error
393
Fax Codec Error
394
Incorrect Password
396
Fax Codec Error
397
Fax Codec Error
398
Fax Job Cancelled
400
Fax Send Error
401
Fax Communication Error
402
Fax Communication Error
403
Fax Number Error
404
Target Fax no Answer
405
Fax Communication Error
406
Target Fax no Answer
408
Fax Communication Error
409
No Dial Tone
410
EEPROM Error
411
4 General Troubleshooting
413
Introduction
414
System Startup
414
Power on Self Test (POST)
415
Service Diagnostics
417
Entering Service Diagnostics
417
Using Service Diagnostics
417
Service Diagnostics Control Panel Button Descriptions
418
Service Diagnostics Menu Map
419
Fax/Scanner Diag
419
Printer Diag
420
Printer Diag (Cont.)
421
Printer Components
423
Motors, Clutches, Solenoids, Lamps
423
Sensors
424
Duplex Components
425
Clutch, Fan, Motor, Sensor
425
Service Diagnostics Tests
426
Service Diagnostic Tests and Utilities
426
Sensor Tests
453
Motor Tests
466
Control Panel Troubleshooting
490
Printer Does Not Come to a "Ready" State
490
Control Panel LED Is On, Control Panel Display Is Blank
490
Engine Test Print
491
Inoperable Printer Troubleshooting
492
Engine Power-Up Sequence
492
Printer Continually Displays Warming up
492
Printer Continually Displays Insert Print Cartridge
493
AC Power Supply Troubleshooting
495
DC Power Supply Troubleshooting
496
LVPS Overcurrent Protection Circuit
496
LVPS Overvoltage Protection Circuit
496
Lvps
496
+24 VDC Interlock Switch
498
Fax Troubleshooting
499
Fault Occurs
499
Transmission Fault
499
Reception Fault
500
Other Problems
501
Fax Failure after Installation/Relocation
503
Fax Failure after Continuous Normal Operation
506
Color Fax Troubleshooting
509
Fax Configuration Settings
511
Abnormal and Electrical Noise
513
Abnormal Noise When Power Is Turned on
513
Abnormal Noise During Printing
517
Electrical Noise
520
High Pitched Noise
521
Operating System and Application Problems
522
Windows 2000, Windows XP, Windows Server Troubleshooting
522
Verify Settings
522
Verify Driver Installation
522
Macintosh Troubleshooting (Mac os 10.2 and Higher)
523
UNIX / Linux
524
5 Print-Quality Troubleshooting
527
Print-Quality Problems Overview
528
Defects Associated with Specific Printer Components
528
Checklist before Troubleshooting Print-Quality
531
Checking the Printer Condition
531
Checklist
532
Test Prints
538
No Image IOT
538
Pattern IOT
539
Grid 2 ESS
539
Cyan 20% ESS
540
Magenta 20% ESS
540
Yellow 20% ESS
541
Black 20% ESS
541
Cmy 20% Ess
542
Gradation ESS
542
Print-Quality Specifications
543
Environmental Condition
543
Quality Paper
543
Paper Condition
543
Printer Condition
543
Specifications
544
Print-Quality Troubleshooting
548
Print-Quality Defect Definitions
548
Repeating Defect Measurement
550
Light or Undertone Print
552
Blank Print (no Print)
554
Black Print
557
Vertical Blank Lines
560
Horizontal Band, Voids, or Streaks
562
Vertical Stripes
564
Horizontal Stripes
566
Faded or Missing Image
568
Random Spots
570
Defects in One Color (C, M, Y, or K)
572
Repeating Bands, Lines, Marks, or Spots
574
Residual Image or Ghosting
576
Background Contamination
578
Skew
580
Damaged Paper
583
Unfused Image
586
Color Registration
588
Wavy Lines
590
Incorrect Magnification
591
Lines or Streaks (from ADF)
592
Spots (from ADF)
593
Pattern in the Halftone (Moire)
594
6 Adjustments and Calibrations
597
Adjustments
598
Color Registration
598
Printing the Color Registration Correction Chart
598
Enabling/Disabling Automatic Color Registration
599
Adjusting Color Registration
599
Resetting the Fuser
601
Calibrations
602
Initializing Print Meter
602
Initializing NVM (NVRAM)
602
Saving NVM (NVRAM)
603
Loading NVM (NVRAM)
603
Scanner Calibration
604
Parameter Setting
606
Fax/Scanner Parameter Setting
606
Printer Parameter Setting
607
7 Cleaning and Maintenance
611
Service Maintenance Procedure
612
Recommended Tools
612
Cleaning
612
Cleaning the Print Cartridge
613
Cleaning the Laser Unit
614
Cleaning the Document Glass
615
Cleaning the ADF Roller
616
Maintenance
617
RIP (Repair, Inspect, and Prevent) Procedure
617
8 Service Parts Disassembly
619
Overview
620
Standard Orientation of the Printer
621
Preparation
622
Notations in the Disassembly Text
623
Fastener Types
624
Disassembly Flow Charts
625
Printer Disassembly Flow Chart
625
Tray 1 (MPT) and Optional 550-Sheet Feeder Disassembly Flow Charts
626
Maintenance Items and Consumables
627
Transfer Unit (PL4.1.1)
627
Print Cartridge (C/M/Y/K) (PL5.1.17-20)
629
Fuser Unit (PL6.1.10)
630
Tray 1 (MPT) Feed Roller (PL3.1.10)
631
Tray 2 Feed Roller (PL3.2.53)
632
Tray 2 Retard Roller (PL2.2.17)
633
Tray 3 Feed Roller (PL13.2.10)
634
Tray 3 Retard Roller (PL13.4.10)
635
Covers
636
Rear Cover (PL1.1.6)
636
Bottom Cover (PL1.1.5)
637
Right Pole Inner Cover (PL1.1.4)
639
Right Pole Cover (PL1.1.8)
640
Right Cover (PL1.1.9)
641
Left Pole Inner Cover (PL1.1.3)
642
Left Pole Cover (PL1.1.11)
643
Left Cover (PL1.1.10)
644
Top Cover (PL1.1.1)
645
Front Cover (PL1.2.1)
646
Control Panel (PL1.2.2)
648
Tray 2 Rear Cover (PL1.1.7)
651
Tray 1 (MPT) Cover (PL1.2.26)
652
Wiring Harness A-OP-OPP (PL1.2.24)
654
Paper Tray
656
Tray 1 (MPT) Retard Holder Kit (PL2.1.3)
656
Tray 1 (MPT) no Paper Actuator (PL2.1.24)
657
Paper Feeder
658
Tray 1 (MPT) Feed Solenoid (PL3.1.3)
658
Tray 1 (MPT) Roller (PL3.1.8)
660
Tray 1 (MPT) no Paper Sensor (PL3.1.15)
662
Registration Clutch (PL3.1.19)
663
Feeder Clutch (PL3.1.20)
664
Tray 2 Feeder Unit (PL3.2.1)
665
Turn Clutch (PL3.2.25)
669
Xerographics
670
Laser Unit (PL5.1.12)
670
CRUM Connector (PL5.2.1)
674
Print Cartridge Sensor Assembly (Black) (PL5.2.2)
675
Print Cartridge Sensor Assembly (Cyan/Magenta/Yellow) (PL5.2.2)
676
Toner Dispenser Motor (C/M/Y/K) (PL5.2.10)
677
BIAS Assembly (PL5.2.11)
679
LED Assembly (PL5.2.13)
681
Hvps (Pl5.2.15)
682
Exit Chute
685
Exit out Chute Assembly (PL6.1.1)
685
Duplex Gate Chute (PL6.1.13)
686
Frame
687
Star Wheel (Spur Assembly)(PL7.1.1)
687
Left Arm Assembly (PL7.1.3)
688
Right Arm Assembly (PL7.1.13)
690
Tray 2 Size Switch Assembly (PL7.1.18)
692
Drive
693
Main Drive Assembly (PL8.1.2)
693
Feed Drive Assembly (PL8.1.7)
696
Electrical
699
EEPROM Board (PL9.2.1)
699
Interlock Switch (PL9.2.3)
700
Lvps (Pl9.2.14)
701
Main Fan (PL9.2.10)
702
Power Switch (PL9.2.4)
704
Humidity/Temperature Sensor (PL9.2.11)
705
MCU Board (PL9.2.13)
706
Image Processor Board (PL9.1.20)
708
Controller Shield Box Assembly (PRT AIO Box Assembly) (PL9.1.13)
710
Memory Card (PL9.1.22)
712
Multi-Protocol Network Card (PL9.1.23)
713
Fax Shield Box Assembly (PL9.1.4)
714
Fax Board (PL9.1.3)
716
Scanner Controller Board (PL9.1.1)
717
Speaker Assembly (PL9.2.6)
720
Automatic Document Feeder and Scanner Assembly
721
ADF Scanner Assembly (PL11.1.1)
721
ADF Feeder Roller (PL11.1.3, ADF Separator Pad, PL11.1.5), ADF Separator Spring (PL11.1.6)
728
Main Tray Kit (PL11.1.10)
732
Options
733
Duplex Unit (PL12.1.1)
733
Optional 550-Sheet Feeder (PL13.1.1)
734
Optional Feeder Assembly (PL13.2.8)
735
Tray 3 Rear Cover (PL13.2.3)
736
Tray 3 Front Left Cover (PL13.2.1)
737
Tray 3 OPF Left Cover (PL13.2.2)
738
Tray 3 Front Right Cover (PL13.2.7)
739
Tray 3 OPF Right Cover (PL13.2.6)
740
Tray 3 Turn Clutch (PL13.2.4)
741
Tray 3 Feed Clutch (PL13.2.5)
742
Tray 3 Right Guide (PL13.3.11)
743
Tray 3 Left Tray Guide (PL13.3.13)
744
Tray 3 Feeder Unit (PL13.2.9)
745
Tray 3 Size Switch (PL13.3.5)
747
9 Parts List
749
Serial Number Format
750
Using the Parts List
751
Print Engine Parts
752
Parts List 1.1 Covers (1 of 2)
752
Parts List 1.2 Covers (2 of 2)
754
Parts List 2.1 Tray 2 (1 of 2)
757
Parts List 2.2 Tray 2 (2 of 2)
759
Parts List 3.1 Paper Feeder (1 of 2)
761
Parts List 3.2 Paper Feeder (2 of 2)
763
Parts List 4.1 Transfer Unit
766
Parts List 5.1 Xerographics (1 of 2)
767
Parts List 5.2 Xerographics (2 of 2)
769
Parts List 6.1 Fuser & Exit
771
Parts List 7.1 Frame
773
Parts List 8.1 Drive
775
Parts List 9.1 Electrical (1 of 2)
777
Parts List 9.2 Electrical (2 of 2)
779
Parts List 10.1 Wiring Harness (with Scanner)
781
Parts List 11.1 Scanner Assembly
783
Options
785
Parts List 12.1 Duplex
785
Parts List 13.1 Optional-550 Sheet Feeder - Tray 3 (1 of 4)
787
Parts List 13.2 Optional 550-Sheet Feeder - Tray 3 (2 of 4)
789
Parts List 13.3 Optional 550-Sheet Feeder - Tray 3 (3 of 4)
791
Parts List 13.4 Optional 550-Sheet Feeder - Tray 3 (4 of 4)
793
Xerox Supplies and Accessories
795
Service Kits
796
10 Plug/Jack and Wiring Diagrams
799
Plug/Jack Diagrams and Designators
800
Print Engine Plug/Jack Designators
800
Duplex Plug/Jack Designators
805
Optional Feeder Plug/Jack Designators
805
Plug/Jack Locators
807
Map 1 - Electrical and Drive
808
Map 2 - Laser Unit and Feeder
809
Map 3 - Image Processor Board and Dispenser Motors
810
Map 4 - LVPS and MCU Board
811
Map 5 - Duplex Unit
812
Map 6 - Optional 550-Sheet Feeder
813
Notations Used in the Wiring Diagrams
814
Print Engine Wiring Diagrams
818
Wiring Diagram Configurations
818
General Wiring Diagram
821
DC Power Supply
822
Tray 1 (MPT) and Registration
824
Main Drive
826
Feeder
828
Laser Unit
830
Xerographic
832
High Voltage
834
Developer
836
Fuser
838
Controller
840
Optional 550-Sheet Feeder Wiring Diagram
843
Duplex Wiring Diagram
846
Fax Controller Wiring Diagram
848
Scanner Wiring Diagram
849
Automatic Document Feeder Wiring Diagram
851
Phaser 6180MFP Menu Map
854
Firmware Update
855
Control Panel Bit Map Display Update
855
Boot Controller Update
857
Firmware Controller Update
858
Firmware MPC Update
860
Chain Link for Fax Parameter Setting
861
Acronyms and Abbreviations
864
Other manuals for Xerox Phaser 6180MFP
User Guide
248 pages
Supplementary Guide
3 pages
Quick Use Guide
15 pages
Brochure & Specs
4 pages
Features Setup Guide
103 pages
4
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Xerox Phaser 6180MFP Specifications
General
Brand
Xerox
Model
Phaser 6180MFP
Category
All in One Printer
Language
English
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