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Phaser 6500
Xerox Phaser 6500 Service Manual
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Phaser 6500/W
o
rkC
e
ntr
e
6505 Service
Manual
X
e
r
o
x Int
e
rnal
Use
O
n
ly
8-73
Service Parts Disassem
bly
MFP F
eeder Assembly
PL3.1.98 (MFP Feeder Assy)
1.
R
emov
e the MFP Upper F
r
ame Assembly (page
8-67).
2.
R
emov
e the MFP HVPS (page
8-154).
3.
R
emove the 14 scr
ews that secure th
e HVPS chassis to the F
eeder Assembly.
s6500-240
520
522
Table of Contents
Default Chapter
3
Table of Contents
3
About this Service Manual
15
Manual Organization
16
Symbols Marked on the Product
17
Power Safety Precautions
18
Electrostatic Discharge (ESD) Precautions
19
Service Safety Summary
20
Regulatory
22
1 General Information
25
Printer Introduction and Overview
26
Technical Support Information
26
Printer Configuration
27
Parts of the Printer
28
SFP Front and Side Views
28
MFP Front and Side Views
29
SFP Rear View
30
MFP Rear View
31
Internal View, SFP
32
Internal View, MFP
33
Control Panel
34
Printer Options
36
Additional Memory
36
Optional Feeder
37
Duplex Unit
38
Maintenance Items
39
Consumables
40
Specifications
41
Printing Specifications
41
Scanning Specifications
42
Copy Specifications
43
Fax Specifications
44
Memory Specifications
45
Electrical Specifications
45
Print Speed
46
Environmental Specifications
46
Operating Mode
47
First Print Output Time
48
First Copy Output Time
49
Physical Dimensions and Clearances
49
Mounting Surface Specifications
51
Media and Tray Specifications
52
2 Theory of Operation
55
Phaser 6500/Workcentre 6505 Operational Overview
56
Print Process
56
Charging
58
Exposure
59
Development
61
Toner Dispense Path
62
Image Transfer
63
Imaging Unit
65
Excess Toner Collection
66
Fusing
67
Transfer Belt Cleaning
67
Media Path
68
Media Path Drive
68
Media Path Components
69
ADF Media Path
70
Sensors
71
Sensor Types
71
Sensors in the Media Path
73
Sensors in the Automatic Document Feeder
73
Major Assemblies and Functions
74
Tray
74
Feeder
76
Optional Feeder
78
Duplex Unit
79
Manual Feed & Registration
81
Transfer Belt and Fuser
85
Laser Unit
86
Toner Cartridge & Dispenser
88
Imaging Unit
89
Drive
90
Electrical
92
Operation Modes
97
Printer Control
97
Media Size Detection
97
Laser Control
97
Process Control
98
Color Registration Control
99
Fuser Control
100
Drive
101
Main Drive Assembly
101
Sub Drive Assembly
103
Feed Drive Assembly
104
Development and Toner Collection
107
Dispense Assembly
109
Duplex Unit
110
Optional Feeder
112
Scanner
114
CCD Image Sensor
117
MFP System Configuration
117
Scanning on Document Glass
118
Automatic Document Feeder
119
ADF Components
119
ADF Media Path
121
ADF Drive
123
Fax
125
Fax Overview
125
Fax Standards (ITU-T Recommendations)
127
Xerox Internal Use Only Phaser 6500/Workcentre 6505 Service Manual
128
3 Error Messages and Codes
129
Introduction
130
Accessing Error History Report
130
Error History Report
130
Servicing Instructions
132
Messages, Codes, and Procedures
133
Error Message Abbreviations
133
Error Message and Code Summary
134
Error Code Troubleshooting
163
IOT Option Feeder I/F Failure
163
MFP Pickup Jam / ADF Jam / Virtual Jam
164
ADF Cover Open
165
IOT Fuser Detached
166
IOT Fuser Life over
168
IOT Fuser Failure
169
IOT Fuser Near Life
171
Image Processor Board Error
172
Server Setting Error
173
Ipsec Certificate Error
174
LDAP Address Book - Access Error
175
Memory over Flow
176
PDL Error
177
Check Sum Error / Download Header Error
178
PDF Password Error / PDF Print Disabled Error
179
Auditron - Invalid User
179
Auditron - Disabled Function
180
Auditron - Reached Limit
180
USB Memory Error
181
Job Environment Violation
181
USB HOST Error
182
Disk Full
183
Mail Size Error / File Size Error
184
Out of Memory
184
PWBA FAX (FAX Board) Error
186
PC Scan Time out
187
IOT Firmware Error
188
MCU Download Error
190
IOT Start Image Marking Time-Out
191
MCU-ESS Communication Fail
192
Waiting for "Continue" Key to be Pressed after Reloading Paper to the SSF
193
Ipv6 Duplicate / Ipv4 Duplicate
193
SMB Logging Error
194
SMB Server Error/Dns Error/In SMB Scan, Server Connection Error
194
SMB Scan User Overlimit
195
SMB Scan Client Has no Access Right (Win9X)
196
SMB Error
197
FTP File Appended Error
197
FTP File Changed Error
198
CODEC Error
199
Communication Error
200
Communication Job Failure
201
DFAX Password Error
202
During Call Busy Tone
203
DM Prevention Function Receive Refuse
204
Buffer over
205
Buffer Job Failure
206
NSS/DCS Function Disagreement
207
Communication Job Failure
208
Check Line Connection
208
FAX FWD Document Change Error
209
Busy Job Failure
209
Digital Line Detection
210
IOT NVRAM Error
211
IOT Fan Motor Failure
212
IOT Main Motor Failure
214
IOT Sub Motor Failure
215
IOT K Mode Solenoid Error 1/2
216
IOT over Heat Stop
218
IOT ROS Failure
219
IIT Error
220
Scanner Error
221
Copy Limit
222
IOT Tray1 Misfeed JAM
223
IOT Tray2 Misfeed JAM
228
IOT Feeder 2 JAM
233
IOT Feeder Configuration Failure
238
Option Feeder Motor Failure
239
IOT Remain Option Feeder JAM
240
IOT SSF Insert JAM / IOT SSF Paper Pullout JAM / Waiting for Reseat Paper of SSF
241
IOT Regi on Early JAM
243
IOT Regi off Jam
245
IOT Exit on JAM / IOT Exit on Early JAM / IOT Stop Reservation JAM
249
IOT Exit off JAM / IOT Exit off Early JAM
253
IOT Duplex Misfeed JAM / IOT Duplex JAM
255
IOT Duplexer Failure
257
IOT Cover Front Open
259
IOT Side Cover Open
260
IOT Exit JAM
262
IOT Remain Registration JAM
264
IOT Remain Duplex JAM
266
IOT PHD Life Pre Warning
267
PHD Tape Staying
268
IOT PHD CRUM ID Error
269
IOT PHD Life over
270
IOT CRU Waste (YMCK) Full
271
IOT PHD Detached
272
IOT CTD (ADC) Sensor Error
273
CTD (ADC) Sensor Dustiness Warning / IOT CTD (ADC) Sensor Dustiness
276
IOT Environment Sensor Error
277
IOT Toner Cartridge Near Life
278
IOT YMCK Toner Low Density
279
IOT Toner (YMCK) CRUM Comm Error
282
IOT (YMCK) CRUM ID Error
283
IOT Toner Cartridge Life over
285
IOT Print Cartridge Detached
285
IOT Belt Unit Near Life
287
IOT Belt Unit Life over
288
ESS DIMM Slot RAM R/W Check Fail / ESS DIMM Slot RAM Error
288
On Board Network Fatal Error
289
PCI Bus# (0/1) Error Detected / PCI Bus# (0/1) Host Bridge Controller Error / PCI Error Messages Received from Bus#0-Device# (0/1)
290
Collate Full
290
Fax Card Modem Error
291
Custom Toner Mode
292
4 General Troubleshooting
293
Introduction
294
Initial Actions
294
Display Problems
294
Printing Problems
294
Media-Based Problems
295
System Startup
297
Power on Self Test (POST)
298
Service Diagnostics
299
Using Service Diagnostics
299
Entering Service Diagnostics
300
Exiting Service Diagnostics
300
Service Diagnostics Menu Maps
301
Printer Diagnostic Test Descriptions
304
Print Engine Test Procedures
312
Sensor Tests
312
Motor Tests
319
NVM Settings
329
Duplex Unit Test Procedures
330
Duplex Exit Motor
331
Duplex Clutch
332
Duplex Motor
333
Optional Feeder Test Procedures
334
Tray 2 no Paper Sensor
334
Tray 2 Paper Path Sensor
335
Tray 2 Feeder Motor Test
336
Tray 2 Feed Solenoid Test
337
Tray 2 Drive Clutch
338
Engine Test Print (SFP)
339
Engine Test Print (MFP)
342
Fax/Scanner Diagnostic Tests
343
Scanner I/O Diagnostic Testing Procedures
350
Control Panel Troubleshooting
358
Printer Does Not Come to a "Ready" State
358
Ready LED Is On, Display Is Blank
358
Control Panel Has Failed
358
Inoperable Printer Troubleshooting
359
AC Power Troubleshooting
359
DC Power Supply Troubleshooting
360
+24 VDC Interlock Switch
362
Image Processor Board
363
Printer Continually Displays Warming up
364
Abnormal Noises
365
Abnormal Noise When Power Is Turned on
365
Abnormal Noise During Standby
366
Abnormal Noise During Printing
367
Electrical Noise
371
Operating System and Application Problems
372
Windows 2000, Windows XP, Windows Server Troubleshooting
372
Verify Settings
372
Verify Driver Installation
372
Macintosh Troubleshooting
373
5 Print-Quality Troubleshooting
375
Print-Quality Problems Overview
376
Defects Associated with Specific Printer Components
376
Checklist before Troubleshooting Print-Quality
378
Check Printer Condition
378
Symptom Checklist
378
Print-Quality Troubleshooting
381
Print-Quality Defect Definitions
381
Light or Undertone Print
382
Blank Print
384
Black Print
387
Vertical Blank Lines
389
Horizontal Band, Voids, or Streaks
391
Vertical Stripes
393
Horizontal Stripes
395
Partial Band
397
Random Spots
399
Repeating Bands, Lines, Marks, or Spots
401
Residual Image or Ghosting
402
Background Contamination
404
Skew
406
Damaged Media
408
Unfused Image
410
Color Registration
411
Wavy Lines
413
Incorrect Magnification
414
Lines or Streaks (from ADF)
415
Spots from ADF
416
Test Prints
417
No Image IOT Test Print
417
Pattern IOT Test Print
418
Grid 2 ESS Test Print
418
Cyan 20% ESS Test Print
419
Magenta 20% ESS Test Print
419
Yellow 20% ESS Test Print
420
Black 20% ESS Test Print
420
CMY 20% ESS Test Print
421
Gradation ESS Test Print
421
Toner Pallet Check Test Print
422
Contamination Check Test Prints
423
Pitch Chart Test Print
424
Image Specifications
425
Skew
426
Parallelism
427
Linearity
427
Perpendicularity
428
Magnification Error
428
Registration
429
Guaranteed Print Areas
430
6 Adjustments and Calibrations
431
Adjustments
432
Color Registration
432
Enabling/Disabling Automatic Color Registration
432
Printing the Color Registration Correction Chart
433
Adjusting Color Registration
434
Resetting the Fuser
435
Calibrations
436
Initializing Print Meter
436
Initializing NVM (NVRAM)
436
Parameter Setting
437
Registration Adjustment
438
Life Counter Values
439
Scanner Parameter Setting
441
7 Cleaning and Maintenance
443
Service Maintenance Procedure
444
Recommended Tools
444
Cleaning
444
Cleaning the Laser Lens
445
Maintenance
446
Moving the Printer
447
8 Service Parts Disassembly
449
Overview
450
Standard Orientation of the Printer
450
Preparation
451
Notations in the Disassembly Text
452
Fastener Types
453
Maintenance Items and Consumables
454
Separator Holder
454
Imaging Unit
455
Feed Roller
457
Fuser
458
Toner Cartridges
460
ADF Feed Roll Assembly
461
ADF Separator Pad
462
SFP Covers
463
SFP Top Cover
463
SFP Output Tray Extension
464
SFP Right Side Cover
465
SFP Left Side Cover
466
SFP Rear Tray Cover
467
SFP Rear Cover
468
SFP Toner Door
469
SFP Front Cover
470
SFP Right Front Holder
473
SFP Left Front Holder
476
Upper Link Pivot Shaft Kit
479
SFP Cassette Stopper
480
MFP Covers
481
MFP Front Cover
481
MFP Left Side Cover
485
MFP IP Board Cover
486
Outer Pole Cover
487
MFP Right Side Cover
488
MFP Front Door Retainer Strap Assembly
489
MFP Toner Door
490
MFP Rear Cover
491
Inner Pole Cover
492
MFP Top Cover
493
Lower Scanner Cover
494
MFP Cassette Stopper
495
Feeder
496
Drive Clutch and Regi Bearing Kit
496
Feed Solenoid
497
SFP Upper Frame Assembly
499
MFP Chassis
507
MFP Top Plate Assembly
507
MFP Inlet Chassis
511
MFP LVPS Card Cage
512
MFP Upper Frame Assembly
515
Paper Feeder
520
SFP Feeder Assembly
520
MFP Feeder Assembly
521
Registration Roller
523
Registration Input Actuator
525
Manual Feed no Paper Sensor
526
Tray 1 no Paper Sensor
527
Registration Sensor
528
Manual Feed Sensor Actuator
530
Tray 1 no Paper Sensor Actuator
532
Lower Chute Assembly
532
Xerographics
534
SFP Laser Unit
534
MFP Laser Unit
540
Right Imaging Unit Restraint Block
542
Left Imaging Unit Restraint Block
543
Erase LED Assembly
545
SFP Dispenser Assembly
546
MFP Dispenser Assembly
552
Toner Cartridge Holders
555
Transfer Belt Pivot Kit
557
Transfer Belt
560
Drive
561
Sub-Drive Assembly
561
Main Drive Assembly
562
Gear P2
564
SFP Electrical
567
SFP Fan
567
SFP Image Processor Board
568
Sfp Lvps
572
SFP Interlock Harness
573
SFP Control Panel
574
SFP Control Panel Harness a
575
SFP PHD XPRO Harness
576
SFP Humidity Sensor
578
SFP AC Power Inlet and Power Switch Harness
579
SFP Toner Door Switch
583
Sfp Hvps
584
SFP HVPS Frame
585
SFP MCU Board
586
SFP EEPROM Board
587
SFP IP Board Cage
588
MFP Electrical
589
MFP Fan
589
MFP IP Board Shield
590
MFP Fax Board
591
MFP Image Processor Board
592
Mfp Lvps
593
MFP Interlock Harness
594
MFP PHD XPRO Harness
596
MFP Toner Door Switch
598
MFP Control Panel
599
MFP Humidity Sensor
601
Mfp Hvps
602
MFP AC Power Inlet and Power Switch Harness
603
Front USB Assembly
606
MFP MCU Board
608
MFP EEPROM Board
609
Duplex Unit
610
Duplex Harness
611
Duplex Board
613
Optional Feeder
615
Option Left Side Cover
617
Option Chute Cover
618
Option Rear Cover
619
Option Right Side Cover
620
Optional Feeder Board
621
Option Drive Clutch and Bearing
622
Option Feed Gear Assembly
623
Option Feed Solenoid Kit
624
Option Feed Motor Kit
625
Option Feed Gear Kit
626
Optional Feeder Harness
627
Option Registration Roller Bearing
629
Option Feed Roller
630
Option Registration Roller
631
Option Registration Input Actuator
633
Option no Paper Sensor
634
Option Paper Path Sensor
635
Option no Paper Sensor Actuator
636
Option Separator Holder
638
IIT Procedures
639
ADF Input Tray
639
ADF Assembly
640
IIT Sub-Assembly
643
9 Parts Lists
649
Serial Number Format
650
Using the Parts List
652
Parts Lists
653
SFP Parts List 1.1 Covers (1/2)
653
SFP Parts List 1.2 Covers (2/2)
655
MFP Parts List 1.1 Covers (1/2)
657
MFP Parts List 1.2 Covers (2/2)
659
Parts List 2.1 Tray 1
661
Parts List 3.1 Feeder (1/2)
663
Parts List 3.2 Feeder (2/2)
666
Parts List 4.1 Xerographics
668
Parts List 5.1 Toner Dispense
671
Parts List 6.1 Transfer & Fuser
673
Parts List 7.1 Drive
675
SFP Parts List 8.1 Electrical (1/2)
677
SFP Parts List 8.2 Electrical (2/2)
679
MFP Parts List 8.1 Electrical & Frame (1/4)
681
MFP Parts List 8.2 Electrical & Frame (2/4)
683
MFP PL8.3 Electrical & Frame (3/4)
685
MFP PL8.4 Electrical & Frame (4/4)
687
Parts List 9.1 Harnesses
689
PL10.1 Scanner Assembly
692
Parts List 11.1 Duplex Unit
694
Parts List 11.2 Duplex Unit (2/2)
696
Parts List 12.1 Optional Feeder (1/5)
698
Parts List 12.2 Optional Feeder (2/5)
701
Parts List 12.3 Optional Feeder (3/5)
703
Parts List 12.4 Optional Feeder (4/5)
705
Parts List 12.5 Optional Feeder (5/5)
707
Xerox Supplies and Accessories
709
Consumables and Maintenance Items
709
Service Kits
710
10 Wiring
712
SFP Plug/Jack Designations
712
SFP Print Engine Plug/Jack Designators
712
SFP Optional Feeder Plug/Jack Designators
715
SFP Plug/Jack Locator Maps
716
Map 2 - SFP Laser Unit and Feeder
717
Map 3 - SFP IP Board, LVPS, and Drive
718
Map 4 - SFP MCU Board
719
Map 5 - SFP Optional Feeder
720
MFP Plug/Jack Designations
721
MFP Print Engine P/J Designators
721
MFP Optional Feeder Plug/Jack Designators
724
MFP Plug/Jack Locator Maps
725
Map 6 - MFP Print Engine
725
Map 7 - MFP Laser Unit and Feeder
726
Map 8 - MFP LVPS, IP Board, and Drive
727
Map 9 - MFP MCU Board and HVPS
728
Map 10 - MFP Optional Feeder
729
Duplex Unit Plug/Jack Designators & Locator Map
730
Map 11 - Duplex Unit
730
Wiring Diagrams
731
Notations Used in the Wiring Diagrams
731
SFP Wiring Diagrams
734
SFP System Connections
734
SFP Wiring Diagram Descriptions
735
Sfp Lvps
736
SFP Media Feed
737
SFP Main Drive
738
SFP Laser Unit
739
SFP Xerographics
740
Sfp Hvps
741
SFP Toner Dispenser
742
SFP Fuser
743
SFP System Control
744
SFP Option Feeder
745
SFP Duplex Unit
746
MFP Wiring Diagrams
747
MFP Wiring Diagram Descriptions
748
Mfp Lvps
749
MFP Media Feed
750
MFP Main Drive
751
MFP Laser Unit
752
MFP Xerographics
753
Mfp Hvps
754
MFP Toner Dispenser
755
MFP Fuser
756
MFP System Control
757
Adf
758
Scanner - IIT Sub-Assembly
759
MFP Option Feeder
760
MFP Duplex Unit
761
Phaser 6500 Menu Map
764
Workcentre 6505 Menu Map
765
Configuration
766
Startup
767
Job History Report
768
Error History Report
769
Print Volume Report
770
Protocol Monitor
773
Email Address Book List
774
Server Address List
775
Media Guidelines
776
Unacceptable Paper
777
Firmware Update
778
Boot Firmware Update
778
Main Firmware Update
779
Acronyms and Abbreviations
780
Other manuals for Xerox Phaser 6500
User Guide
162 pages
Brochure & Specs
4 pages
Installation Guide
2 pages
Quick Use Guide
5 pages
4
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Xerox Phaser 6500 Specifications
General
Brand
Xerox
Model
Phaser 6500
Category
Printer
Language
English
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