Phaser 6115 MFP Service Manual

Service Manual 701P45784
Phaser 6115MFP Product Color Laser Multifunction
Service Manual
701P45784
Phaser6115MFP
Color Laser Multifunction Product
Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so. First Printing: Jan 2007
Copyright 2007 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. XEROX, The Document Company, the digital X, CentreWare, infoSMART, Made For Each Other, PagePack, Phaser, PhaserSMART, and Walk-Up are trademarks of Xerox Corporation in the United States and/or other countries. Acrobat, Adobe Reader, Adobe Type Manager, ATM, Illustrator, PageMaker, Photoshop, PostScript, Adobe Brilliant Screens, Adobe Garamond, Adobe Jenson, Birch, Carta, IntelliSelect, Mythos, Quake, and Tekton are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple, AppleTalk, EtherTalk, LaserWriter, LocalTalk, Macintosh, Mac OS, TrueType, Apple Chancery, Chicago, Geneva, Monaco, New York , and QuickDraw are trademarks of Apple Computer, Inc. in the United States and/or other countries. HP-GL, HP-UX, and PCLare trademarks of Hewlett-Packard Corporation in the United States and/or other countries. IBM and AIX are trademarks of International Business Machines Corporation in the United States and/or other countries. Windows, Windows NT, Windows Server, and Wingdings are trademarks of Microsoft Corporation in the United States and/or other countries. Novell, NetWare, NDPS, NDS, Novell Directory Services , IPX, and Novell Distributed Print Servicesare trademarks of Novell, Incorporated in the United States and/or other countries. SunSM, Sun Microsystems, and Solaris are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries. SWOP is a trademark of SWOP, Inc. UNIX is a trademark in the United States and other countries, licensed exclusively through X/Open Company Limited. As an ENERGY STAR partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
PANTONE Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTONE and other Pantone, Inc. trademarks are the property of Pantone, Inc. Pantone, Inc., 2000.
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Phaser 6115MFP Multifunction Product Service Manual
Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION, and WARNING statements.
Common Acronyms:
The following list defines the acronyms that may be found in this manual. ADC: Automatic Density Control BTR: Bias Transfer Roller CTD: Toner Density Control ECB: Engine Control Board ESD: Electrostatic Discharge FRU: Field Replaceable Unit IPB: Image Processor Board IU: Imaging Unit NCS: Non-Contact Sensor PL: Corresponds to the FRU Parts List.
Note A note indicates an operating or maintenance procedure, practice or condition that is necessary to efficiently accomplish a task. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action. Caution A caution indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment. Warning A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life.
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Danger: A personal injury hazard exists in the area where you see the sign.
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Symbols Marked on the Product
Hot surface on or in the printer. Use caution to avoid personal injury.
Do not touch the item.
Use caution (or draws attention to a particular component). Refer to the manual(s) for information.
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Power Safety Precautions

Power Source
For 115 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. This manual assumes that the reader is a qualified service technician. Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.
Disconnecting Power
Warning Turning the power off using the power switch does not completely deenergize the printer. You must also disconnect the power cord from the printers AC inlet. Disconnect the power cord by pulling the plug, not the cord. Disconnect the power cord in the following cases:

if the power cord or plug is frayed or otherwise damaged, if any liquid or foreign material is spilled into the product, if the printer is exposed to any excess moisture, if the printer is dropped or damaged, if you suspect that the product needs servicing or repair, whenever you clean the product.
Moving the Printer

Follow these guidelines to avoid injuring yourself or damaging the printer:

Do not place any food or liquids on the printer. Turn off the printer and unplug all power cables before moving the printer.
Always lift the printer from the designated lift points.
s6115-418
Caution Damage to the printer resulting from improper moving or failure to repackage the printer properly for shipment, is not covered by the warranty, service agreement, or Total Satisfaction Guarantee. The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.
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Electrostatic Discharge (ESD) Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity. Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.
Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock. Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it. After removing a static sensitive assembly (such as a PCB board or an NVRAM) 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. Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed. Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device Handle ICs and EPROMs carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCBs).
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Service Safety Summary

General Guidelines
For qualified service personnel only: Refer also to the preceding Power Safety Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components. Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use caution when working on or around the printer.
CLASS 1 LASER PRODUCT

The Phaser 6115MFP Multifunction Product is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this product does not emit hazardous laser radiation; which is possible only because the laser beam is totally enclosed during all modes of customer operation. When servicing the printer or laser unit, follow the procedures specified in this manual and there will be no hazards from the laser.
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Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock. Warning Do not touch any electrical component unless you are instructed to do so by a service procedure.
s6115-216
Servicing Mechanical Components

When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
s6115-217
Servicing Fuser Components

Warning This printer uses heat to fuse the toner image to media. The Fusing Unit is VERY HOT. Turn the printer power off and wait at least 5 minutes for the Fusing Unit to cool before you attempt to service the unit or adjacent components.
5 min.
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Regulatory Specifications
Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.
United States (FCC Regulations)

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with these instructions, it may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

Reorient or relocate the receiver (device being interfered with). Increase the separation between the printer and the receiver. Connect the equipment into an outlet on a circuit different from that which the receiver is connected. Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.
Canada (Regulations)
This Class B digital apparatus complies with Canadian ICES-003. Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada.
European Union
Xerox Corporation declares, under our sole responsibility, that the product to which this declaration relates is in conformity with the following standards and other normative documents:
January 1, 1995: Low Voltage Directive 73/23/EEC as amended by 93/ 68/EEC. January 1, 1996: Electromagnetic Compatibility Directive 89/336/ EEC. March 9, 1999: Radio & Telecommunications Terminal Equipment Directive 1999/5/EC.
This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment. To ensure compliance with European Union regulations, use shielded interface cables. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.
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Manual Organization
The Phaser 6115MFP Multifunction Product Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the print engine and attached options. Also included are detailed replacement procedures, parts lists, and wiring diagrams. The Phaser 6115MFP Multifunction Product Service Manual contains these sections: Introductory, Safety, and Regulatory Information: This section contains important safety information and regulatory requirements. Chapter 1 - General Information: This section contains an overview of the printers operation, configuration, specifications, and consumables. Chapter 2 - Theory of Operation: This section contains detailed functional information on print engine components. Chapter 3 - Error Codes and Messages: This section provides detailed troubleshooting procedures for error messages and codes generated by resident diagnostics. Chapter 4 - General Troubleshooting: Troubleshooting discussions cover the operation of Power On Self Test (POST), Service Diagnostics, In addition, this section includes troubleshooting methods for situations where no error indicator is available. Chapter 5 - Print-Quality Troubleshooting: This section focuses on techniques to correct image quality problems associated with printer output. Chapter 6 - Adjustments and Print Function Settings: This section provides procedures for the adjustment of print engine components and service settings for print functions. Chapter 7 - Cleaning and Maintenance: This section provides periodic cleaning procedures for the printer. Chapter 8 - Service Parts Disassembly: This section contains removal procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary. Chapter 9 - Parts List: This section contains exploded views of the print engine and option FRUs, as well as part numbers for orderable parts. Chapter 10 - Wiring Diagrams: This section contains the plug/jack locations and the wiring diagrams for the print engine. Index: This section indexes all part numbered components and associated error codes, troubleshooting, operational information, disassembly procedures, and wiring.
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Table of Contents
Table of Contents
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Phaser 6115MFP Front View (with Optional Sheet Feeder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Phaser 6115 MFP Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 System Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 ADF Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Options Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Control Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Main Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Boards and Power Supplies Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Motors and Fans Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Sensors and Switches Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Solenoids and Power Switch Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Consumables and Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2 Theory of Operation
Operational Overview of the Phaser 6115MFP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Laser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Toner Cartridge Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Transfer Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Process Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 System Thermal Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Waste Toner Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Tray 1 Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Exit Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Automatic Document Feeder (ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 500-Sheet Feeder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Photo Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Microswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Sensor Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
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Table of Contents
3 Error Codes and Messages

Overview of Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Index of Error and Warning Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Other Error/Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Error Message Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Measurement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 04H Engine Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 05H Flash ROM Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 08H Main Motor Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 0BH Ventilation Fan Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 0CH Power Supply Cooling Fan Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 10H Polygon Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 12H Laser Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 14H Second Image Transfer Pressure/Retraction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 15H Cleaning Blade Pressure/Retraction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 16H Transfer Belt Rotation Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 17H Rack Rotation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 18H Heating Roller Warmup Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 19H Abnormally Low Heating Roller Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 1AH Abnormally High Heating Roller Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 1BH Faulty Thermistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 21H Faulty Transparency Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 23H Faulty Waste Toner Near Full Detection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 31H Scanner Cooling Fan Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 101H Scanner Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 102H Faulty Scanner Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Machine is Not Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Control Panel Indicators Do Not Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Fusing Heaters Do Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
4 General Troubleshooting
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Main Print Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Multiple-Sheet Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Mis-Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Misfeed at Paper Feed Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Misfeed at 2nd Transfer Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Misfeed at Fusing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Misfeed at Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Undefined Misfeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Auto Document Feeder Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Misfeed at the Document Feeding Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Misfeed at the Document Transport Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Misfeed at the Document Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Lower Feeder Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Misfeed at Tray 2 Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Duplexer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Misfeed at Duplex Option Reverse Drive/Storage Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Misfeed at Duplex Option Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
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Contents
5 Print-Quality Troubleshooting
Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Defects Associated with Specific Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Print Quality Troubleshooting Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Automatic Document Feeder (ADF) Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Scanner System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Blank Copy or Black Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Low Image Density or Rough Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Foggy Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Black Streaks or Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Black Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 White Streaks or Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Uneven Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Image Processing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 White or Colored Lines and Bands in Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 White or Colored Lines and Bands in Scan Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Uneven Density in the Feed Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Uneven Density in The Scan Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Low Image Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Gradation Reproduction Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Foggy Background. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Poor Color Reproduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Void Areas and White Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Colored Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Blurred Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Black or Blank Copy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Incorrect Color Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Fusing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Poor Fusing Performance or Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Brush Effect or Blurred Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Back Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Uneven Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
6 Adjustments and Print Function Settings

Adjust Function Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Using the Adjust Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Service Mode Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Service Mode Entry Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Service Mode Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 1 System Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Send Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Receive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Send Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Receive Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 DTMF Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 CNG Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 CED Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 ECM Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Coding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 TNR Empty Rep (Toner Empty Report) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Protocol Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 GDI Time-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Energy Save Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
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Table of Contents 2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 PRN Main Regist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 PRN Sub Regist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CCD Main Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 CCD Sub Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 CCD Main Regist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 CCD Sub Regist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 ADF Sub Zoom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 ADF Main Regist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 ADF Sub Regist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 DMAX (Manufacturing Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 1st Transfer Voltage (Manufacturing Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 2nd Transfer Voltage (Manufacturing Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 VPP Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 ROHS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Flicker Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 3 Counter Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Total Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Total Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Printer Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 ADF Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 4 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Main F/W Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Engine F/W Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 NIC F/W Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Main Ram Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 BB CPLD Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 NAND Code Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 5 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Paper Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Print Test Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 ADF Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Copy ADF Glass Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Park Scan Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 FAX Reg Copy Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Scan Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 6 Soft Switch Functions (Internal Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 7 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Service Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Error Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Protocol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 8 Fixed Zoom Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 9 Factory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Signal Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Dial Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Volume Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Panel Buzzer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 RAM Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 10 Clear Data Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 SRAM Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Memory Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Maintenance Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Maintenance Mode Entry Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Maintenance Mode Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 xvi Phaser 6115MFP Multifunction Product Service Manual
Table of Contents 1 FAX Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Send Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Receive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Send Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Receive Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 DTMF Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 CNG Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 CED Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 ECM Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Coding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Toner Empty Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Protocol Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 2 SVC Part Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Transfer Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 3 Reset Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Transfer Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Transfer Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 4 Park Scan Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Additional Scanner Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Scanner CD Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Scanner FD Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Scanner Function Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Additional ADF Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 ADF FD Magnify. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 ADF CD Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 ADF FD Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Leading Edge Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
7 Cleaning and Maintenance

Service Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Consumables/Routine Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Paper Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Laser Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 500-Sheet Feeder Paper Pick-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ADF Pick Up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 ADF Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Duplexer Transport Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Maintenance Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Toner Cartridge Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
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Table of Contents
8 Service Parts Disassembly

Overview Of Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Notations in the Disassembly Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Cover Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Top Cover (PL4.1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Rear Cover (PL2.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Left Cover (PL2.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Right Cover (PL2.1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Tray 1 and Cover (PL4.21.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Front Cover (PL2.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Unit Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Auto Document Feeder Unit (PL1.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Imaging Unit (PL4.15.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Laser Unit (PL4.14.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Scanner Unit (PL3.1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Transfer Belt Unit (PL4.15.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33 Fusing Unit (PL4.18.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36 Paper Take-Up Unit (PL4.20.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45 High Voltage Unit (PL4.19.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50 Disassembly/Assembly Procedures (Main Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53 Control Panel (PL3.1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53 Image Processor Board (PL4.19.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55 Engine Control Board (PL4.19.15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57 DC Power Supply 1 (PL4.19.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60 DC Power Supply 2 (PL4.5.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68 Waste Toner Near Full Detection Board/LED (PL4.6.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70 LAN (and FAX Modem) Board (PL4.19.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72 NCU (Network Card) Board (PL4.19.14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74 AC Inlet Harness (PL4.19.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77 Paper Feed Roller (PL4.20.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-84 Transfer Roller (PL4.16.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86 Tray 1 Separation Pad (PL4.20.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89 Print Engine Motors and Fans Disassembly Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90 Main Motor (PL4.12.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93 Power Supply Cooling Fan Motor (PL4.8.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94 Ventilation Fan Motor (PL4.8.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96 Fusing Motor (PL4.11.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98 Developing Motor (PL4.13.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98 Rack Motor (PL4.13.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101 Print Engine Solenoids and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102 Tray 1 Paper Pick Solenoid (PL4.20.20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-102 Registration Roller Solenoid (PL4.12.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104 Cleaning Blade Solenoid (PL4.11.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105 Image Transfer Solenoid (4.10.14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106 Exit Tray Full Sensor (PL4.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-107 Rack Positioning Sensor (PL4.3.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112 Fusing Paper Loop Sensor (PL4.17.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114 Registration Sensor (PL4.17.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-116 Transparency Sensor (PL4.17.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-117 Temperature/Humidity Sensor (PL4.20.37). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118 Tray 1 No Paper Sensor (PL4.20.39). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-120 Exit Sensor (PL4.18.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-122
xviii
Table of Contents Disassembly/Assembly Procedures (500-Sheet Feeder Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-125 500-Sheet Feeder Unit (PL5.1.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-125 Tray Removal (PL5.3.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-126 Rear Cover (PL5.1.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-126 Pick Roller and Holder (PL5.2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-127 Paper Feed Drive Board (PL5.2.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-130 Paper Pick-Up Solenoid (PL5.2.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-131 Paper Size Switch (PL5.2.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-133 Disassembly/Assembly Procedures (Duplexer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134 Duplex Unit Replacement (PL6.1.27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134 Duplex Right Cover (6.1.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-138 Duplex Drive Board Removal (PL6.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-139 Transport Motor (PL6.1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-145 Reverse Motor (PL6.1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146 Registration Solenoid (PL6.3.15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-147 Tray Set Actuator (PL6.1.17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148
9 Parts Lists
Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Parts List Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Automatic Document Feeder Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Parts List 1.1 ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 PL 2.1 External Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Scanner Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 PL 3.1 Scanner Platen and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Print Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 PL 4.1 Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 PL 4.3 Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 PL 4.4 Side Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 PL 4.5 Left Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 PL 4.6 Left Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 PL 4.7 Left Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21 PL 4.8 Right Frame (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23 PL 4.9 Right Frame (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 PL 4.10 Drive (1/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27 PL 4.11 Drive (2/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29 PL 4.12 Drive (3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31 PL 4.13 Drive (4/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33 PL 4.14 Laser Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35 PL 4.15 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37 PL 4.16 Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39 PL 4.17 Vertical Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41 PL 4.18 Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43 PL 4.19 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45 PL 4.20 Media Feeder Assembly (1/2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47 PL 4.20 Media Input (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48 PL 4.21 Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50 PL 4.22 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52 PL 4.24 Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54 500-Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56 PL 5.1 Feeder Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56 PL 5.2 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58 PL 5.3 Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60 PL 5.4 Feeder Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62 Phaser 6115MFP Multifunction Product Service Manual xix
Table of Contents Duplex Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64 PL 6.1 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64 Pl 6.2 Duplex Cover and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66 PL 6.3 Duplex Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68 PL 6.4 Duplex Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-70 PL 7.1 Xerox Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-72
10 Wiring Diagrams
Plug/Jack Locator Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Print Engine Board Plug/Jack Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Map 1 - Engine Control Board Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Map 2 - Image Processor Board Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Map 3 - DC Power Supply 1 Board Plug/Jack Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Map 4 - DC Power Supply 2 Board Plug/Jack Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Map 5 - High Voltage Power Supply Board Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Map 6 - LAN (and FAX) Board Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Map 7 - NCU Board Plug/Jack Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Print Engine Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Print Engine Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Engine Control Board to Solenoid and Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Engine Control Board to Power Supply and Laser Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Engine Control Board to Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Engine Control Board to Main Motor and Positioning Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Engine Control Board to Miscellaneous Motor and Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Engine Control Board to DC Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Engine Control Board to Duplex Unit and Feeder Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Engine Control Board to Image Processor Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Image Processor Board to Laser and Scanner Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Image Processor Board to Scanner and Control Panel Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Document Feeder Control Board to Optional Feeder Tray Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Image Processor Board to LAN and NCU Board Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Service Wiring Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Front View: Covers Removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 Rear View: Covers Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Rear View: Image Processor Board Cover Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 Right Rear View: Covers Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 Left Side View: Covers Removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Left Side View: Scanner Removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Left Side View: Left Frame Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 Right Side View: Covers Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Right Side View: Scanner Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Right Side View: Right Frame Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Index
xx
General Information
In this chapter...

Printer Introduction and Overview System Options System Specifications
Chapter
General Information
Printer Introduction and Overview

The Xerox Phaser 6115MFP Multifunction Product combines a color laser print engine, a Copier, Scanner, and Fax. The system is a high performance, Letter or A4, 20 page per minute (ppm) monochrome, 5 ppm Color desktop multifunction product supporting resolutions up to 2400 x 600 dots-per-inch (dpi). The system features USB and 10/100baseT Ethernet ports. The Phaser 6115MFP provides a 200-sheet Tray 1 (MPT) from which specialty media, card stock, and envelopes are fed. Tray 1 (MPT) also supports manual feeding. An additional tray, Tray 2, provides 500 sheets of capacity. The Exit Tray holds 100 sheets facedown. Phaser 6115MFP options add paper capacity and functionality. For configurations not originally equipped, a 500-Sheet Feeder (Tray 2) adds input capacity, and the Duplex Unit enables auto-duplexed (2-sided) printing. The Fax portion of the system incorporates a resolution of up to 203 dpi by 392 dpi. Fax features include a modem speed of up to 33.6 Kbps using V.34 standard transmission, print capability of up to a maximum of 250 printed pages. The Fax includes a phone book, real time clock, and auto redial.
Phaser 6115MFP Front View (with Optional Sheet Feeder)
Automatic Document Feeder Control Panel
Scanner
Tray 1
Optional Sheet Feeder
s6115-419
1-2
General Information
Phaser 6115 MFP Rear View
Power Switch Duplex

s6115-420
1-3
General Information
System Configurations
The Phaser 6115MFP Multifunction Product is available in two configurations. The main differences is the addition of the Duplex Unit to enable 2-sided printing. The following table lists both configurations.
Configuration
Features
6115N Max Print Speed (ppm) color/monochrome Memory* USB Port 10/100 Ethernet Port Duplex Unit PostScript and PCL Fonts Print Resolutions (dpi): Draft Standard Enhanced Copy Speed (dpi or ppm): 600x300 600x600 Scan Resolutions (dpi or ppm): 600x300 600x600 5/20 128 MB Yes Yes No Yes 600x600 1200x600 2400x600 Color/Mono 5/12 ppm 2.5/6 ppm Color/Mono 70/30 mm/ sec 35/14 mm/ sec Optional
6115D 5/20 128 MB Yes Yes Yes Yes 600x600 1200x600 2400x600 Color/Mono 5/12 ppm 2.5/6 ppm Color/Mono 70/30 mm/ sec 35/14 mm/ sec Optional
500-Sheet Feeder**
* All configurations have two memory slots supporting 256 MB and 512 MB cards, to a maximum of 1 GB. **One 500-sheet feeder (Tray 2)
1-4
General Information
System Specifications
Electrical Specifications
Power Requirements Voltage: AC 110 to 127 V AC 220 to 240 V 1100 W or less 528 (W) x 475 (D) x 531 (H) mm 20 3/4 (W) x 18 3/4 (D) x 21 (H) inch 32 kg (70 1/2 lb) or less 39 kg (86 lb) or less (w/packing material) Operating Noise During standby: 39 dB (A) or less During printing: 53 dB (A) or less
Frequency: 50/60 Hz 3 Hz Max Power Consumption Dimensions Weight
Operating Environment
Operating Noise Operating Range Temperature Operating Range Humidity Operating Range Altitude Transportation Range Temperature Transportation Range Humidity
During standby: 35 dB (A) or less During printing: 54 dB (A) or less 10 to 32 C / 50 to 90 F (with a fluctuation of 10 C / 18 F or less per hour) 10%-80% RH @ 15 to 32 C/59 to 89 F to with water vapor no higher than 25.5 C/77.9 F 80% condition. 0-2,500 meters (8,000 ft.) -20 C to +55 C/-4 to 131 F
30%-85% RH, non-condensing
1-5
General Information
Product Specifications
Media Input Capacity
Type Desktop
Printing System
Semiconductor laser and electrostatic image transfer to plain paper OPC (organic photo conductor) Blade cleaning system 600 x 600 dpi, 600 x 300 dpi 2400 x 600 dpi, 1200 x 600 dpi, 600 x 600 dpi 600 x 600 dpi Stationary Rear left edge Tray1: 200 sheets Tray2: 500 sheets (Option) Single-element developing system
Exposure System 2 laser diodes and polygon mirror PC Drum Type Photoconductor Cleaning Scan Resolution Print Resolution Copy Resolution Platen Registration Paper Feeding System Developing System Image Transfer System
Original Scanning Scanning in main scanning direction with a CCD
Charging System DC comb electrode Scorotron system Intermediate transfer belt system
Paper Separating Curvature separation + Charge-neutralizing system System Fusing System Roller fusing Paper Exit System Face down (Exit Tray capacity: 100 sheets)
Built-in Controllers
CPU Standard memory
Embedded RISC processor 48MHz 128 MB on IPB SDRAM 16 MB on LANB
Optional Memory Interfaces
Not supported Host (PC) interface Camera direct interface Network interface PSTN line (Fax RX/TX) USB device (High-speed mode 480 Mbps) USB Host (Full-speed mode 12 Mbps) Ethernet 10/100 BaseT Telephone line jack/External device jack
OS compatibility
Windows 98SE/Me/2000/XP/Server 2003
1-6
General Information
Media Specifications
Paper Type Letter A4 Legal Folio Executive B5 (JIS) B5 (ISO) A5 Statement Foolscap UK Quatro Custom Paper Sizes Media Types
Size 8.5" x 11" 210 x 297 mm 8.5" x 14" 210 x 330 mm 7.25" x 10.5" 182 x 257 mm 176 x 250 mm 148 x 210 mm 5.5" x 8.5" 8" x 13" 8" x 10"
Paper Type Government Letter Government Legal SP Folio DL C5 C6 Monarch Com 10 Japanese PostCard Custom size
Size 8.0" x 10.5" 8.0" x 13" 8.5" x 12.69" 110 x 220 mm 162 x 229 mm 114 x 162 mm 3.88" x 7.5" 4.13" x 9.5" 100 x 148 mm Width 92-216 mm Length 148-356 mm*
Paper width: 92 to 216 mm (3.6" to 8.5") Paper length: 148 to 356 mm (5.9" to 14") Plain Paper (60 to 90 g/m2 / 16 to 24 lb.) Transparencies Thick stock (90 to 163 g/m2/ 25 to 40 lb.) Postcards Envelopes Letterhead Label stock (60-163 g/m2/16-43 lb. bond) Glossy stock(163 g/m2 index max/110 lb. book max)
1-7
General Information
Functional Specifications
Function Table Function Warm-up time Description Average: 45 seconds (100 V area) Average: 49 seconds (200 - 240 V area) (at ambient temperature of 23 C/73.4 F and rated source voltage) Plain paper System Speed Thick stock 126.78 mm/second 63.39 mm/second
Transparency 42.26 mm/second film

First-page-out time (Plain paper) First copy time (Plain paper) Full color Monochrome Full color Monochrome 22 seconds or less: LetterS, A4S 13 seconds or less: LetterS, A4S 52 seconds (600 x 300 dpi scan) 23 seconds (600 x 300 dpi scan) 5 pages/minute 20 pages/minute
1 2 1 2
Copy / Print speed Full color (Plain paper) Monochrome
Custom paper sizes
Paper width: 92 to 216 mm (3 / to 8 / inch) Paper length: 148 to 356 mm (5 / to 14 inch)

3 4
Media types
Plain Paper (60 to 90 g/m / 16 to 24 lb) Recycled paper (60 to 90 g/m / 16 to 24 lb) Transparencies Thick stock (91 to 163 g/m / 25 to 40 lb) Postcards Envelopes Letterhead Label stock Glossy stock
2 2 2
Plain paper and letterhead, 200 sheets Tray capacities Transparencies, thick stock, postcards, labels stock, and glossy stock, 50 sheets Envelopes, 10 sheets Machine Durability 200,000 prints or 5 years, whichever comes first
1-8
General Information
FAX Specifications
Standard (203 dpi x 98 dpi) Resolution Halftone Level Fine (203 dpi x 196 dpi) Super fine (203 dpi x 392dpi) Standard/Fine/Super fine Half tone standard/Half tone fine/Half tone super fine Automatic reduction Compatibility Modem speed Transmit speed Compression Memory for receiving Receive Transmit Supported Not supported
ECM/Super G3 V.34 (up to 33.6 Kbps) 3 second/page (at V.34) MH/MR/MMR/JBIG 4 MB for fax-RX (approx. 250 pages), (included in 32 MB NAND flash)
Remote setting Available via USB/Network Paper size A4, Legal, Letter One touch dial Functions Speed dial Group dial Broadcast 9 one-touch key on operation panel 100 fax numbers 9 groups (50 destination stations for one group) Available maximum 125 stations. (One-touch dial 9 stations, speed dial 100 stations, full dial 16 stations) Timer transmission, phone book, real time clock, auto redial, reduce/split, smoothing
Other supported functions
1-9
General Information
Physical Dimensions and Clearances

To ensure easy operation, consumable replacement and maintenance, adhere to the recommended space requirements detailed below.
76.4 cm (30.1 in.) 10 cm (3.9 in.)
10 cm (3.9 in.)
10 cm (3.9 in.) 72.8 cm (28.7 in.) 10 cm (3.9 in.) 72.6 cm (28.6 in.)
90.2 cm (35.5 in.) 10 cm (3.9 in.) 10 cm (3.9 in.) 32 cm (12.6 in.) 80 cm (31.5 in.)
s6115-459
10 cm (3.9 in.)
72.8 cm (28.7 in.)
1-10
General Information
ADF Specifications
ADF Unit
Power requirements
DC 24 V (supplied from the main unit) DC 5 V (supplied from the main unit)
Max. power consumption Dimensions
30 W 518 (W) x 350.1 (D) x 90.3 (H) mm 20 1/2 (W) x 13 3/4 (D) x 3 1/2 (H) inch
Weight
3.2 kg (7 lb)
Options Specifications
Duplex Unit
Power Requirements
DC 24 V 10% (supplied from the main unit) DC 5 V 5% (supplied from the main unit)
Max. Power Consumption Dimensions Weight
42 W 370 (W) 153 (D) 318 (H) mm 14 / (W) 6 (D) 12 / (H) inch
1 2 3 4
Approx. 2.4 kg (5 / lb)

1 4
500-Sheet Feeder
Power Requirements
DC 24 V 10% (supplied from the main unit) DC 5 V 5%
Max. Power Consumption Dimensions Weight
12 W 495 (W) 581 (D) 138 (H) mm 19 / (W) 22 / (H) 5 / (D) inch
1 2 3 4 1 2
5.0 kg
1-11
General Information
Control Panel Description

The Control Panel contains one tricolor LED, a display window, and six function buttons. These buttons navigate the menu system shown in the display window, perform various functions, and select modes of operation for the printer.
Control Panel Buttons
Auto Receive
Resolution
Error
Display
Phaser 6115MFP
ABC
DEF
Fax
Scan
Copy
MIX
Redial / Pause Speed Dial On Hook Function Quality
x1.00 A4
Y M C
01 EMPTY
K
1
GHI
2
JKL
3
MNO
4
PQRS
5
TUV
6
WXYZ Start Stop / Reset
01
02
03
2 in 1 Reduce / Enlarge Collate Light / Dark Menu Select

C
8 0
9 #
04
05
06
07
08
09
5 6
s6115-422
1 2 3 4
LED (Power/Status) Control Panel Display Cancel Button Back Button
5 6 7 8
Up Arrow Button - scrolls up the menu Down Arrow Button - scrolls down the menu OK (select) Button TC Change Button - rotates the toner rack to select the individual toner cartridges
LED Indicators:
LED State Green Flashing Yellow Flashing Green Flashing Red Printer State Ready to Print Warning (but can still print) In Power Saver mode or busy (receiving or processing data) Error; cannot print
1-12
General Information
Control Panel Display

After Power-up, the following screen appears on the Control Panel:
s6115-351
No.
Name
Description
[1] [2] [3] [4] [5] [6]
Document type Zoom ratio Number of copies Status Paper tray/paper size Copy density
Displays the type of the document currently set. Displays the zoom ratio currently set. Displays the number of copies set to be made. Displays messages such as when paper is empty. Displays messages such as when toner is low. Indicates the selected paper tray and paper size. Displays the copy density currently set.
Pressing the Display key will display the [TONER REMAINING] screen. Pressing the Cancel/C key will cause the Main screen to reappear.
TONER REMAINING
s6115-352
1-13
General Information
Main Engine Components

Boards and Power Supplies Locator
The following illustration provides a basic locator for the main system boards and power supplies.
Engine Control Board Thermistor DC Power Supply 1 Image Processor Board Control Panel
Fuser Connectors High Voltage Power Supply
DC Power Supply 2
s6115-513
1-14
General Information
Motors and Fans Locator

The following illustration provides a basic locator for the main engine motors and fans.
Scanner Cooling Fan Fusing Motor Scanner Motor Main Motor
Ventilation Fan Developing Motor Rack Motor
Power Supply Cooling Fan
s6115-512
1-15
General Information
Sensors and Switches Locator

The following illustration provides a basic locator for the main system sensors and switches.
Original Cover Set Switch Scanner Open/Close Output Tray Full Sensor Sensor Cleaning Blade Sensor Fuser Exit Sensor
Fusing Paper Loop Sensor Waste Toner Near Full Detect Board Registration Sensor
Interlock Switch Rack Positioning Sensor Temperature/ Humidity Sensor Tray 1 Paper Empty Sensor 2nd Image Transfer Sensor
s6115-510
Transparency Sensor IDC Sensor
1-16
General Information
Solenoids and Power Switch Locator

The following illustration provides a basic locator for the main system solenoids.
Image Transfer Solenoid Cleaning Blade Solenoid
Power Switch Tray 1 Paper Take-Up Solenoid Registration Roller Solenoid

s6115-511
1-17
General Information
System Options
Phaser 6115MFP options include a 500-Sheet Feeder and a Duplex Unit.
500-Sheet Feeder (Tray 2)

The 500-Sheet Feeder (Tray 2) increases the input capacity of the system. The feeder attaches below Tray 1 with four screws. Only one 500-Sheet Feeder is supported. Electrical connection to the printer is made by a single interface connector.
s6115-423
1-18
General Information
Duplex Unit
The Duplex Unit adds two-sided printing. The Duplex Unit attaches in back of the system using two twist locks. Electrical connection to the printer is made by an interface cable.
s6115-391
1-19
General Information
Consumables and Maintenance Parts

Consumables consist of the four toner cartridges (standard and high capacity). Maintenance items consist of the imaging unit, the Fusing Unit, the Transfer Roller, the Waste Box, and a maintenance kit of spare hardware.
Consumable Part Numbers

The following table lists the cartridge types and their part numbers. Refer to Chapter 9 for a complete listing of all print engine and option parts. Consumable Part Numbers Description CYAN STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115mfp MAGENTA STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP YELLOW STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP Part number 113R00689 113R00691 113R00690
CYAN HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/ 113R00693 6115MFP MAGENTA HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP YELLOW HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP BLACK HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP 113R00695 113R00694 113R00692
Maintenance Part Numbers

The following table lists the cartridge types and their part numbers. Refer to Chapter 9 for a complete listing of all print engine and option parts. Maintenance Part Numbers Description FUSING UNIT, 110V, PHASER 6120/6115mfp FUSING UNIT, 220V, PHASER 6120/6115MFP IMAGING UNIT, PHASER 6120/6115MFP TRANSFER ROLLER, PHASER 6120/6115MFP HARDWARE MAINTENANCE KIT, PHASER 6120/6115MFP Part number 126K23192 126K23202 108R00691 059E05450 604K35500
1-20
General Information
Consumable Life Counter Behavior

Internal counters track Consumables and Maintenance Items life usage. The Image Processor Board monitors these counters in order to display the near end-of-life and end-of-use messages. Life ratings are based on A-size sheets at 5% coverage. Imaging Unit life ratings are based on average 4 page job length.
Toner Cartridges Print Life
Black-Capacity Color Capacity Standard/Hi

Maintenance Items
4500 1500, 4500
Imaging Unit Fusing Unit Transfer Roller and Waste Box Feed Roller Kit Low/Out Behavior for Consumables Front Panel Message Low Toner (pixel) Toner (page) Imaging unit (rotation) Transfer belt Fusing Unit Low / Out Low / Out Low / Out No No 96% No No No No 96%/ 88%*
35,000 100,000 25,000 up to 100,000
Hard Stop
Reset to 0 By new toner
6000 pages
By new toner
when waste toner box full By new imaging unit No No No No By front panel (user) By control panel (Service) By front panel (Service) none
Transfer roller No Pick roller No
* For 4.5K/1.5K toner. Toner life calculations are based on 5% coverage. ** 45,000 images for continuous printing, shorter job length will shorten the imaging unit life.
1-21
General Information
1-22
Theory of Operation
In this chapter...

Operational Overview of the Phaser 6115MFP Paper Path of the Printer Major Assemblies and Functions Sensors
Chapter
Theory of Operation
Operational Overview of the Phaser 6115MFP

The Phaser 6115MFP Multifunction Product is a full-color laser printer that utilizes electrophotographic recording principals to place a full color image onto the print media. The system, as it appears in the following illustration, contains a drum and developing unit for each color [yellow, magenta, cyan and black (YMCK)], and places the toner image of each color onto print media producing full-color prints.
Print Cycle
The block diagram of the Phaser 6115MFP print cycle provides the sequence of events for the xerographic process and the paper flow into and out of the printer.
Paper Separation 2nd Image Transfer
Transfer Belt Cleaning 1st Image Transfer
Developing
Photo Conductor
PC Drum Cleaning Photo Conductor Charging
Printer Image Processing
Laser Exposure
s6115-396
The Phaser 6115MFP print process consists of these steps: 1. Exposure The surface of the Drum is irradiated with the laser light and an electrostatic latent image is formed. 2. Developing The toner, negatively charged in the Hopper, is attracted onto the electrostatic latent image formed on the surface of the Drum.
2-2
Theory of Operation A DC negative bias voltage is applied to the Developing Roller, thereby preventing toner from sticking to the background image portion.
Developing Roller Photo Conductor
s6115-081
3. Image Transfer to Belt A DC positive voltage is applied to the backside of the Transfer Belt to attract the visible, developed image from the surface of the Drum. 4. Image Transfer to Media A DC positive voltage is applied to the backside of the paper to attract the visible, developed image on the surface of the Transfer Belt to the media. 5. Paper Separation A Charge Neutralizing Cloth is provided on the guide plate to neutralize the charge.
Charge Neutralizing Cloth Charge Neutralizing Cloth
Transfer Belt
2nd Transfer Roller
s6115-096
6. Transfer Roller Cleaning The residual toner left on the surface of the Transfer Roller) is removed by an alternating DC charge that transfers the waste toner back to the Transfer Belt for collection by the Transfer Belt cleaning blade.
2nd Transfer Roller
Transfer Belt
s6115-095
2-3
Theory of Operation 7. Transfer Belt Cleaning A charge is applied to the Transfer Belt. By potential difference, residual toner on the surface of the Transfer Belt is collected for cleaning. The toner scraped off the surface of the photo conductor is collected in the Imaging Unit. 8. Fusing Toner is permanently fused to the paper by the combination of heat and pressure applied by the Fuser.
System Control
The following diagram shows the major operating components and their basic connection to each other.
CCD Unit Scanner Motor Various Scanner Sensors Scanner Control Panel Auto Document Feeder
DC Power Supply 2 Scanner Cooling Fan Motor Scanner Unit Open/Close Sensor
Image Processing Board
Image Processing
DC Power Supply 1
Laser unit
Lower Feeder Unit Engine Control Board Duplex Unit CPU Paper Pick-up/ Transport Control System Line Image Bus Line Image Process Fusing Power Supply/ High Voltage
s6115-068
2-4
Theory of Operation
Paper Path of the Printer

Main Print Engine Paper Path
The print media is supplied from Tray 1 or the optional Tray 2, and is transported into the printer along the paper path as shown in the diagram.
Output Tray
Tray 1 (MPT)
Tray 2 (Optional 500-Sheet Feeder)

s6115-045
Automatic Document Feeder (ADF) Print Path

ADF Tray
s6115-047
2-5
Theory of Operation
Major Assemblies and Functions

The location of the systems primary functional components is shown.
11 10
9 2 8 7 3
6 4
s6115-044
1 2 3 4 5 6
Fusing Unit Duplex Unit Transfer Roller Tray 2 Feeder Tray 1 Feeder Laser
7 8 9 10 11
Toner Cartridges Imaging Unit Transfer Belt Scanner Auto Document Feeder (ADF)
2-6
Theory of Operation
Fusing Unit
Functional components of the Fusing Unit appear below.
Thermistor Thermostat Exit Sensor
Cleaning Roller
Heater Lamp Heating Roller Pressure Roller

s6115-057
Fuser Speed Regulation

The Fuser is driven by the Fusing Motor and employs both speed and temperature regulation to maintain the proper fusing properties. The fusing speed is changed in three steps depending on the media type.
Fusing Speeds
Media Type Fusing Speed (mm/sec) Fusing Speed (PPM)
Plain paper, letterhead Thick stock, postcards, labels, glossy stock Transparency film, envelopes
126.78 63.39 42.26
13 6 4
To prevent double transferred image or brush effect, the difference between the fusing speed and paper transport speed during image transfer is corrected. The fusing speed is changed in two steps relative to the system speed, either at high speed (which is +2% of the system speed) or low speed (which is -2.5% of the system speed).
2-7
Theory of Operation Fusing Motor speed is regulated using the Fusing Loop Sensor output following this process: 1. The initial fusing speed is set to the low speed. This causes the Transfer Roller of the paper transport system to feed paper at a faster rate than the speed of the fuser. This action causes a loop, or a bending effect of the paper (see illustration below). 2. When the length of the loop formed in the paper becomes greater, the Fusing Loop Sensor is activated (blocked). 3. While the Fusing Paper Loop Sensor remains activated, the fusing speed increases to the high level. 4. When the Fusing Paper Loop Sensor is deactivated, the fusing speed immediately switches to the low level. 5. The sequence of these operations is repeated so that the fusing speed is changed automatically according to the loop length. This effectively compensates for the difference between the fusing speed and paper transport speed during image transfer.
s6115-073
s6115-072
2-8
Theory of Operation
Fuser Temperature Regulation

A thermistor detects the surface temperature of the Fusing Units heat roller. The heater lamp is turned On and Off as necessary to achieve the set temperature. The following chart illustrates fusing temperature regulation during monochrome printing on plain paper.
Power Switch ON Copy/Print Start Fusing Ready Temperature [1] [2] [*a] [*b] [3] [4]
(C)
185 180 174 169 167
100
60
Approx. 45 sec.
s6115-069
Warm-up (1), heat the roller to 178 C set temperature. Warm-up requires approximately 45 seconds (120 V) or 49 seconds (240 V). Standby state (2), maintain the roller temperature at 180 C. If the roller temperature is 60 C or less when the warm-up cycle starts, the set temperature changes to 185 C. (5 min.) After 5 min., the set temperature returns to 180 C. Print cycle (3), the set temperature is 189 C. If the Temperature/Humidity Sensor indicates a temperature of less than 60 C, the set temperature is increased to 184 C. Standby state (4), maintain the roller temperature at 180 C.
2-9
Theory of Operation The following chart illustrates fusing temperature regulation during color printing on plain paper.
Power Switch ON Copy/Print Start Fusing Ready Temperature [1] [*a] [2] [*b] [3] [4]
(C)
189 184 185 180 167
100
60
Approx. 45 sec.
s6115-070
Warm-up (1), heat the roller to 178 C set temperature. Warm-up requires approximately 45 seconds (120 V) or 49 seconds (240 V). Standby state (2), maintain the roller temperature at 180 C. If the roller temperature is 60 C or less when the warm-up cycle starts, the set temperature changes to 185 C. (5 min.) After 5 min., the set temperature returns to 180 C. Print cycle (3), the set temperature is 169 C. If the Temperature/Humidity Sensor indicates a temperature of less than 20 C, the set temperature is increased to 174 C. Standby state (4), maintain the roller temperature at 180 C.
Warm-up regulation is performed when the Power Switch is turned On, a malfunction or paper misfeed is reset, the Energy Saver mode is canceled, or the door is opened and closed. After 20 minutes of inactivity, the standby state set temperature changes to 170 C if interior temperature is less than 20 C or 165 C if the interior temperature is 20 C or higher.
2-10
Theory of Operation
Fusing Temperatures by Media

During printing, the roller set temperature varies according to the media as listed in the following tables: Fusing Temperatures for Monochrome
Media Type Typical (C) Temperature/humidity Sensor more than 20 C
Plain paper, letterhead
169
174 174
Plain paper, letterhead 257 mm 169 or less Thick stock, postcards, labels Transparencies Envelopes Glossy stock 169 169 194* 169
* The temperature is controlled at 159 C if the systems interior temperature is 20 C or more and relative humidity is 40% or higher.
Note There is a Control Panel command which obtains environmental temperature and humidity levels. However, this command is for internal use only and not available from the service menus. If the print cycle is started while the Temperature/Humidity Sensor indicates an internal temperature of 20 C or more, control is returned back to one having a control temperature of more than 60 C after five printed pages have been produced. Fusing Temperatures for Color (1-sided)
Roller temp at warm-up start Temperature/ humidity Sensor less than 20 C Temperature/ humidity Sensor more than 20 C
Media Type
Typical (C)
Plain paper, letterhead Plain paper, letterhead 257 mm or less Thick stock, postcards, labels
60 C or less More than 60 C 60 C or less More than 60 C _
189 184 189 184 184
194 194 194 194
189 184 189 184
Transparencies _ Envelopes Glossy stock _ _
179 194* 190 190 185
2-11
Theory of Operation
* The temperature is controlled at 159 C if the systems interior temperature is 20 C or more and relative humidity is 40% or higher.
Note Fuser thermal regulation stops and the Fuser heat lamp turned Off when the system enters Energy Saver mode, a door is opened, or an error occurs.
Fuser Overheat Protection

The machine provides protection at three different stages to prevent abnormally high temperature of the Fusing Unit.
Soft Protection. If the Thermistor detects a temperature exceeding a predetermined value, the error code representing abnormally high temperature is displayed. At this time, the heater lamp is turned Off, and new print cycles are prohibited. Hard Protection. If the CPU overruns and the output level of the CPU of the Mechanical Control Board becomes a HIGH or LOW level, and not a pulse output, and a predetermined temperature or higher is detected, a circuit within the Mechanical Control Board turns OFF the relay to shut down the power supply to the Heater Lamp. Thermostat Protection. If neither the soft protection nor hard protection detect an abnormally high temperature due to a defective Thermistor or other reason, the Thermostat operates at the specified temperature. This shuts down the power supply to the Heater Lamp, thus forcibly turning it OFF.
5V
Engine Control Board CPU
Heater Lamp Thermistor Thermostat Heating Roller GND Hard Protection Circuit
A/D
Fusing Pressure Roller Laser Safety Switch
Watchdog Circuit Triac Circuit
Fuser Wdt Reset
Power Switch
Heater Remote ON/OFF

s6115-101
2-12
Theory of Operation
Print Speed Thermal Control

Print speed thermal control prevents the temperature on edges of the heat roller from increasing during a multi-print cycle using smaller size media. The process timing between sheets increases according to the number of printed pages per job and the paper length. The following tables provide page per minute (ppm) output by media size during print speed thermal control conditions. Output speeds are also affected by environmental conditions. Monochrome Prints in Typical Environmental Conditions
In millimeters(mm)
Media Length Less than 210 14 ppm 18 ppm 19 ppm 20 ppm 210 ~ 215 14 ppm 18 ppm 18 ppm 20 ppm 216 ~ 256 14 ppm 14 ppm 14 ppm 20 ppm 257 ~ 296 14 ppm 14 ppm 14 ppm 14 ppm
Width 139 mm or less 140 - 148 mm 149 - 182 mm 183 ~ 210 mm
The low temperature environment refers to the condition, in which the Temperature/Humidity Sensor detects a temperature of less than 20 C. Note There is a Control Panel command which obtains environmental temperature and humidity levels. However, this command is for internal use only and not available from the service menus. Monochrome Prints in Low Temperature Environmental Conditions
In millimeters(mm)
Media Length 210 12 ppm 15 ppm 16 ppm 17 ppm 211 ~ 216 12 ppm 15 ppm 15 ppm 17 ppm 217 ~ 257 12 ppm 12 ppm 12 ppm 17 ppm 258~ 297 12 ppm 12 ppm 12 ppm 12 ppm
For Color printing, these output speeds apply: Color Prints in Typical Environmental Conditions
In millimeters(mm)
Media Length 210 3 ppm 5 ppm 5 ppm 5 ppm 211 ~ 216 3 ppm 5 ppm 5 ppm 5 ppm 217 ~ 257 3 ppm 3 ppm 3 ppm 5 ppm 258~ 297 3 ppm 3 ppm 3 ppm 3 ppm
2-13
Theory of Operation
Scanner
Scanner components include:

Scanner Latch Scanner Motor and Drive Belt Scanner Fan Platen Glass Scanhead
Functional components of the Scanner are illustrated below.
s6115-067
The Scanner does not include sensors for determining the size of the original document. Original media size settings are made on the Control Panel. An error occurs following the print cycle if the correct media size is not selected on the Control Panel or loaded in the tray.
2-14
Theory of Operation
Scanner Latch
The Scanner Latch works with the ADF Lever to prevent the simultaneous opening of both assemblies. When the Scanner is opened, the ADF is locked closed. Likewise, when the ADF is opened, the Scanner is locked closed. Pulling the Scanner Latch Lever disengages the Scanner Lock Pawl, allowing the Scanner to be opened.
s6115-059
If the ADF is open, the ADF Lever locks the Scanner Latch mechanism to prevent the Scanner from opening.
s6115-058
Laser Assembly
The Laser Assembly in the Phaser 6115MFP printer has two laser diodes. The laser diode control circuitry adjusts the light intensity for each beam automatically. Image data is transmitted to the laser diodes in the Laser Assembly as digital signals. The laser diodes convert the image data from digital signals to optical signals. The Laser Assembly monitors and adjusts the intensity of the laser beams to attain a stable electrostatic image. The Laser Assembly is replaced as a complete assembly. Functional components within the Laser appear below.
2-15
Theory of Operation
Semiconductor Laser Assembly G2 Lens SOS Board Mirror
G1 Lens Prism
Polygon Mirror Assembly
s6115-048
Imaging Unit Exposure

The surface of the Imaging Unit is irradiated with a laser light and an electrostatic latent image is formed. The polygon mirror has four faces. The two-beam laser array consists of two laser diodes arranged vertically. Two lines are scanned through a single face of the polygon mirror.
Photo Conductor Surface Beam A Beam B Beam A Beam B

Photo Conductor
Laser Diode
G2 Lens G1 Lens Return Mirror
Polygon Mirror
s6115-076
2-16
Direction of Rotation of Photo Conductor
Direction of Rotation of Photo Conductor
Two lines are scanned in a single scan motion.
Theory of Operation
Laser Write Process

1. The laser light strikes the polygon mirror. 2. The four-sided polygon mirror rotates at high speeds driven by the polygon motor. 3. The Start-of-Scan (SOS) Sensor monitors laser light emission and initiates timing for each line of the scanning process.
Photo Conductor Semiconductor Laser
SOS Board
Polygon Motor
s6115-077
Laser Write Timing

When a Ready signal is detected after the print cycle begins, a Laser On signal is output from the Engine Control Board. The Laser On signal triggers each laser diode illuminating the SOS Board and generating an SOS signal. The SOS signal is used to synchronize the timing at which the laser write each scan line. The print start position in the CD direction is determined by the CD Print Start signal (/HSYNC) that is output from the Image Processor Board and the width of the paper. The print start position in the FD direction is determined by the Image Write Start signal (TOD) that is output from the Image Processor Board and the length of the paper. The laser emission area is determined by the paper size.
2-17
Theory of Operation The area of 4 mm on both the leading and trailing edges of the paper is, however, the void image area.
/HSYNC /VIDEO /VIDEO /TOD
s6115-041
2-18
Theory of Operation
Imaging Unit
The Imaging Unit contains the photo-conductive drum, a cleaning blade, and a waste toner reservoir. The Drum is driven by the Main Motor through a series of gears. When the Main Motor is energized, it turns the drive gear, which in turn rotates the drum.
Main Motor
Photo Conductor
s6115-071
The cleaning blade is pressed against the drum to remove excess toner. Waste toner is stored in the Imaging Unit.
2-19
Theory of Operation Waste toner levels are monitored by the Waste Toner Sensor.
Cleaning Blade
s6115-078
An electrical charge is applied to the drum by an electrode mounted near the drum. This charge attracts toner from the Toner Cartridge developer roller. The image stabilization control process controls the grid voltage (Vg) applied to the electrodes grid mesh.
Grid Mesh
s6115-049
2-20
Theory of Operation
Imaging Unit Life

A counter tracks the number of prints since the last detection of a new Imaging Unit. As this count nears its maximum value, the system generates a warning message. When the count reaches the maximum value, a replacement error is generated. The counter is reset following the detection of a new Imaging Unit. The system checks for a new Imaging Unit when the Power Switch is turned On or the front door is closed. If a new Imaging Unit is detected, the image stabilization sequence is carried out. The life counter is reset when a new DC is detected. When a predetermined number of printed pages are produced after the life value has been reached, the machine displays a DC replacement message.
Toner Cartridge
The system employs four Toner Cartridges (CMYK) installed in a revolving Toner Cartridge Rack that positions each cartridges developer roller over the Drum. A cross section of the Toner Cartridge showing functional components appears below.
Hopper Supply Roller Developing Roller
2nd Regulator Blade
Agitating Blade
1st Regulator Blade
s6115-079
1. Toner stored in the hopper is agitated by the agitating blade and conveyed into the toner supply portion by the conveyance blade fitted to the leading edge of the agitating blade. 2. Toner in the toner supply portion is conveyed by the supply roller onto the developing roller. 3. At this time, the 1st and 2nd regulator blades moderate the height of toner on the surface of the developer roller. 4. When positioned by the Toner Cartridge Rack in the developing position, toner adheres to the latent image on the drum. Toner left on the surface of the developer roller following transfer to the drum is returned to the toner supply portion. To attract toner to the drum, a developing bias voltage (Vb) that includes both DC (-) and + AC components is applied to the developing roller during development. The AC component is applied only during Phaser 6115MFP Multifunction Product Service Manual 2-21
Theory of Operation development. The developing bias voltage (Vb) supplied by the High Voltage Power Supply is applied to the developing roller at the contact point shown below.
Developing Bias Contact Point
Seal Bias Contact Point
Regulator Blade Contact Points
s6115-080
Developer Roller Drive

The Developer Roller is driven by the Developing Motor and intermediate gears.
Main Motor
Photoconductor
Developer Roller
Developing Motor
s6115-050
2-22
Theory of Operation When the Toner Cartridge Rack is stationery at the developing position, the Developer Roller drive gear meshes with intermediate gears allowing the Development Motor to engage the roller.
Intermediate Gear
s6115-051
2-23
Theory of Operation
Toner Cartridge Rack

The Toner Cartridge Rack holds the four Toner Cartridges and rotates to position each cartridges Developer Roller in the developing position. The rack is driven by the Rack Motor.
s6115-065
The Toner Cartridge Rack has three stop positions: the standby (reference) position, the developing position, and the cartridge replacement position:
The standby position is the Toner Cartridge Rack position when the system completes a warm-up cycle or waits for a print command. The development position is when the Toner Cartridge Rack stops during development of a specific color of toner. The cartridge replacement position refers to the position at which the Toner Cartridge Rack is stopped for replacement of the Toner Cartridge of a specific color of toner.
2-24
Theory of Operation The standby position is 45 degrees before the developing position of the Black (K) Toner Cartridge.
C K M Y
45
Standby Position
s6115-082
The developing position is where the Toner Cartridge Rack is rotated 45 degrees from the standby position.
Photo Conductor
C K M Y 45
K 0
Developing Position
s6115-083
The cartridge replacement position is where the Toner Cartridge Rack is rotated 70 degrees from the developing position.
For Developing of K 70 C K C K Y
K Developing Position
Cartridge Replacement Position

s6115-084
2-25
Theory of Operation
Operation for Monochrome

The Toner Cartridge Rack follows these steps for monochrome prints. 1. The Toner Cartridge Rack is stationary at the standby position. 2. When a print request is received from the controller, the Toner Cartridge Rack is rotated to bring the K Toner Cartridge to its developing position. 3. Development of monochrome printing is started. 4. When the development is completed, the Toner Cartridge Rack is rotated and brought to a stop at the standby position.
Step 1 C M Y Standby Position K
Step 2 C M K Y
Step 3 C M K Y
Step 4 C M Y Standby Position

s6115-085
Rack is Rotated
Monochrome Printing
Operation for Color

The Toner Cartridge Rack follows these steps for color prints. 1. The Toner Cartridge Rack is stationary at the standby position. 2. When a print request is received, the Toner Cartridge Rack rotates to place the Y Toner Cartridge to its developing position. 3. Development of Y is carried out. 4. When development of Y is completed, the Toner Cartridge Rack is rotated to bring the M Toner Cartridge to its developing position. 5. Development of M is carried out. 6. Similarly, the Toner Cartridge Rack rotates and development of C is carried out, followed by K. 7. When the development of K is completed, the Toner Cartridge Rack rotates to the standby position. Step 4 Step 1 Step 2 Step 3
C M Y Standby Position Step 5 Y K M C K
K C
Y M
K C
Y M
Y K
M C
Rack is Rotated Step 6 M Y C K
Y Development Step 7 C M K Y
Rack is Rotated Step 8 C M Y Standby Position

s6115-086
M Development
Rack is Rotated + C Development
Rack is Rotated + K Development
2-26
Theory of Operation
Position Detection
The Toner Cartridge Rack stop position for each color of toner is detected by the Rack Positioning Sensor. Openings around the circumference of the Toner Cartridge Rack actuate the Rack Position Sensor at each stop position.
Slits
Rack Positioning Sensor

s6115-087
When the Toner Cartridge Rack rotates past the slit for the K developing position, the Rack Positioning Sensor is actuated. This indicates that the current development is for K. Through pulse control of the Rack Motor, the Rack Motor drives the Toner Cartridge Rack to the standby position.
Direction of Rotation of the Toner Cartridge Rack M Rack Positioning Sensor Standby Position Detecting Position
C K Y Toner Cartridge Rack Standby Position
K Detection of C Developing Position
C Detection of M Developing Position
M Detection of Y Developing Position
Y Detection of K Developing Position
s6115-088
When a replacement request is made for a Toner Cartridge, the Toner Cartridge Rack is rotated 70 degrees from the depleted cartridges developing position through pulse control of the Rack Motor.
2-27
Theory of Operation
Transfer Belt
The Transfer Belt serves to accumulate the images produced by the four developer rollers before transferring the composite image to the media with the Transfer Roller. Components of the Transfer Belt appear below.
Driven Roller Transport Belt 1st Transfer Roller IDC Sensor Transfer Belt Drive Roller
Cleaning Blade Toner Collecting Auger Belt Positioning Sensor

s6115-052
Photoconductor
In addition to the Transfer Belt, a Transfer Roller (sometimes referred to as the 2nd Transfer Roller) transfers the composite image to the media for fusing.
2nd Transfer Roller
Pressure Slider Pressure/Retraction Roller

s6115-053
2-28
Theory of Operation
Transfer Drive
The Transfer Belt and Transfer Roller (sometimes referred to as the 2nd Transfer Roller) are driven by the Main Motor. The Transfer Roller Clutch at one end of the (2nd) Transfer Roller engages the Main Motor drive.
Main Motor
Transfer Roller Clutch 2nd Transfer Roller Transfer Belt Drive Roller
Transfer Belt Unit 1st Transfer Roller

s6115-054
2-29
Theory of Operation
Transfer Belt Cleaning

The Transfer Belt Cleaning Blade collects residual toner off the surface of the Transfer Belt, and a toner collecting auger transfers waste toner to the Imaging Unit reservoir. During color printing, an image is formed on the Transfer Belt for each color. The Cleaning Blade uses a retraction mechanism to lift off the belt during the printing process. During monochrome printing, no retraction sequence is needed. The Cleaning Blade is normally in contact with the Transfer Belt.
Driven Roller
Cleaning Blade
Toner Collecting Screw
s6115-089
Cleaning Blade retraction operations are driven by the Main Motor, Cleaning Blade Solenoid, pressure cam, lever, and Cleaning Blade Position Sensor.
2-30
Theory of Operation When the Cleaning Blade Solenoid is energized, drive from the Main Motor is transmitted to the pressure cam.
Cleaning Blade Solenoid
Lever Pressure Cam
Main Motor
Cleaning Blade Sensor
Belt Cleaner Assy

s6115-090
The sequence of events to retract the Cleaning Blade are: 1. Drive from the Main Motor is transmitted to the drive gear. 2. Rotation of the drive gear is transmitted to the pressure cam. 3. When the Cleaning Blade Solenoid is energized, the half-moon-shaped pressure cam rotates a half turn to push the lever forward to retract the Cleaning Blade.
2-31
Theory of Operation 4. The Cleaning Blade Position Sensor signal indicates whether or not the Cleaning Blade is retracted from the Transfer Belt.
Lever Pressure Cam
s6115-091
The position of the Cleaning Blade is unknown when the Power Switch is turned On or the cover is opened and closed. To determine home position for the Cleaning Blade, the system performs a home position detection sequence during a warm-up cycle. The Cleaning Blade Solenoid is energized to start a retraction sequence. When the Cleaning Blade Position Sensor is blocked, indicating home position, the Cleaning Blade Solenoid is de energized.
Transfer Belt Position Sensor

Image development requires the creation of a composite image on the surface of the Transfer Belt. The leading edge of each color component of the image must register correctly on the Transfer Belts surface. The position of the Transfer Belt is monitored by the Transfer Belt Position Sensor. The optical sensor detects holes in the Transfer Belt. Two detection holes are punched in the Transfer Belt. The image write start position varies according to the media size. For A4 or smaller media, the image write start position, as determined by the sensor, is detection hole A.
2-32
Theory of Operation For a media sizes larger than A4, detection hole B is the reference for the image write start position.
Direction of Rotation of Transfer Belt
Detection Hole B
Belt Positioning Sensor
Detection Hole A
s6115-104
Transfer Roller
The Transfer Roller (sometimes referred to as the 2nd Transfer Roller) transfers the developed image from the Transfer Belt to the media. To allow development of the composite color image on the Transfer Belt, the Transfer Roller retracts from the belt while the image is developed. The Transfer Roller retraction operation is performed by the Main Motor, Image Transfer Solenoid, and Transfer Roller Clutch. When the Image Transfer Solenoid is energized, drive from the Main Motor is transmitted to the Transfer Roller Clutch.
Main Motor Pressure/Retraction Clutch
Transfer Belt 2nd Transfer Assy
2nd Transfer Roller
Pressure/Retraction Clutch 2nd Image Transfer Solenoid

s6115-092
2-33
Theory of Operation
Image Transfer
To apply pressure to the Transfer Roller (sometimes referred to as the 2nd Transfer Roller), the system follows these steps: 1. Drive from the Main Motor is transmitted to the drive gear. 2. Rotation of the drive gear is transmitted to the Transfer Roller Clutch. 3. When the 2nd Image Transfer Solenoid is energized, the Transfer Roller Clutch rotates a half turn. This moves the Pressure Slider. 4. When the Pressure Slider is moved, the ribs push against the Pressure Retraction Roller. 5. When the assembly is pushed up, the Transfer Roller presses against the Transfer Belt.
Pressure/Retraction Roller
2nd Transfer Assy 2nd Image Transfer Solenoid
Pressure Slider
Pressure/Retraction Clutch Ribs 2nd Image Transfer

s6115-093
Transfer Roller Retraction

To retract the Transfer Roller from the Transfer Belt, the system performs the following steps: 1. When the Image Transfer Solenoid is energized, the Transfer Roller is presses against the Transfer Belt and the Transfer Roller Clutch rotates a half turn. This moves the Pressure Slider. 2. When the Pressure Slider moves, the Transfer Assembly, which has been pushed up by the ribs on the Pressure Slider, lowers.
2-34
Theory of Operation 3. When the Transfer Assembly lowers, the Transfer Roller retracts from the Transfer Belt.
Pressure/Retraction Roller
2nd Transfer Assy 2nd Image Transfer Solenoid
Pressure Slider
Pressure/Retraction Clutch Ribs 2nd Image Transfer

s6115-094
Transfer Roller Cleaning

DC positive and negative transfer bias voltages are alternately applied to the Transfer Roller. These charges oppose those on the Transfer Belt attracting toner residue on the Transfer Roller back to the Transfer Belt. The Transfer Belt cleaning blade collects the waste toner from the belt and stores the waste in the Imaging Unit. Transfer Roller cleaning occurs when:

Power Switch is turned ON Cover is opened and closed A media error occurs during a print cycle. A paper empty condition occurs during a print cycle. A paper size error occurs during a print cycle.
Process Control
For stable printing, the parameters related to forming both the electrostatic and toner image are continuously monitored and adjusted by the printer. Parameter correction and control over the entire printing process is called process control. Two primary process control mechanisms are used by the system, Automatic Transfer Voltage Control (ATVC) and Automatic Image Density Control (AIDC).
2-35
Theory of Operation
Automatic Transfer Voltage Control (ATVC)

ATVC optimizes the transfer output. A constant current flows through each of the Transfer Rollers. The resistance of each of the 1st Transfer Roller, the Transfer Roller (sometimes referred to as the 2nd Transfer Roller), and Transfer Belt is measured. ATVC automatically adjusts the appropriate image transfer output voltage (bias) to be applied to each Transfer Roller and transfer belt during the print cycle.
Apply the constant current to the 1st Transfer Roller Constant Voltage Measure the resistance of the 1st Transfer Roller Constant Current Establish the 1st Transfer output voltage 2nd Transfer Roller Apply the constant current to the 2nd Transfer Roller Measure Resistance
HVPS
Constant Current
1st Transfer Roller
Transfer Belt Transfer Belt Drive Roller
Transfer Belt Photo Conductor Ground
Measure the resistance of the 2nd Transfer Roller
Establish the 2nd Transfer output voltage
s6115-397
Automatic Image Density Control (AIDC)

AIDC stabilizes image density to provide accurate tone reproduction. AIDC uses the IDC Sensor and Temperature/Humidity Sensor to monitor system and environmental parameters to regulate the following:
Leak detection control For the clearance between the Drum and Developing Roller, an optimum developing bias voltage is established that prevents leak image or uneven density. IDC Sensor intensity control Adjustments are made to correct changes in IDC Sensor characteristics due to changes over time or contamination. The IDC Sensor is a photoreflective sensor that emits light from an LED and detects the reflected light returning from the Transfer Belt. The light emitted from the LED is controlled so that the reflected light density is constant.
2-36
Theory of Operation
Reflectance measurement control The reflectance of the Transfer Belt is measured using the IDC Sensor. The measurement is taken for one complete revolution of the Transfer Belt. The measured value is corrected during the intensity adjustment and G-correction control. Toner adherence control The developing bias voltage value is adjusted to keep constant the amount of toner sticking to the surface of the Drum with reference to the 100% solid image. Laser intensity adjustment control Characteristics of the Drum, developing, and charging processes are affected over time and by the environment. The intensity of the laser light is adjusted so that fine lines and gradations of a predetermined level are reproduced at all times. G-correction control A gradation pattern is produced on the surface of the Transfer Belt. The IDC Sensor measures the density of the pattern and sends the measured result to the controller for gradation adjustment.
AIDC Sensor
1st Transfer Roller
2nd Transfer Roller Developing PC Charging
Developing Bias
Grid Bias
AIDC Control
ATVC IN OUT
s6115-102
Temperature/ Humidity Sensor
2-37
Theory of Operation Depending on the state of the system, the process control mechanisms are activated. Factors for each state are listed in the following table. Process Control Operational Mode Definitions
Mode Process Control Criteria
Mode 1
When the Power Switch is turned On, the current environmental readings are different from when the Power Switch was turned Off. The stored environmental readings taken when Energy Saver mode was entered differ from those taken when the system woke from Energy Saver mode. The Power Switch is turned Off and On or Energy Saver mode is canceled after a predetermined number of printed pages have been produced. A new Imaging Unit or Toner Cartridge is detected.
Mode 2
Only the Power Switch is turned Off and On, or Energy Saver mode is canceled after a predetermined number of printed pages have been produced.
The process controls invoked and the order in which they occur for each mode appears below.
Mode 1
Mode 2
ATVC Control
AIDC Intensity Control
Leak Detection Control
Control Of The Maximum Amount Of Toner Sticking
AIDC Intensity Control
Reflectance Measurement Control
Reflectance Measurement Control
Laser Intensity Control
Control Of The Maximum Amount Of Toner Sticking
Laser Intensity Control
G Correction Control
s6115-103
2-38
Theory of Operation
Temperature/Humidity Sensor
The Temperature/Humidity Sensor monitors the internal temperature of the system. It is also used for image stabilization, transfer ATVC, and fusing temperature control. Note There is a Control Panel command which obtains environmental temperature and humidity levels. However, this command is for internal use only and not available from the service menus.
s6115-064
2-39
Theory of Operation
System Thermal Regulation

Fans are the primary means used to limit the rise in internal temperature. Three fans are controlled by specialized circuity on the Main Board. The following illustration shows the location and airflow direction of the Scanner Unit, Power Supply, and Chassis Fans.
Scanner Fan
Power Supply Fan
Ventilation Fan
s6115-063
Power Supply Cooling Fan

The Power Supply Cooling Fan cools the system Power Supply and operates at full-speed, half-speed, or stopped states according to these conditions: The Power Supply Cooling Fan runs at full-speed for:

A predetermined period of time after the Power Switch is turned On A specified period of time representing the end of Energy Saver mode
2-40
Theory of Operation
At the start of a print cycle following the lapse of a predetermined period of time needed for half-speed rotation. Note No full-speed rotation is performed if the print cycle completes during half-speed rotation.
The Power Supply Cooling Fan runs at half-speed:
At the end of a print cycle (half-speed rotation following the predetermined period of time needed for full-speed rotation) During half-speed rotation under any condition other than above
The Power Supply Fan stops when:

The system enters the Energy Saver mode The fan develops a malfunction The Power Switch is turned Off
Chassis Fan
The Chassis Fan cools the system cabinet and operates at full-speed, halfspeed, or stopped states according to these conditions: The Chassis Fan runs at full-speed:
When the Main Motor is in operation
The Chassis Fan stops:

After a predetermined period of time after the Main Motor stops When a Door is opened, a media misfeed or malfunction occurs, or the Power Switch is turned Off
Scanner Fan
The Scanner Fan cools the Scanner and operates at full-speed, half-speed, or stopped states according to these conditions: The Scanner Fan runs at full-speed:
For the predetermined period of time after the Power Switch has been turned On At the start of a print cycle (full-speed rotation after a predetermined period of time needed for half-speed rotation)
The Scanner Supply Fan runs at half-speed:
At the end of a print cycle (half-speed rotation after a predetermined period of time needed for full-speed rotation) During half-speed rotation under any condition other than above
2-41
Theory of Operation
Waste Toner Collection

Waste toner removed from the Transfer Belt and Drum by the Cleaning Blade is transferred by gear driven augers along the Waste Toner Transfer Unit into the Imaging Unit waste toner reservoir.
Toner Collecting Screw
Toner Agitating Screw

s6115-097
Waste Toner Full Sensor

The Waste Toner Full Sensor detects a near full condition within the Imaging Unit waste toner reservoir. Two agitating augers are used in the reservoir to provide the maximum waste toner storage capacity. A waste toner near full
2-42
Theory of Operation condition occurs when light emitted from the sensor LED is obstructed during its travel through the light guide.
Waste Toner Detection Area Light Guide Waste Toner Near Full Detection Board
s6115-098
A waste toner full condition exists when 200 images are reached after a waste toner near full condition is detected. The initiation of any new print cycle is prohibited when 50 full-color printed pages are produced after the waste toner near full condition is detected. When the LED light is unblocked following Imaging Unit replacement, the waste toner full condition is reset.
Tray 1 Feeder
Tray 1
Pick Roller
Tray 2 Pick Solenoid
Tray 2 No Paper Sensor

s6115-060
2-43
Theory of Operation
Tray 1 Drive
When the Tray1 Pick Solenoid is energized, drive from the Main Motor is transmitted to the Pick Roller via the Tray 1 Pick Clutch. At the same time, the Lift Cam is rotated, which raises the Lift Plate. This allows the media to be taken up and fed in by the Pick Roller.
Main Motor
Tray 1 Pick Clutch
Pick Roller Tray 1 Pick Solenoid

s6115-055
2-44
Theory of Operation The fixed Separation Pad system plus the Retard Rollers are used for paper separation. This ensures that only one sheet of paper is fed.
Pick-up Roller
Separation Pad
Retard Rollers
s6115-099
To reduce the number of detected paper misfeeds, another paper feed sequence is carried out if the Registration Sensor is not unblocked and blocked within a predetermined period of time.

The Tray1 No Paper Sensor is located on the underside of Tray 1, and detects the presence of media in the tray. When there is media loaded in the tray, the actuator drops into the tray, unblocking the sensor. When media runs out, the actuator raises, blocking the sensor.
2-45
Theory of Operation
Registration
The Registration Sensor detects whether or not media has reached the rollers. The rollers move the media in synchronization with the image. Since the Conveyance Roller and Registration Roller are synchronized with each other, no loop is formed in the paper at the Registration Roller.
Registration Roller
Main Motor
Registration Sensor
Registration Roller Solenoid
Conveyance Roller
s6115-056
Transparency Sensor
The Transparency Sensor detects the type of the media in the registration section. When the Registration Sensor is activated, the signal from the Transparency Sensor is also read to determine the media type. If the Transparency Sensor signal is High, Transparency film is in the registration section.
2-46
Theory of Operation If the paper type specified by the controller when a print request is made does not match the results of Transparency Sensor detection, the machine suspends the print cycle and displays a corresponding message on the control panel.
OHP Sensor
Reflection Mirror
s6115-100
Media Size Detection

Media size is detected using the Registration Sensor. The length of the media is determined by the length of time the Registration Sensor remains High indicating media in the registration section. If the media size specified by the controller does not match the media size detected by the Registration Sensor, the system displays an error message on the Control Panel. The sheet causing the size error continues through the print process and is output to the tray. Operations for subsequent sheets are specified from the controller.
2-47
Theory of Operation
Exit Tray
Media is transported from the Fuser to the Exit Tray using the Exit Roller. the The Exit Sensor monitors the Media output.
Exit Roller
Exit Sensor
Actuator
s6115-061
The Fusing Motor drives the Exit Roller.
2-48
Theory of Operation
Exit Tray Full Sensor

The Exit Tray Full Sensor monitors the Exit Tray status.
s6115-062
Automatic Document Feeder (ADF)

The ADF feeds documents to the Scanner platen for scanning. The functional components within the ADF are illustrated below.
s6115-113
ADF Pick Operation

Media loaded in the ADF is detected by the Original Detection Sensor. The Document Stopper establishes the leading edge position of the document loaded in the Document Feeder. The stopper is lowered in the standby state and raised when the document is taken up and fed in. A Separation Pad limits the number of sheets picked to one. Phaser 6115MFP Multifunction Product Service Manual 2-49
Theory of Operation 1. The Document Stopper is raised and lowered in synchronism with the raising and lowering motion of the Pick Roller. 2. The ADF Motor drives the Pick Roller and Take-up Roller through a gear train and the ADF Feed Clutch. 3. The Pick Roller and Take-up Roller turn to take up and feed the original properly. 4. The Pick Roller transports the original up to the Take-up Roller.
s6115-110
ADF Transport Operation

When the sheet obstructs the ADF Feed Sensor, the Transport Roller, driven by the ADF Motor, turns to move the original to the document scanning position.
s6115-111
2-50
Theory of Operation
ADF Exit Operation

When the leading edge of the sheet obstructs the Leading Edge Detect Sensor, the Exit Roller, driven by the ADF Motor, turns to feed the original to the ADF Output Tray.
s6115-112
ADF Interlock
The ADF contains a magnet at its edge that activates a switch located in the Scanner to indicate the position of the ADF.
Magnet
Switch
s6115-066
2-51
Theory of Operation
Duplex Unit
The Duplex Unit adds 2-sided print capability to the system. The following illustration shows the location of components within the Duplex Module.
Reverse Motor Duplex Fan
Transport Motor
Transport Sensor
Door Sensor Duplex Solenoid
Duplex Control Board Paper Loop Sensor
Registration Rollers
s6115-038
Duplex Drive
The print engines Exit Roller, typically driven by the Fusing Motor during onesided operations, feeds media into the Duplex Option. For duplex operation, a lever disengages the Fusing Motor from the Exit Roller, and engages the Duplex Reverse Motor.
2-52
Theory of Operation This reverses the Exit Roller feeding the media into the Duplex Module.
s6115-039
After entering the Duplex Module, two Transport Rollers, driven by the Duplex Transport Motor, move media through the system.
s6115-040
A deskew loop correction mechanism is provided to prevent skew from occurring in the second page. The Registration Solenoid is energized after the lapse of a given period of time after the Paper Loop Sensor has been activated. This drives the Registration Roller. When the Registration Roller is driven, the paper is conveyed into the machine.
2-53
Theory of Operation
Duplex Transport Operations

The following steps detail the transport operations for single, hand-fed sheets. 1. The first sheet of paper is taken up and fed in from the main tray and the first print cycle begins. Immediately before the one-sided print leaves the Exit Roller, the direction of rotation of the Exit Roller is reversed and the 1sided print is transported toward and into the Duplex Unit. 2. The print moves through the Duplex Unit and is temporarily stopped at the Duplex take-up position. Any skew in the paper is corrected at the Registration Roller before the paper is fed by the Duplex Unit. 3. The second print cycle begins to produce the second image on the original sheet. While feeding the first two-sided print to the Exit Tray, the first print cycle for the second sheet begins. This process repeats until the print job is complete. 4. The first sheet of paper is then taken up and fed in from the tray and the first print cycle begins to produce the print image on the second page of the original. Immediately before the first one-sided print leaves the Exit Roller, the Exit Roller is reversed and the first 1-sided print is transported into the Duplex Option. 5. At the same time, the second sheet of paper is fed into the print engine. The first print cycle for the second sheet produces the image on the fourth page of the original. 6. Also at the same time, the first 1-sided print is transported through the Duplex Option. The main unit produces the print image of the first page of the original on the first one-sided print that has been fed through the Duplex Option. At the same time, the second sheet of paper is subjected to a switchback sequence at the exit section and fed into the Duplex Option. Also, the third sheet of paper is taken up and fed into the main unit. 7. While feeding the first 2-sided print out, the main unit produces the print image of the 6th page of the original on the third sheet of paper. The second sheet of paper waits at the Duplex take-up position until the third sheet of paper is subjected to a switchback sequence. 8. Immediately before the first one-sided print leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first 1sided print for the third sheet is transported toward and into the Duplex Unit. 9. At the same time, the second sheet of paper is fed into the main unit again.The main unit carries out the first print cycle for the second sheet of paper to produce the print image of the third page of the original. At the same time, the first 1-sided print for the third is transported through the Duplex Option. Also at the same time, the forth sheet of paper is taken up and fed into the main unit. 10. While feeding the second 2-sided print out, main unit produces the print image of the 8th page of the original on the fourth sheet of paper. The third sheet of paper waits at the Duplex take-up position until the fourth sheet of paper is subjected to a switchback sequence. The process repeats until the print job is complete.
2-54
Theory of Operation
500-Sheet Feeder Unit

The optional 500-Sheet Feeder is replaced as a single assembly. Components of the optional 500-Sheet Feeder appear below.
s6115-034
Feeder
The feeder is driven by the systems Main Motor through a coupling gear. The paper separation mechanism uses separation claws installed in the unit and elasticity of the paper. It ensures that only one sheet of paper is fed in at time. The Pick Solenoid is controlled by the system through the Feeder Control Board mounted in the feeder.
Coupling gear
PF Drive Board
Paper Empty Sensor
Paper Pick-up Solenoid

s6115-035
2-55
Theory of Operation

The Tray 1 No Paper Sensor located on the Feeder Control Board detects when the tray is empty. When media is present in the tray, the actuator is raised unblocking the sensor. When the tray is empty, the actuator drops into the slit in the Lift Plate blocking the sensor
PF Drive Board
Paper Empty Sensor
At Paper Empty Condition
Under Normal Conditions
s6115-036
2-56
Theory of Operation
Tray Detect Switch

The Tray Detect Switch signals the presence of a tray in the feeder. The switch is On when the tray is fully-inserted in the feeder.
Lever Tray Set Detecting Switch OFF
Switch Actuator
ON
Tray 2
s6115-037
Sensors
The printer contains sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the paper path, and detects if a paper jam occurs. Other sensors detect the presence of the Toner Cartridges, stop printer activity if a door is open (interlock), detect the presence and size of media in the trays, and monitor the fusing temperature. The types of sensors used vary with function. In general, there are three types in use:
Photo Sensors
Two types of photo sensors are used, photo-reflective and photo-receptive. Photo-reflective sensors use light reflected back from an object to detect its presence. Photo-receptive sensors use an actuator or the object itself to block the light path to detect an object or condition. Photo-reflective sensors have the light emitter and light receiver aligned on a single surface. Output of the photo-receptor is High (> +4.5 V) when light is being reflected back and Low (< +.3 V) when it isnt. Photo-receptive sensors consist of a LED in one arm of a U-shaped holder, and a photo-transistor in the other arm. When the sensing area is vacant, nothing is between the arms of the sensor, light falls on the photo-receptor sending the signal High. If the light is interrupted, the photo-transistor goes Low.
2-57
Theory of Operation
Microswitches
Microswitches are used primarily as tray detect sensors and cover interlocks. They are in a normally open state, and close when actuated. A bank of microswitches detect the paper size in the universal trays. Microswitches also employ hooks or catches for retention in the bracket or frame.
Thermistors
Thermistors have a known value of resistance whose value varies with temperature. Used primarily in the Fuser for temperature sensing.
Sensor Layout
Exit Sensor
Fusing Paper Loop Sensor Registration Sensor
s6115-350
2-58
Error Codes and Messages

In this chapter...

Overview of Error Messages Index of Error and Warning Messages Messages, Codes, and Procedures Jam Error Procedures
Chapter
Overview of Error Messages

This section describes error messages and numeric codes displayed on the Control Panel. These error indications serve as the entry point into the troubleshooting process. Printer problems not directly indicated by, or associated with an error message or code are covered in Chapter 4, General Troubleshooting. Print-quality problems are covered in Chapter 5, PrintQuality Troubleshooting. The printer tracks and reports errors in a number of ways. The two types of error reporting discussed in this Section include:

Error messages and help text displayed on the Control Panel. Engine (fatal) and Jam Error logs displayed on the Control Panel or listed in the Service Usage Profile.
Index of Error and Warning Messages

The following table lists errors that will halt printing and require a service technician. All of the call designators (e.g. CALL 04) are proceeded with the display of *CAUTION* MACHINE TROUBLE. Service call Messages
Message Description
CALL 04 CALL 05 CALL 08 CALL 0B CALL 0C CALL 0F CALL 10 CALL 12 CALL 14 CALL 15 CALL 16 CALL 17 CALL 18 CALL 19 CALL 1A CALL 1B CALL 21 CALL 23 CALL 24
Engine Controller Board error Engine Controller FLASH ROM error Engine Main Motor error Fusing Fan Error Power Supply Fan error Duplex Fan error. Laser Unit Mirror Motor error Laser Unit error - no sync signal Transfer Roller contact pressure error Transfer Belt contact pressure error Transfer Belt rotation error Toner Carousel rotation error Fuser warmup error Fuser temperature low error Fuser temperature high error Fuser Thermistor error Transparency Detect Sensor error Waste Toner Full Detection Sensor error Fuser temperature resistance error
3-2
Message
Description
CALL 29 CALL 2A CALL 2B CALL 2C CALL 31 CALL 101 CALL 102 ENGINE INTERFACE CONTROLLER
Controller Memory Checksum error Controller Memory Data error Controller Memory Access error Controller Memory Mounting error Scanner Fan Motor error Scanner Motor error Scanner Lamp error Communication error between Main Controller and Engine controller Main Controller Error
Other Error/Warning Messages

These are errors that will require customers to do some corrective action. Some require user intervention to continue printing.
Message
Description
K TONER EMPTY PAPER EMPTY PAPER JAM* OUTPUT TRAY FULL OUTPUT TRAY FULL REMOVE PAPER MEDIA TYPE ERRO REMOVE PAPER REPLACE Y TONER EJECT MODE REMOVE Y TONER PAPER EMPTY LOAD PAPER(xYYY) PAPER SIZE ERROR RESET PAPER(xYYY) MEDIA TYPE ERROR CHANGE xyyz->XYYZ MEMORY FULL PRESS ANY KEY Phaser 6115MFP Multifunction Product Service Manual
Error in Fax mode -- black toner empty (color toner is not used in fax) Error in Fax mode Error in Fax mode (paper jam in ADF) Error in Fax mode (idle) Error in sending out fax Media type error for fax mode Toner replacement mode, this message covers all 4 colors, Y is just an example. Toner eject mode, this message cover all 4 colors, Y is just an example Paper empty error in Printing Paper size error in printing Paper type error Memory full in printing
3-3
Message
Description
MEM.FULL/JOB CANCEL? OK=SEL (SEND=START) MEMORY FULL PRESS ANY KEY *CAUTION* FILE FULL *CAUTION* PRESS ANY KEY *CAUTION PAPER MISSFEED *CAUTION!* OPEN TOP COVER *CAUTION* PAPER JAM *CAUTION* OPEN DUPLEX COVER *CAUTION* PAPER JAM *CAUTION* OPEN TOP COVER *CAUTION* ORIGINAL DOC.JAM *CAUTION* OPEN DOC FEED COVER *CAUTION* PC CONNECTION FAILED *CAUTION* PRESS ANY KEY *CAUTION* FRONT COVER OPEN *CAUTION* CLOSE FRONT COVER *CAUTION* TOP COVER OPEN *CAUTIO!* CLOSE TOP COVER *CAUTION* DUPLEX COVER OPEN *CAUTION* CLOSE DUPLEX COVER *CAUTION* SCANNER UNIT OPEN *CAUTION* CLOSE SCANNER UNIT DOC FEED COVER OPEN CLOSE DOC FEED COVER PAPER EMPTY LOAD PAPER(xYYY) OUTPUT TRAY FULL REMOVE PAPER
Memory nearly full in Scanning mode Memory full in Scanning Files full in Scanning
Paper jam at input tray
Paper jam at duplex unit
Paper jam in the engine
Paper jam at ADF
Scanner Interface error (cable not attached?)
3-4
Message
Description
YMCK TONER EMPTY REPLACE YMCK TONER TEXT x1.00 <-A-> 1A4 YMCK TONER TEXT x1.00 <-A-> 1A4 LOW TONER LIFE END CHANGE YMCK TONER IMAGE UNIT DEPLETED REPLACE IMAGING UNIT IMAGING UNIT NOT INSTALLED CYAN TONER NOT INSTALLED MAGENTA TONER NOT INSTALLED YELLOW TONER NOT INSTALLED BLACK TONER NOT INSTALLED CURRENCY DETECTED LOAD DOC FEEDER SET ORIGINAL TO ADF REMOVE ORIG.IN ADF ADMINISTEREDBY PC LINE PROBLEM CHECK LINE *FAX COMM. ERROR*(XXXX) *NO DIAL TONE* 030524120 *LINE IS BUSY* 030524120 *NO ANSWER* 030524120 *REDIAL WAITING* 030524120 *REDIAL ALL FAILED* 030524120 *HANG UP THE PHONE* 030524120
Only the low one will show, if cyan and magenta are low, it will show MC TONER EMPTY Only the low one will show, if cyan and magenta are low, it will show MC TONER EMPTY, also Imaging unit, this is in the copy mode Only the EOL one will show, if cyan and magenta are low, it will show MC TONER Life end EOL for drum (waste toner full, sensor trigger) Error
No original document at ADF No original at ADF for 2in1 copy When there is original at ADF but call for flatbed scanning CWIS or MCC prevent changes from the front panel Fax line problem FAX communication error 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo)
3-5
Message
Description
*MEM.FULL/SEND* 030524120 *MEM.FULL/RECEIVE* 030524120 *FILE FULL/SEND* 030524120 *FILE FULL/RECEIVE* 030524120 *MEMORY FULL* *FILE FULL* *DESTINATION FULL* *DESTINATION SET BY MANUALUPTO 16* *DUPLICATE SETTING* *NOT REGISTERED!* *WRONG PASSWORD* *WRONG NUMBER SET* *NOT AVAILABLE* CYAN TONER NOT INSTALLED MAGENTA TONER NOT INSTALLED YELLOW TONER NOT INSTALLED BLACK TONER NOT INSTALLED *CAUTION* CURRENCY DETECTED *CAUTION* LOAD DOC FEEDER *CAUTION* SET ORIGINAL TO ADF *CAUTION* REMOVE ORIG.IN ADF *PLEASE WAIT* ADMINISTERED BY PC
030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) 030524120 is an example for phone number (as in Tokyo) Fax memory full (receiving) Fax transmitting error Group dial can be set to 50 destination by CWIS and MCC, but from Front Panel, you can not set this more than 15 Same destination is set in One-Touch one Speed Dial One-Touch or Speed Dial button is not registered Incorrect Password for the Memory RX Setting is not correct in Date or Time (like March, 50,,,) Selection is not available
No original document at ADF No original at ADF for 2in1 copy When there is original at ADF but call for flatbed scanning CWIS or MCC prevent changes from the front panel
STD 100% LINE PROBLEM Fax line problem STD 100% CHECK LINE REGISTERED! GROUP An error occurs if Group dial was selected when inputting the destination for Hook function.
3-6
Message
Description
The following are scan to Email errors *NOT E-MAIL ADDRESS* *NOT REGISTERED!* *NO NETWORK SETTING* *IP ADDRESS NOT SET* *FILE FULL* *JOB CANCELED* MEMORY FULL PRESS ANY KEY *COMM.ERROR* SMTP Server *DISCONNECT* SMTP Server *CANNOT CONNECT* SMTP Server *CANNOT CONNECT* DNS Server *SERVER MEMORY FULL *SMTP Server
Setting is not E-mail address
No setting in the selected key Setting is not completed Cannot get IP Address
In case of Memory Full
Communication Error Cannot connect Communication Error Communication Error Mail Receiving Memory of the SMPT Server is full.
For details of malfunction messages and troubleshooting procedures, see Main Print Engine Troubleshooting on page 4-3
Messages, Codes, and Procedures

The error messages and codes generated by the printers operating system are the lead-in to the troubleshooting procedures that follow in subsequent pages. This section correlates the output of the printers diagnostic aids and provides the location of the troubleshooting procedure to correct reported errors.
3-7
Error Message Summary

The following table provides a listing of error messages and the page number for the description of each.
Control Panel Message Boards and FLASH ROM 04H Engine Malfunction 05H Flash ROM Malfunction Motors and Fans 08H Main Motor Malfunction 0BH Ventilation Fan Motor Malfunction 0CH Power Supply Cooling Fan Malfunction 10H Polygon Motor Malfunction Image Components 12H Laser Malfunction 14H Second Image Transfer Pressure/Retraction Failure 15H Cleaning Blade Pressure/Retraction Failure 16H Transfer Belt Rotation Failure 17H Rack Rotation Failure Thermistors and Sensors 18H Heating Roller Warmup Failure 19H Abnormally Low Heating Roller Temperature 1AH Abnormally High Heating Roller Temperature 1BH Faulty Thermistor 21H Faulty Transparency Sensor 23H Faulty Waste Toner Near Full Detection Board Miscellaneous Motors and Lamps 31H Scanner Cooling Fan Motor Malfunction 101H Scanner Motor Malfunction 102H Faulty Scanner Exposure Lamp Power Supply Errors Machine is Not Energized Control Panel Indicators Do Not Light Fusing Heaters Do Not Operate
Code
Go to Page
O4H 05H
3-11 3-12
08H 0BH 0CH 10H
3-13 3-14 3-15 3-16
12H 14H 15H 16H 17H
3-17 3-18 3-19 3-21 3-22
18H 19H 1AH 1BH 21H 23H
3-23 3-23 3-23 3-23 3-25 3-26
31H 101H 102H
3-27 3-28 3-29
N/A N/A N/A
3-31 3-32 3-33
3-8
Using the Troubleshooting Procedures

1. Applicable Status Code(s) lists the error message(s) addressed by each troubleshooting procedure. 2. Applicable Parts and Wiring and Plug/Jack References assist you in locating information available for a particular part or procedure. 3. Follow each Step in a troubleshooting procedure sequentially in the order given until the problem is fixed or resolved. 4. The Actions and Questions box instructs you to perform a certain action or procedure. Also included are precautions and/or additional procedures you must follow to isolate the problem. 5. Some actions are followed by a question. If your response to the question is Yes, then follow the instructions for a Yes reply. If your response to the question is No, then follow the instructions for a No reply. 6. Note that two types of photo sensors are used: photo-reflective and photo-receptive. Photo-reflective sensors use light reflected back from an object to detect its presence or absence. Photo-receptive sensors use an actuator or the object itself to block the light path to detect an object or condition. 7. Troubleshooting procedures frequently ask you to take voltage readings or test for continuity or resistance at certain test points. The Wiring and Plug/Jack References table provides pointers to the diagrams that provide this information. 8. Troubleshooting procedures often ask you to replace a printer component. When instructed to replace a non-spared component and that component is part of a parent assembly, replace the entire parent assembly.
Measurement Techniques
1. Unless indicated otherwise, the instruction switch On printer power means for you to switch On printer power and let the printer proceed through Power On Self Test (POST) to a Ready condition. 2. Conventions used in this manual to represent connectors. P/Jxx
YY
Plug and Jack
3. When instructed to take voltage, continuity or resistance readings on wiring harness, proceed as follows; Check P/J 2321 to P/J 2105 by placing the red probe (+) of your meter on pin 1 of P/J 232, and place the black probe () of your meter on pin 5 of P/J 210. 4. When you are instructed to take resistance readings between P/J 232 <=> P/J 210 (without specified pin numbers), check all pins. Refer to the section "Wiring Diagrams" for the location of all wiring harnesses and pins. 5. When you are instructed to run a test, run the Service Diagnostics test associated with the component being examined. 6. When you are instructed to take a voltage reading, the black probe () is generally connected to a pin that is either RTN (Return) or SG (Signal Ground). You can substitute any RTN pin or test point in the printer, and you can use FG (frame ground) in place of any SG pin or test point.
3-9
Error Codes and Messages 7. Before measuring voltages make sure the printer is switched On, the Imaging Unit and the paper trays are in place, and the interlock switch is actuated, unless a troubleshooting procedure instructs otherwise. 8. All voltage values given in the troubleshooting procedures are approximate values. The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi-meter. 9. When a troubleshooting procedure instructs you to replace a non-spared component and that component is part of a parent assembly, you should replace the entire parent assembly. 10. Ensure that you are using a supported media size and type, refer to Product Specifications on page 1-6. 11. Power and signal grounds are connected to the frame ground. All circuit troubleshooting can be performed using the metal frame (chassis) as the grounding point. To locate connectors or test points, refer to the section "Plug/Jack Locator Maps" on page 10-2. 12. Unless otherwise specified, the following voltage tolerances are used within this section: Stated +3.3 VDC +5.0 VDC +24.0 VDC 0.0 VDC Measured +3.135 to +3.465 VDC +4.75 to +5.25 VDC +21.6 to +26.4 VDC Less than +0.5 VDC
3-10
Jam Error Procedures

04H Engine Malfunction
Power is on but no printer functions are available.
Applicable Status Code

04H: Engine Malfunction
Initial Actions

Check for faulty connections Power down and reboot the system.
Troubleshooting Reference Table Applicable Parts
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board Locator (page 10-5)
Engine Control Board, PL4.19.15
Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing Step 3 of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connectors. Are the connections properly seated? Power up the system. Does the system operate correctly? Replace the board and power up the system (page 8-57). Yes Go to Step 3. No Reconnect and go to Step 2. Go to Step 3.
2 3
Complete Complete
3-11
05H Flash ROM Malfunction

FLASH ROM will not display or load.

05H: Flash ROM Malfunction
Initial Actions

Check to see if the correct FLASH ROM is installed. Power down and reboot the system.
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board Locator (page 10-5)
Engine Control Board, PL4.19.15
Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing Step 3 of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connector P/J702 to the Control Panel. Is the connection properly seated? Power up the system. Does the system operate correctly? Replace the board and power up the system (page 8-57). Complete Yes Go to Step 3. No Reconnect and go to Step 2. Go to Step 3.
2 3
3-12
08H Main Motor Malfunction

Main motor inoperative, noisy, or erratic.

08H: Main Motor Malfunction
Initial Actions

Check power cord and connections. Power down and reboot the system.
Troubleshooting Reference Table Applicable Parts Main Motor, PL4.12.1 Engine Control Board, PL4.19.15 DC Power Supply 1, PL4.19.3

Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Main Motor Plug/Jack Locator (page 10-16) Engine Control Board to Main Motor and Positioning Sensor Wiring (page 10-16)
Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Main Motor connector P/J8 to the Engine Control Board for proper connection. Is the connector seated properly? Check the Main Motor for proper positioning. Is the motor engaged with the gears? Yes Go to Step 2. No Reseat the connector. If the problem persists, go to Step 2. Reseat the motor drive properly. If the problem persists, go to Step 3. Go to Step 4.
Go to Step 3.
Check the operation of the Main Motor. Is the motor faulty?
Replace the motor (page 8-93). If the problem persists, go to Step 4.
3-13
Error Codes and Messages Troubleshooting Procedure Table Step Action and Questions 4 Replace the Engine Control Board (page 8-57). Does the problem persist? Replace the DC Power Supply 1 (page 8-60). Yes Go to Step 5. No Complete.
Complete
0BH Ventilation Fan Motor Malfunction

Ventilation fan motor inoperative, noisy, or erratic.

0BH: Ventilation Motor Malfunction
Initial Actions


Wiring and Plug/Jack References
Ventilation Fan Motor, PL4.8.2 Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board, PL4.19.15 Engine Control Board to Motor Wiring (page 10-15) DC Power Supply 1, PL4.19.3 Engine Control Board to DC Power Wiring (page 10-18) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Ventilation Fan Motor connector CN2 for proper connection. Is the connector seated properly? Yes Go to Step 2. No Reseat the connector. If the problem persists, go to Step 2.
3-14
Error Codes and Messages Troubleshooting Procedure Table (Continued) Step Action and Questions 2 Check the Engine Control Board connector P/J4. Is the connector seated properly. Yes Go to Step 4. No Reseat the connector. If the problem persists, go to Step 4. Go to Step 5.
Check the operation of the Ventilation Fan motor. Is the motor faulty?
Replace the motor (page 8-96). If the problem persists, go to Step 5. Go to Step 6.
Replace the Engine Control Board (page 8-57). Does the problem persist? Replace the DC Power Supply 1 (page 8-60).
Complete.
Complete
0CH Power Supply Cooling Fan Malfunction

Power Supply cooling fan motor inoperative, noisy, or erratic.

0CH: Power Supply Cooling Fan Motor Malfunction
Initial Actions

Troubleshooting Reference Table Applicable Parts Power Supply Cooling Fan Motor, PL4.8.1 Engine Control Board, PL4.19.15 DC Power Supply 1, PL4.19.3
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Motor Wiring (page 10-15) Engine Control Board to DC Power Wiring (page 10-18)
3-15
Troubleshooting Procedure Table Step Action and Questions 1 Check the Power Supply Cooling Fan connector P/J4 between the fan and the Engine Control Board. Is the connector seated properly? Check the Power Supply Cooling Fan for proper operation. Is the fan operational? Replace the Engine Control Board (page 8-57). Does the problem persist? Replace the DC Power Supply 1 (page 8-60). Yes Go to Step 2. No Reseat the connector. If the problem persists, go to Step 2. Replace the motor (page 8-94). Complete.
Go to Step 3.
Go to Step 4.
Complete
10H Polygon Motor Malfunction

Polygon Motor inoperative, noisy, or erratic.

10H: Polygon Motor Malfunction
Initial Actions


Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Power Supply and Laser Unit Wiring (page 10-14) Image Processor Board to Laser and Scanner Wiring (page 10-21)
Laser Unit, PL4.14.1 Engine Control Board, PL4.19.15
3-16
Troubleshooting Procedure Table Step Action and Questions 1 Yes No Reseat the connectors. If the problem persists, go to Step 2. Complete. Complete
Check the connectors P/J3, P/J19, and P/ Go to Step 2. J20 between the Laser Unit and both the Engine Control Board and the Image Processor (IP) board for proper connection. Are the connectors seated properly? Replace the Laser Unit (page 8-15). Does the problem persist? Replace the Image Processor Board (page 8-55). Does the problem persist? Replace the Engine Control Board (page 8-57). Go to Step 3. Go to Step 4.
2 3
Complete.
12H Laser Malfunction

Laser inoperative or malfunctioning.

12H: Laser Malfunction
Initial Actions

Run the printer test page. Power down and reboot the system.
Troubleshooting Reference Table Applicable Parts Laser Unit, PL4.14.1 Engine Control Board, PL4.19.15 Image Processor Board, PL4.19.1

Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Power Supply and Laser Unit Wiring (page 10-14) Image Processor Board to Laser and Scanner Wiring (page 10-21)
3-17
Troubleshooting Procedure Table Step Action and Questions 1 Yes No Reseat the connectors. If the problem persists, go to Step 2. Complete. Complete
Check the connectors P/J3, P/J19, and P/ Go to Step 2. J20 between the Laser Unit and both the Engine Control Board and the Image Processor (IP) board for proper connection. Are the connectors seated properly? Replace the Laser Unit (page 8-15). Does the problem persist? Replace the Image Processor Board (page 8-55). Does the problem persist? Replace the Engine Control Board (page 8-57). Go to Step 3. Go to Step 4.
2 3
Complete.
14H Second Image Transfer Pressure/Retraction Failure

Incorrect image transfer due to faulty pressure or retraction process.

04H: Faulty image transfer
Initial Actions

Power down then reboot the system. Run a test print page.
Troubleshooting Reference Table Applicable Parts Cleaning Blade Solenoid, PL4.11.2 Main Motor, PL4.12.1 Engine Control Board, PL4.19.15 Transfer Belt Unit, PL4.15.5
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Solenoid and Sensor Wiring (page 10-13) Engine Control Board to Motor Wiring (page 10-15)
3-18
Troubleshooting Procedure Table Step Action and Questions 1 Check the Main Motor connector P/J8 to the Engine Control Board. Is the connection seated properly? Check the Main Motor for proper drive operation. Is the motor operational? Check the Cleaning Blade solenoid. Is it operational? Yes Go to Step 2. No Reseat the connector and go to Step 2. Replace the motor (page 8-93). Replace the solenoid (page 8-105). If the problem persists, go to Step 4. Complete
Go to Step 3.
Go to Step 4.
Replace the Engine Control Board (page 8-57). Does the problem persist? Check the 2nd Image Sensor connector P/J11 to the Engine Control Board. Does the problem persist?
Go to Step 5.
Replace the transfer Belt Unit (page 8-33).
Complete
15H Cleaning Blade Pressure/Retraction Failure

Faulty sensor, solenoid, or cleaning blade retraction.

15H: Cleaning Blade Pressure/Retraction Failure
Initial Actions

Remove power from the system and reboot. Print a test page.
3-19
Troubleshooting Reference Table Applicable Parts Transfer Belt Unit, PL4.15.5 Cleaning Blade Solenoid, PL4.11.2 Main Motor, PL4.12.1

Wiring and Plug/Jack References Solenoids and Power Switch Locator (page 1-17) Motors and Fans Locator (page 1-15) Engine Control Board to Motor Wiring (page 10-15)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Main Motor connector P/J8. Is the connection seated properly? Check Main Motor for proper operation. Is the motor operational? Check the Cleaning Blade Solenoid connector CN3 to the Engine Control Board. Is the connector seated properly. Check the Cleaning Blade Solenoid. Is it operational? Yes Go to Step 2. No Reseat the connector and go to Step 2. Replace the motor (page 8-93). Reseat the connector. If the problem persists, go to Step 4. Replace the solenoid (page 8-105). If the problem persists, go to Step 5.
Go to Step 3.
Go to Step 4.
Go to Step 5.
Replace the Engine Control Board (page 8-57).
Complete.
3-20
16H Transfer Belt Rotation Failure

Faulty belt rotation.

16H: Transfer Belt Rotation Failure
Initial Actions


Transfer Belt Unit, PL4.15.5
Print Engine Wiring Map (page 10-12) Map 1 - Engine Control Board Plug/Jack Locator (page 10-5)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connector P/J9 and the Belt Positioning sensor connector P/J37. Are the connectors seated properly? Replace the Engine Control Board (page 8-57) and reboot. Is the system operational? Replace the Transfer Belt Unit (page 8-33). Yes Go to Step 2. No Reseat the connectors and go to Step 2. If the problem persists, go to Step 3.
Complete
Complete.
3-21
17H Rack Rotation Failure

Faulty rack sensor or rack motor.

17H: Rack Rotation Failure
Initial Actions

Troubleshooting Reference Table Applicable Parts Rack Positioning Sensor, PL4.3.12 Rack Motor, PL4.13.9
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Miscellaneous Motor and Sensor Wiring (page 10-17)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Rack Motor connector P/J30. Is the connector seated properly? Check the Rack Motor for proper operation. Is the motor operational? Yes Go to Step 2. No Reseat the connector and go to Step 2. Replace the motor (page 8-101). If the problem persists, go to Step 3. Reseat the connector. If the problem persists, go to Step 4.
Go to Step 3.
Check the Engine Control Board connector P/J5. Is the connector seated properly.
Go to Step 4.
3-22
Error Codes and Messages Troubleshooting Procedure Table (Continued) Step Action and Questions 4 Check the Rack Positioning sensor at PJ5, pin 11. Is the sensor on? Yes Go to Step 6. No Replace the sensor (page 8-112). If the problem persists, go to Step 6.
Complete.
18H Heating Roller Warmup Failure

18H: Heating Roller Warmup Failure
19H Abnormally Low Heating Roller Temperature

19H: Abnormally Low Heating Roller Temperature
1AH Abnormally High Heating Roller Temperature

1AH: Abnormally High Heating Roller Temperature
1BH Faulty Thermistor

Faulty thermistor in the Fusing Unit.

1BH: Faulty Thermistor
Initial Actions

3-23

Fusing Unit, PL4.18.12 Print Engine Wiring Map (page 10-12) Engine Control Board, Engine Control Board to DC Power Wiring PL4.19.15 (page 10-18) DC Power Supply 1, PL4.19.3 Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Fusing Unit for correct installation. Is the unit secured in position? Yes Go to Step 2. No Reinstall the Fusing Unit (page 8-36). If the problem persists, go to Step 2. Reseat the connectors. If the problem persists, go to Step 3. Reposition the switch and reseat the connector. If the problem persists, go to Step 4. Go to Step 5.
Check the connections between the Fusing Unit (CN2), Engine Control Board (P/J3 and P/J2)), and the power supply (CN4, CN5, and CN6). Are the connections correct? Check the lever of the safety switch at connector CN3. Is the switch positioned properly and is the connector seated properly.
Go to Step 3.
Go to Step 4.
Replace the Engine Control Board (page 8-57). Is the system operational? Replace the DC Power Supply 1 (page 8-60).
Complete
Complete
3-24
21H Faulty Transparency Sensor

Faulty Transparency sensor in image subassembly.

21H: Faulty Transparency Sensor
Initial Actions

Troubleshooting Reference Table Applicable Parts Transparency Sensor, PL4.17.16 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Engine Control Board to Solenoid and Sensor Wiring (page 10-13)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connector at P/J12. Is the connector seated properly? Check the Transparency Sensor at P/J40 pin 6. Is the sensor on? Yes Go to Step 2. No Reseat the connector and go to Step 2. Replace the sensor (page 8-117). If the problem persists, go to Step 3.
Go to Step 3.
Complete.
3-25
23H Faulty Waste Toner Near Full Detection Board

Incorrect detection of waste toner.

23H: Faulty Waste Toner Near Full Detection Board
Initial Actions

Troubleshooting Reference Table Applicable Parts Waste Toner near full detect board, PL4.6.6 Imaging Unit, PL4.15.9 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Print Engine Wiring Map, page 10-12 Engine Control Board to Solenoid and Sensor Wiring (page 10-13)
Troubleshooting Procedure Table Step Action and Questions 1 Check the WTDTB/LED connector P/J1 for proper connection. Is the connector seated properly? Check the Engine Control Board connector P/J13 for proper connection. Is the connector seated properly? Replace the Imaging Unit (page 8-13). Is the system operational? Replace the WTDTB/LED Board (page 8-70). Is the system operational? Replace the Engine Control Board (page 8-57). Is the system operational? Yes Go to Step 2. No Reseat the connector and go to Step 2. Reseat the connector and go to Step 3. Go to Step 4. Go to Step 5.
Go to Step 3.
3 4 5
Complete Complete Complete.
3-26
31H Scanner Cooling Fan Motor Malfunction

Inoperative Scanner Cooling Fan Motor.

31H: Scanner Cooling Fan Motor Malfunction
Initial Actions

Engine Control Board, Boards and Power Supplies Locator (page 1-14) PL4.19.15 Motors and Fans Locator (page 1-15) Scanner Cooling Fan Motor, Image Processor Board to Laser and Scanner PL4.8.10 Wiring (page 10-21) DC Power Supply 1, PL4.19.3 Engine Control Board to DC Power Wiring DC Power Supply 2, PL4.5.4 (page 10-18) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check the Scanner Cooling Fan Motor connector CN9 for proper connection. Is the connector seated properly? Yes Go to Step 2. No Reseat the connector. If the problem persists, go to Step 2. Reseat the connector. If the problem persists, go to Step 3.
Check the Engine Control Board connector MP/J1 for proper connection. Is the connector seated properly?
Go to Step 3.
3-27
Error Codes and Messages Troubleshooting Procedure Table (Continued) Step Action and Questions 3 Check the operation of the Scanner Cooling Fan Motor. Is the motor operational? Yes Go to Step 4. No Check pulse output of L-9 from MP/J1, pin 1 (ON) and MP/J1, pin 3 (LOCK). If no output, go to Step 5. Go to Step 5.
Replace the Engine Control Board (page 8-57). Is the system operational? Replace the DC Power Supply 2 (page 8-68). Is the system operational? Replace the DC Power Supply 1 (page 8-60).
Complete
Complete
Go to Step 6.
Complete
101H Scanner Motor Malfunction

Inoperative Scanner motor.

101H: Scanner Motor Malfunction
Initial Actions

Engine Control Board, Boards and Power Supplies Locator (page 1-14) PL4.19.15 Motors and Fans Locator (page 1-15) Scanner Motor, PL4.8.11 Image Processor Board to Laser and Scanner DC Power Supply 1, PL4.19.3 Wiring (page 10-21) DC Power Supply 2, PL4.5.4 Engine Control Board to DC Power Wiring (page 10-18) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
3-28
Troubleshooting Procedure Table Step Action and Questions 1 Yes No Go to Step 2.
Check the lock lever of the scanning unit. Unlock the lock Is the lever locked? lever. If the problem persists, go to Step 2. Check the Scanner Motor connector CN10 for proper connection. Is the connector seated properly? Go to Step 3.
Reseat the connector. If the problem persists, go to Step 3. Reseat the connector, then go to Step 5. Check pulse output pins 1 thru 4 on P/J8. If no output, go to Step 5. Go to Step 6.
Check the Engine Control Board connector P/J8 for proper connection. Is the connector seated properly? Check the operation of the Scanner Motor. Is the motor operational?
Go to Step 5.
Go to Step 5.
Replace the Engine Control Board (page 8-57). Is the system operational? Replace the DC Power Supply 2 (page 8-68). Is the system operational? Replace the DC Power Supply 1 (page 8-60).
Complete
Complete
Go to Step 7.
Complete
102H Faulty Scanner Exposure Lamp

Incorrect printer exposure.

102H: Faulty Scanner Exposure Lamp
Initial Actions

3-29
Troubleshooting Reference Table Applicable Parts Engine Control Board, PL4.19.15 Image Processor Board, PL4.19.1 Scanner Unit, PL3.1.1
Wiring and Plug/Jack References Print Engine Board Plug/Jack Designators (page 10-3) Print Engine Wiring Map (page 10-12) Engine Control Board to DC Power Wiring (page 10-18) Image Processor Board to Laser and Scanner Wiring (page 10-21)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connector P2. Is the connector seated properly. Check the Image Processor Board connector P/J6. Is the connector seated properly. Check the exposure lamp when power is applied. Is the lighting normal? Replace the scanner unit (page 8-25). Is the system operational? Replace the Engine Control Board (page 8-57). Is the system operational? Replace the Image Processor Board (page 8-55). Yes Go to Step 2. No Reseat the connector, then go to Step 2. Reseat the connector, then go to Step 3. Go to Step 4. Go to Step 5. Go to Step 6
Go to Step 3.
3 4 5 6
Complete Complete Complete Complete.
3-30
Machine is Not Energized

Machine is not energized at all (operational check)

N/A
Initial Actions


Power Switch, PL4.5.6 Solenoids and Power Switch Locator (page 1-17) Engine Control Board, Engine Control Board to DC Power Wiring PL4.19.15 DC Power Supply 1, PL4.19.3 (page 10-18) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Is power source voltage being applied to connector CN3 of the DC Power Supply 1? Yes Go to Step 2. No Check wiring from the AC power plug through the Power Switch. If problem persists, go to Step 2. Replace the DC Power Supply 1 (page 8-60). If problem persists, go to Step 3. Go to Step 4.
Are fuses (F1 and F2) on the DC Power Supply 1 conducting?
Go to Step 3.
3 4
Is DC24V and DC5V being applied to PJ2 on the Engine Control Board? Replace the Engine Control Board (page 8-57).
Complete Complete
3-31
Control Panel Indicators Do Not Light

No Control Panel or Faulty Indicator lights.

N/A
Initial Actions

Remove system power and reboot. View any control panel activity. Run printer test print.
Image Processor Board, Boards and Power Supplies Locator (page 1-14) PL4.19.1 Print Engine Board Plug/Jack Designators Control Panel Board, PL3.1.2 (page 10-3) DC Power Supply 1, PL4.19.3 Engine Control Board to DC Power Wiring (page 10-18) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing these procedures.
Troubleshooting Procedure Table Step Action and Questions 1 Is power source voltage being applied to connector CN3 of the DC Power Supply 1? Yes Go to Step 2. No Check wiring from the AC power plug through the Power Switch. If problem persists, go to Step 2. Replace the DC Power Supply 1 (page 8-60). If the problem persists, go to Step 3.
Are fuses (F1 and F2) on the DC Power Supply 1conducting?
Go to Step 3.
3-32
Error Codes and Messages Troubleshooting Procedure Table (Continued) Step Action and Questions 3 Is P/J7 on the Image Processor Board properly connected? Yes Go to Step 4. No Reseat the connector. If the problem persists, go to Step 4 Go to Step 5.
4 5
Replace the Control Panel Board (page 8-53). Is the system operational? Replace the Image Processing Board (page 8-55).
Complete Complete
Fusing Heaters Do Not Operate

Inoperative fusing heaters.

N/A
Initial Actions

Remove system power and reboot. Run printer test print.


Fusing Unit, PL4.18.12 DC Power Supply 1, PL4.19.3
Print Engine Wiring Map (page 10-12) Engine Control Board to DC Power Wiring (page 10-18)
Troubleshooting Procedure Table Step Action and Questions 1 Is power source voltage being applied to CN3 on the DC Power Supply 1?
NOTE The top and front cover should be in the closed position at this time.
Yes Go to Step 2.
No At J-7, check wiring from PG1 to CN1. If problem persists, go to Step 2.
3-33
Error Codes and Messages Troubleshooting Procedure Table (Continued) Step Action and Questions 2 Yes No Replace the DC Power Supply 1 (page 8-60).
Is the power source voltage being applied Replace the to CN2 on DC Power Supply 1? Fusing Unit (page 8-36).
3-34
General Troubleshooting
In this chapter...

Servicing Instructions Main Print Engine Troubleshooting Auto Document Feeder Troubleshooting Lower Feeder Unit Troubleshooting Duplexer Troubleshooting
Chapter
Servicing Instructions
The service checklist below is an overview of the path a service technician should take when servicing the printer and printer optional equipment. Step 1 - Identify the Problem 1. Verify the reported problem does exist. Verify failure symptoms/behavior/ noises with customer/end user. 2. Check for any error codes and write them down. 3. Print normal customer prints and service test prints. 4. Make note of any print quality problems in the test prints. 5. Make note of any mechanical or electrical abnormalities present. 6. Make note of any unusual noise or smell coming from the printer. 7. Print a Status page, if the printer is able to print. 8. View the fault history under the Service Tools Menu. 9. Verify the AC input power supply is within proper specifications. Step 2 - Inspect and Clean the Printer 1. Switch Off printer power. 2. Disconnect the AC power cord from the wall outlet. 3. Verify the power cord is serviceable. 4. Remove the Imaging Unit and protect it from light. 5. Inspect the printer interior and remove any foreign matter, dust or loose toner.
a. b. c. d. Do not use solvents or chemical cleaners to clean the printer interior. Do not use any type of oil or lubricant on printer parts. Do not use canned air to clean spilled toner or dust from the printer. Use only an approved toner vacuum.
6. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water. 7. Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. 8. Replace damaged or empty Toner Cartridges with new, customer-supplied ones. Step 3 - Find the Cause of the Problem 1. Read and understand the theory of how the printer operates. 2. Use the troubleshooting procedures to find the cause of the problem. 3. Use Service Diagnostics to check printer and optional components. 4. Use the wiring diagrams and plug/jack locator to locate test points. 5. Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure. Step 4 - Correct the Problem 1. Use the Parts List to locate a part number. 2. Use the Disassembly Procedures to replace the part. Step 5 - Final Check Test the printer to be sure you have corrected the initial problem and verify there are no additional problems present.
4-2
Main Print Engine Troubleshooting

Media-Based Problems
1. Check that the correct type of media is being used; for the correct media types and weights, see Product Specifications on page 1-6. The customer should be using a quality laser printer paper. The printer may have trouble picking glossy or overly smooth paper. 2. Only Phaser 25-Series Premium Transparency Film can be used in this machine. 3. Inspect the paper for bent, torn, or folded corners. 4. Check the paper path for obstructions or debris. 5. Ensure that the correct media type is set in the Control Panel. 6. Ensure that the paper guides are set correctly. 7. Ensure that the media is a supported type for the tray. See Product Specifications on page 1-6, for the correct media types, sizes and weights for each tray. 8. Load a fresh ream of paper in the tray.
Multiple-Sheet Pick
1. Ensure that the paper is in good condition and is listed on the Paper Tips page as supported media; quality office laser printer paper works best. 2. Ensure that the printer is printing within its environmental specifications by printing and reviewing the Status page. 3. Remove the tray and remove, fan, and reload the media. Ensure that 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 trays Retard Roller for damage. 6. Clean the Feed Rollers with a clean, dry, lint-free wipe. 7. Replace the Feed Rollers. 8. Replace the paper tray.
Mis-Pick
1. Check that the correct type of media for the tray is being used and the paper guides are set correctly. 2. Remove, fan, and reload the media. Ensure that the tray has not been over filled. 3. Try loading paper from a fresh ream, fan the paper, and then insert into the tray or flip existing paper over. 4. Clean the Feed Rollers with a clean, dry, lint-free wipe. 5. Troubleshoot the Paper Pick Assembly.
4-3
Misfeed at Paper Feed Section

The leading edge of the paper does not block the Registration Sensor even after the lapse of a predetermined period of time after the Tray 1 Paper Pickup Solenoid has been energized.
Troubleshooting Reference Table Applicable Parts Registration Sensor, PL4.17.2 Tray 1 Pick-up Solenoid, PL5.2.16 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14) Sensors and Switches Locator (page 1-16) Solenoids and Power Switch Locator (page 1-17) Engine Control Board to Solenoid and Sensor Wiring (page 10-13) Engine Control Board to Power Supply and Laser Unit Wiring (page 10-14)

Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connectors P/J12 and P/J18. Are the connectors seated properly? Yes Go to Step 2. No Reseat the connectors. If the problem persists, go to Step 2. Replace the sensor (page 8-116). Replace the solenoid (page 8-102).
Check the Registration Sensor at P/J39 (pin 3). Does the sensor read ON? Check the Tray 1 Paper Pick-Up Solenoid operation at P/J18 (pin 18). Is the solenoid operational. Replace the Engine Control Board (page 8-57).
Go to Step 3.
Go to Step 4.
Complete.
4-4
Misfeed at 2nd Transfer Section

For misfeed detection, the paper does not unblock the Registration Sensor even after the lapse of a predetermined period of time following the activation of the Registration Roller Solenoid. In some cases, the Fusing Paper Loop Sensor is not blocked by the paper that has moved past the position where the sensor is blocked. For detection of paper, the Registration Sensor is blocked when the power switch is turned ON, a cover is opened and closed, or a misfeed or malfunction is reset. In some cases, the Fusing Paper Loop Sensor is blocked when the power switch is turned ON, a cover is opened and closed, or a misfeed or malfunction is reset.
Troubleshooting Reference Table Applicable Parts Registration Sensor, PL4.17.2 Fusing Paper Loop Sensor, PL4.17.2 Registration Roller Solenoid, PL4.12.3 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14) Sensors and Switches Locator (page 1-16) Solenoids and Power Switch Locator (page 1-17) Engine Control Board to Solenoid and Sensor Wiring (page 10-13)

Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control connectors P/ J14, P/J12, and P/J11. Are the connectors seated properly. Yes Go to Step 2. No Reseat the connectors. If the problem persists, go to Step 2. Replace the sensor (page 8-116). Replace the sensor (page 8-114). Replace the solenoid (page 8-104).
Check the Registration Sensor at P/J12 (pin 3). Is the sensor operational? Check the Fusing Paper Loop Sensor at P/J14 (Pin 6). Is the sensor operational. Check the Registration Roller Solenoid at P/J11 (Pin 4). Is the solenoid operational? Replace the Engine Control Board (page 8-57).
Go to Step 3.
Go to Step 4.
Go to Step 5.
Complete
4-5
Misfeed at Fusing Section

For detection of misfeeds, the paper does not block the Exit Sensor even after the lapse of a predetermined period of time following the activation of the Registration Roller Solenoid. In some cases, the Exit Sensor is unblocked within a predetermined period of time after it has been blocked by the paper, the Main Motor, the Polygon Motor, and Rack Motor are energized even after the lapse of a predetermined period of time after paper information has been created. For detection of paper left, the Exit Sensor is blocked when the power switch is turned ON, a cover is opened and closed, or a misfeed or malfunction is reset.
Troubleshooting Reference Table Applicable Parts Exit Sensor, PL4.18.9 Registration Roller Solenoid, PL4.12.3 Image Processor Board, PL4.19.1 Engine Control Board, PL4.19.15

Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14) Sensors and Switches Locator (page 1-16) Solenoids and Power Switch Locator (page 1-17) Engine Control Board to Solenoid and Sensor Wiring (page 10-13) Engine Control Board to Miscellaneous Motor and Sensor Wiring (page 10-17)

Troubleshooting Procedure Table Step Action and Questions 1 Check all Image Processor Board connectors. Are the connectors seated properly? Yes Go to Step 2. No Reseat the connectors. If the problem persists, go to Step 2. Reseat the connectors. If the problem persists, go to Step 3. Replace the sensor (page 8-122). Replace the solenoid (page 8-104).
Check all Engine Control Board connectors. Are the connectors seated properly?
Go to Step 3.
Check the Exit Sensor at P/J6 (pin 3). Is the sensor operational? Check the Registration Roller Solenoid at P/J11 (pin 4). Is the solenoid operational?
Go to Step 4.
Go to Step 5.
4-6
General Troubleshooting Troubleshooting Procedure Table (Continued) Step Action and Questions 5 Replace the Image Processor Board (page 8-55). Does the problem still persist? Replace the Engine Control Board (page 8-57). Yes Go to Step 6. No Complete
Complete
Misfeed at Exit Section

For detection of misfeed, the Exit sensor is not unblocked even after the lapse of a predetermined period of time after it has been blocked by the paper. In some cases, the Exit Tray Full sensor is not blocked even after the set period of time has elapsed after the exit sensor has been blocked by the paper. For detection of paper left in the exit section, the Exit Sensor is blocked when the power switch is turned ON, a cover is opened and closed, or a misfeed or malfunction is reset. For detection of paper loaded fully in the exit section, the Exit Tray Full sensor is blocked when the power switch is turned ON, a cover is opened and closed, or a misfeed or malfunction is reset.

Exit Sensor, PL4.18.9 Boards and Power Supplies Locator (page 1-14) Exit Tray Full Sensor, PL4.1.7 Sensors and Switches Locator (page 1-16) Registration Roller Solenoid, Solenoids and Power Switch Locator PL4.12.3 (page 1-17) Engine Control Board, Engine Control Board to Miscellaneous Motor PL4.19.15 and Sensor Wiring (page 10-17) Engine Control Board to Main Motor and Positioning Sensor Wiring (page 10-16) Warning To avoid the potential of electric shock, ensure the power to the printer is off and the power cord is disconnected from the wall outlet prior to performing each step of the following troubleshooting procedure.
Troubleshooting Procedure Table Step Action and Questions 1 Check all Engine Control Board connectors. Are the connectors seated properly? Yes Go to Step 2. No Reseat the connectors. If the problem persists, go to Step 2. Replace the sensor (page 8-122).
Check the Exit sensor at P/J6 (pin 3). Is the sensor operational?
Go to Step 3.
4-7
General Troubleshooting Troubleshooting Procedure Table (Continued) Step Action and Questions 3 Check the Exit Tray Full Sensor at P/J9 (pin 14). Is the sensor operational? Check the Registration Roller Solenoid at PRCB PJ11PRCB-4 (J-1). Is the solenoid operational? Replace the Engine Control Board (page 8-57). Yes Go to Step 4. No Replace the sensor (page 8-107). Replace the solenoid (page 8-104).
Go to Step 5.
Complete
Undefined Misfeed
For detection of an undefined misfeed, conflicting settings are made in the printer driver.
Troubleshooting Reference Table Applicable Parts Image Processor Board, PL4.19.1 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14). Engine Control Board to Miscellaneous Motor and Sensor Wiring (page 10-17) Engine Control Board to Main Motor and Positioning Sensor Wiring (page 10-16)
Troubleshooting Procedure Table Step Action and Questions 1 Check printer driver settings. Are the settings correct? Yes Go to Step 2. No Reset the settings to the default level. If the problem persists, go to Step 2. Reseat the connectors. If the problem persists, go to Step 3.
Check the Image Processing Board connectors. Are the connectors seated properly?
Go to Step 3.
4-8
General Troubleshooting Troubleshooting Procedure Table (Continued) Step Action and Questions 3 Check the Engine Control Board connectors. Are the connectors seated properly? Yes Go to Step 4. No Reseat the connectors. If the problem persists, go to Step 4.
Complete
Auto Document Feeder Troubleshooting

Misfeed at the Document Feeding Section
For detection of misfeed, the Paper Feed Sensor in the Automatic Document Feeder (ADF) is not unblocked even after the lapse of a predetermined period of time after the Main Motor has been energized. For detection of paper left at the document feeding section, the Paper Feed Sensor in the Automatic Document Feeder is unblocked when the power switch is turned ON, the cover is opened and closed, or a misfeed or malfunction is reset.
ADF Unit, PL1.1.1
Document Feeder Control Board to Optional Feeder Tray Wiring (page 10-23)
Troubleshooting Procedure Table Step Action and Questions 1 Check the media specifications (page 1-7). Does the selected paper meet specifications? Clean the ADF Pick Roller (page 7-9). Does the problem persist? Replace the ADF Unit (page 8-11). Yes Go to Step 2. No Reload the printer with the proper media and go to Step 2. Complete.
2 3
Go to Step 3. Complete
4-9
Misfeed at the Document Transport Section

For detection of misfeed at the document transport section, the Paper Leading Edge detection Sensor is not blocked even after the lapse of a predetermined period of time after the paper feed sensor has been unblocked. For detection of paper left at the document transport section, the Paper Feed Sensor is unblocked and the paper leading edge detection sensor is blocked when the power switch is turned ON, the cover is opened and closed, or a misfeed or malfunction is reset.
ADF Unit, PL1.1.1
2 3
4-10
Misfeed at the Document Exit Section

For detection of misfeed at the document exit section, the Paper Leading Edge Detection Sensor is not unblocked even after the lapse of a predetermined period of time after the Paper Feed Sensor has been unblocked. For detection of paper left at the document exit section, the Paper Leading Edge Detection Sensor is blocked when the power switch is turned ON, the cover is opened and closed, or a misfeed or malfunction is reset.
ADF Unit, PL1.1.1
2 3
4-11
Lower Feeder Unit Troubleshooting

Misfeed at Tray 2 Paper Feed Section
For detection of misfeed at tray 2 paper feed section, the leading edge of the paper does not block the Registration Sensor, even after the lapse of a predetermined period of time after the Paper Pick-up Solenoid has been energized.
Troubleshooting Reference Table Applicable Parts Registration Sensor, PL4.17.2 Paper Pick-up Solenoid, PL5.2.16 Engine Control Board, PL4.19.15
Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14). Engine Control Board to Solenoid and Sensor Wiring (page 10-13) Engine Control Board to Duplex Unit and Feeder Wiring (page 10-19)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Engine Control Board connector P/J22. Is the connector seated properly? Yes Go to Step 2. No Reseat the connector. If the problem persists, go to Step 2. Replace the sensor (page 8-116). Replace the solenoid (page 8-131).
Check the Registration Sensor at P/J12 (Pin 3). Is the sensor operational? Check the Paper Pick-up Solenoid at connector P/J22 (Pin 4). Is the solenoid operational? Replace the Engine Control Board (page 8-57).
Go to Step 3.
Go to Step 4.
Complete
4-12
Duplexer Troubleshooting
Misfeed at Duplex Option Reverse Drive/Storage Section
For detection of misfeed at the duplex option reverse drive/storage section, the Transport Sensor is not unblocked even after the lapse of a predetermined period of time when the Reverse Motor has been energized for reverse drive.
Troubleshooting Reference Table Applicable Parts Transport Motor, PL6.1.6 Reverse Motor, PL6.1.6 Duplex Option Replacement, PL6.1.27 Engine Control Board, PL4.19.15

Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14). Engine Control Board to Duplex Unit and Feeder Wiring (page 10-19)
Troubleshooting Procedures Table Step Action and Questions 1 Check the Transport Motor at connector P/J2 (Pin 1 - 4). Is the motor operational? Yes Go to Step 3. No Replace the motor (page 8-145). Replace the motor (page 8-146). Go to Step 4.
Check the Reverse Motor at connector P/ Go to Step 3. J2 (Pin 5 - 8). Is the motor operational? Replace the Duplex Option (page 8-134). Does the problem persist? Replace the Engine Control Board (page 8-57). Complete Complete
3 4
4-13
Misfeed at Duplex Option Paper Feed Section

For the detection of a misfeed at the Duplex Option paper feed section, the Fusing Paper Loop Sensor is not unblocked even after the lapse of a predetermined period of time after a duplex paper feed sequence has been started. Another indication could be that the Fusing Paper Loop Sensor is not blocked even after the lapse of a predetermined period of time after a duplex paper feed sequence has been started. In some cases, the Transport Sensor is not blocked even after the lapse of a predetermined period of time after a duplex paper feed sequence has been started.
Troubleshooting Reference Table Applicable Parts Transport Motor, PL6.1.6 Fusing Paper Loop Sensor, PL4.17.2 Duplex Option Replacement, PL6.1.27 Engine Control Board, PL4.19.15

Wiring and Plug/Jack References Boards and Power Supplies Locator (page 1-14). Engine Control Board to Duplex Unit and Feeder Wiring (page 10-19) Engine Control Board to Solenoid and Sensor Wiring (page 10-13)
Troubleshooting Procedure Table Step Action and Questions 1 Check the Transport Motor at connector CN7B (Pins 3and 4). Is the motor providing a pulse output? Check the Fusing Paper Loop Sensor connector CN7B (Pin 5). Is the sensor operational? Replace the Duplex Option (page 8-134). Does the problem persist? Replace the Engine Control Board (page 8-57). Yes Go to Step 2. No Replace the motor (page 8-145). Go to Step 4.
Go to Step 3.
3 4
Go to Step 4 Complete.
Complete
4-14
Print-Quality Troubleshooting
In this chapter...

Print-Quality Problems Overview Print Quality Troubleshooting Summary Scanner System Image Processing System Fusing System
Chapter
Print-Quality Problems Overview

Print-quality defects can be attributed to printer components, consumables, media, internal software, external software applications, and environmental conditions. To successfully troubleshoot print-quality problems, eliminate as many variables as possible. The first step is to generate prints using printable pages embedded in the printer on laser paper from the supported media list. Use paper from a fresh ream that is acclimated to room temperature and humidity. See Product Specifications on page 1-6 or the Paper Tips page for media that has been tested and approved for use in Phaser 6115 printers. If the print-quality defect is still present when printing on approved media from an unopened ream, then investigate software applications and environmental conditions. Note There is a Control Panel command which obtains environmental temperature and humidity levels. However, this command is for internal use only and not available from the service menus. Phaser 6115 printers use separate Developer Assemblies to develop a latent image for each color on the Imaging Unit where the colors are combined to form the final image. In most cases, print-quality defects are the result of one particular component in the print engine. When analyzing a print-quality defect, first determine if the defect occurs in all colors or only one color and if it is repeating or random. Continuous defects in the process direction, such as voids and lines, are the most difficult to diagnose. Inspect the visible surfaces of all rollers for obvious defects. If no defects are observed, replace the Imaging Unit, Developer Assembly, Transfer Roller, and Fusing Unit one at a time until the defect is eliminated.
5-2
Defects Associated with Specific Printer Components

Some print-quality problems can be associated with specific assemblies. The most common problems and associated assemblies are listed below. Refer to the specific print-quality troubleshooting procedure for more information.
Developer Assembly

Blank Prints Light Prints Uneven Density Voids (White spots) Streaks (Dark/ light) Repeating Defects
Imaging Unit

Streaks Ghosting Fine Lines Banding in Process Direction Uneven Density Voids Repeating Defects
Note See Cleaning the Imaging Unit on page 7-3 for instructions on how to clean the Imaging Unit rollers.
Transfer Roller

Toner on the back side of the printed page (simplex mode) Light Prints Repeating Defects
Fusing Unit

Hot or Cold Offsetting Repeating Defects
5-3
Repeating Defects Maintenance Item Developer Assembles Imaging Unit Component Magnetic (Mag) Roller [YMCK] Drum Charge (RTC) Rollers OPC Drum Rollers IDT Rollers Transfer Roller Fusing Unit Transfer Roller Heat Roller Belt Distance between Defects 34 mm (1.34 in.) 31 mm (1.22 in.) 74 mm (2.91 in.) 132 mm (5.20 in.) 64 mm (2.52 in.) 83 mm (3.26 in.) 94 mm (3.70 in.)
5-4
Print Quality Troubleshooting Summary

The following table provides a list of possible print quality problems and lists pages for more information. Print Quality Summary Print Quality Problem Scanner System Blank Copy or Black Copy Low Image Density or Rough Image Foggy Background Black Streaks or Bands Black Spots White Streaks or Bands Uneven Pitch Image Processing System White or Colored Lines and Bands in Feed Direction White or Colored Lines and Bands in Scan Direction Uneven Density in the Feed Direction Uneven Density in The Scan Direction Low Image Density Gradation Reproduction Failure Foggy Background Poor Color Reproduction Void Areas and White Spots Colored Spots Blurred Image Black or Blank Copy Incorrect Color Image Registration Fusing Unit Poor Fusing Performance or Offset Brush Effect or Blurred Image Back Marking Uneven Pitch 5-34 5-35 5-36 5-37 5-16 5-17 5-19 5-20 5-22 5-23 5-24 5-26 5-27 5-28 5-30 5-31 5-32 5-6 5-7 5-9 5-10 5-11 5-13 5-14
Go to Page
5-5
Automatic Document Feeder (ADF) Print Quality Problems

The source of print quality problems from the Automatic Document Feeder (ADF) Unit generally come from two sources: 1. Skewing when copying from the ADF. If skewing occurs when using the ADF, try using the platen and repeat the copy. If the image is fine from the platen, but skews from the ADF itself, perform the skew adjustment. See Leading Edge Skew Adjustment on page 53. If this adjustment does not resolve the issue then replace the ADF Unit (page 8-11). 2. Banding defects that occur as a result of uneven feeding motion. In this condition, the original page will pause every so often at uneven intervals. This causes a banding pattern on the output copy. In this case, clean the feed rollers and validate the thickness of the original document. Any media out of specification should be copied from the document glass. If cleaning does not solve the problem, then replace the ADF Unit (page 8-11.
Scanner System
Blank Copy or Black Copy
The printed copies are either blank or solid black.
Initial Actions

Verify the media used is supported by this printer. Verify the media settings are correct at the Control Panel.

Scanner Unit, PL3.1.1
Example Print
Blank Print
Black Print
5-6
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with Scanner Unit, it is a problem within the print image system. Go to page 5-31 to continue troubleshooting the image print image process. Go to Step 3. No The problem is associated with the scanner system. Go to Step 2.
Open the ADF and visually inspect the scanner exposure lamp. Is the exposure lamp on? Reseat all connectors and cables between the scanner and image processing board, and then make another copy. Does the defect still occur? Does the Control Panel display any text? Reseat all connectors and cables between DC Power Supply 2 and the Image Processor Board, and then recheck the expopsure lamp. Is the exposure lamp on?
Problem could be related to the DC Power Supply 2. Go to Step 4 Complete.
Replace the Scanner Unit (page 8-25).
Go to Step 5.
Replace the Image Processing Board (page 8-55). Replace the DC Power Supply 2 (page 8-68).
Complete.
Low Image Density or Rough Image

The overall image density is too light.
Initial Actions

5-7
Example Print
Chrysanthemum x morifolium
Light or Undertone Print
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with the Scanner Unit, it is a problem within the print image system. Go to page 5-22 to continue troubleshooting the image print image process. 2 Increase the copy darkness Go to Step 3. level using the control panel adjustment, and then make another copy. Does the defect still occur? Reseat all connectors and Replace the Scanner cables between the Scanner Unit (page 8-25). Unit and the Image Processor Board, and then make another copy. Does the defect still occur? Complete. No The problem is associated with the scanner system. Go to Step 2.
Complete.
5-8
Foggy Background
The background image is either distorted or foggy.
Initial Actions

Example Print
Background Contamination
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with the Scanner Unit, it is a problem within the print image system. Go to page 5-24 to continue troubleshooting the print image process. No The problem is associated with the scanner system. Go to Step 2.
5-9
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 2 Yes No Complete.
This defect often occurs Go to Step 3. when copying books or other material that prevents the ADF from fully closing. If the ADF does not fully close, external light can be collected by the scanhead and produce background on output. Open and Close the ADF and verify it closes completely. Does the defect still occur? Reseat all connectors and cables between the Scanner Unit and the Image Processor Board, and then make another copy. Does the defect still occur? Replace the Scanner Unit (page 8-25).
Complete.
Black Streaks or Bands

Initial Actions

Example Print
Vertical Stripes
5-10
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with Scanner Unit, it is a problem within the print image system. Go to page 5-28 to continue troubleshooting the image print image process. 2 This defect often occurs Go to Step 3. when foreign material (i.e. paper dust, toner or other material) deposits on the document glass or CVT window. The scanhead will detect the foreign material while scanning, and the defect will appear as streaks or spots on the copy output. Thoroughly clean both the document glass and CVT window. Does the defect still occur? Reseat all connectors and cables between the scanner and image processing board, and then make another copy. Does the defect still occur? Replace the Scanner Unit (page 8-25). Complete. No Go to Step 2.
Complete.
Black Spots
The background image of all copies includes black spots.
Initial Actions

5-11
Example Print
Random Spots
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with Scanner Unit, it is a problem within the print image system. Go to page 5-28 to continue troubleshooting the image print image process. 2 This defect often occurs when foreign material (i.e. paper dust, toner or other material) deposits on the document glass or CVT window. The scanhead will detect the foreign material while scanning, and the defect will appear as streaks or spots on the copy output. Thoroughly clean both the document glass and CVT window. Does the defect still occur? Print out new original. If problem persists, go to Step 3. Complete. No The problem is associated with the scanner system. Go to Step 2.
5-12
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 3 Yes No Complete.
Reseat all connectors and Replace the Scanner cables between the Scanner Unit (page 8-25). Unit and the Image Processor Board, and then make another copy. Does the defect still occur?
White Streaks or Bands

The copy includes white streaks or bands.
Initial Actions


Example Print
Random Light Stripes
Vertical Blank Lines
5-13
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with Scanner Unit, it is a problem within the print image system. Got to page 5-17 to continue troubleshooting the image print image process. 2 This defect often occurs Go to Step 3. when foreign material (i.e. paper dust, toner or other material) deposits on the document glass or CVT window. The scanhead will detect the foreign material while scanning, and the defect will appear as streaks or spots on copy output. Thoroughly clean both the document glass and CVT window. Does the defect still occur? Reseat all connectors and Replace the Scanner cables between the Scanner Unit (page 8-25). Unit and the Image Processor Board, and then make another copy. Does the defect still occur? Complete. No The problem is associated with the scanner system. Go to Step 2.
Complete.
Uneven Pitch
The print on the copy is on an uneven skew from the original.
Initial Actions

5-14
Example Print

Light band
Uneven fill Should see even fill left to right

TP6 Grey Fill
Troubleshooting Procedure Table Step Actions and Questions 1 Execute a print job sent from a computer. Does the defect occur on the printed output? Yes The problem is not with Scanner Unit, it is a problem within the print image system. Got to page 5-37 to continue troubleshooting the image print image process. No The problem is associated with the scanner system. Go to Step 2.
This defect often occurs Go to Step 3. when copying with the ADF partially closed. The ADF will not evenly press the original document against the Document Glass or CVT Window. Uneven pressure will allow segments of the page to slightly lift off the glass surface, and the scanhead will detect different density levels. Open and Close the ADF and verify it closes completely. Does the defect still occur?
Complete.
5-15
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 3 Reseat all connectors and cables between the scanner and image processing board, and then make another copy. Does the defect still occur? Yes Replace the Scanner Unit (page 8-25). No Complete.
Image Processing System

White or Colored Lines and Bands in Feed Direction
Vertical lines or bands in the copy indicate problems in the feed direction.
Initial Actions


Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Fusing Unit, PL4.18.12 Laser Unit, PL4.14.1
Example Print
Vertical Blank Lines
Vertical Stripes
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Are there scratches on the photo conductor surface? Yes Replace the Imaging Unit (page 8-13). No Go to Step 2.
Is the outside of the surface Carefully clean the dirty? surface. If the problem persists, go to Step 3.
Go to Step 3.
5-16
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 3 Is the developing bias contact terminal of the Toner Cartridge in good contact? Check the connectors and terminal contacts of the Laser Unit. Are the connectors, window surface, and contact terminals connected properly? Check the Transfer Belt Unit. Is the transfer belt dirty or scratched? Yes Go to Step 4. No Clean the contact terminal.
Go to Step 5.
Reseat the connectors and clean the terminal contacts. If the problem persists, go to Step 5.
If the surface is dirty, wipe the surface clean with a soft cloth. If the transfer belt is scratched, replace the unit (page 8-33). Replace the roller (page 8-86). If the problem persists, go to Step 7. Remove the object and reprint the test sheet. If the problem persists, go to Step 8. Clean the guide plate and reprint the test sheet. If the problem persists, replace the Fusing Unit (page 8-36) and go to Step 9. Complete
Go to Step 6.
Is the Transfer Roller scratched?
Go to Step 7.
Check the paper path. Is there a foreign object or obstruction in the path? Inspect the Fusing Unit. Is the fusing entrance guide plate or the separation claw dirty or scratched?
Go to Step 8.
Go to Step 9.
Has the problem been eliminated?
Replace the toner cartridge (page 7-11) and the Laser Unit (page 8-15).
White or Colored Lines and Bands in Scan Direction

Horizontal lines or bands in the copy indicate problems in the scan direction.
Initial Actions

5-17

Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Transfer Roller, PL4.16.3 Fusing Unit, PL4.18.12 Laser Unit, PL4.14.1
Example Print
Horizontal Band, Void, or Streaks
Horizontal Stripes
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Are there scratches on the photo conductor surface? Yes Replace the Imaging Unit. No Go to Step 2.
Is the outside of the surface Carefully clean the dirty? surface. If the problem persists, go to Step 3. Is the developing bias contact terminal of the Toner Cartridge in good contact? Check the connectors and terminal contacts of the Laser Unit. Are the connectors and contact terminals connected properly? Check the Transfer Belt Unit. Is the transfer belt dirty or scratched? Go to Step 4.
Go to Step 3.
Clean the contact terminal.
Go to Step 5.
Reseat the connectors and clean the terminal contacts. If the problem persists, go to Step 5. Go to Step 6.
If the surface is dirty, wipe the surface clean with a soft cloth. If the transfer belt is scratched, replace the unit. Replace the roller (page 8-84). If the problem persists, go to Step 7.
Go to Step 7.
5-18
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 7 Check the paper path. Is there a foreign object or obstruction in the path? Inspect the Fusing Unit. Is the fusing entrance guide plate or the separation claw dirty or scratched? Yes Remove the object and reprint the test sheet. If the problem persists, go to Step 8. Clean the guide plate and reprint the test sheet. If the problem persists, replace the Fusing Unit (page 8-36) and go to Step 9. Complete No Go to Step 8.
Go to Step 9.
Uneven Density in the Feed Direction

The density of the print along the length of the copy is inconsistent.
Initial Actions

Troubleshooting Reference Table Applicable Parts Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 High Voltage Unit, PL4.19.6 Laser Unit, PL4.14.1 Toner Cartridge (See consumables parts list)

Example Print
Color Uneven or Wrong (Scan Direction)
5-19
Troubleshooting Procedure Table Step Actions and Questions 1 Yes No Go to Step 2.
Inspect the Imaging Unit. Carefully clean the Is the outside of the surface surface. If problem dirty? persists, go to Step 2. Are there scratches on the photo conductor? Is the window surface dirty on the laser? Check the Transfer Belt Unit. Is the transfer belt dirty or scratched? Is the Transfer Roller scratched? Replace the Imaging Unit (page 8-13). Carefully clean the surface. If problem persists, go to Step 4. Clean the unit with a soft cloth. If the belt is scratched, replace the Transfer Belt Unit (page 8-33). Replace the roller (page 8-86). If the problem persists, go to Step 6. Complete
2 3
Go to Step 3. Go to Step 4.
Go to Step 5.
Go to Step 6.
Replace the following units, listed in order, until problem is eliminated: Toner Cartridge (page 7-11) Laser Unit (page 8-15) High Voltage Unit (page 8-50)
Uneven Density in The Scan Direction

The density of the print along the width of the copy is inconsistent.
Initial Actions

5-20
Troubleshooting Reference Table Applicable Parts Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Transfer Roller, PL4.16.3 High Voltage Unit, PL4.19.6 Toner Cartridge (See consumables parts list)

Example Print
Color Uneven or Wrong (Process Direction)
Troubleshooting Procedure Table Step Actions and Questions 1 Yes No Go to Step 2.
Inspect the Imaging Unit. Carefully clean the Is the outside of the surface surface. If problem dirty? persists, go to Step 2. Are there scratches on the photo conductor? Replace the Imaging Unit (page 8-13).
2 3
Go to Step 3. Reseat and align properly.
Check the Transfer Belt Go to Step 4 Unit. Are the mounting shafts on the assembly fully seated and installed Does the Transfer Belt Unit Clean the unit with a have fingerprints, dirt, or oil soft cloth. If the belt is on it? scratched, replace the Transfer Belt Unit (page 8-33) and go to Step 5. Has the problem been eliminated? Complete
Go to Step 5.
Replace the following units, listed in order, until problem is eliminated: Toner Cartridge (page 7-11) High Voltage Unit (page 8-50)
5-21
Low Image Density

Initial Actions


Example Print
Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Transfer Roller, PL4.16.3 High Voltage Unit, PL4.19.6 Laser Unit, PL4.14.1
Light or Undertone Print
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Is the outside of the unit dirty? Inspect the laser window. Is the outside of the surface dirty? Yes Clean the unit. If the problem persists, go to Step 2 Carefully clean the surfaces. If the problem persists, go to Step 3. No Go to Step 2.
Go to Step 3.
Check the Transfer Belt Go to Step 4 Unit. Are the mounting shafts on the assembly fully seated and installed Is the Transfer Belt Unit dirty or scratched? Clean the unit with a soft cloth. If the belt is scratched, replace the Transfer Belt Unit (page 8-33).
Reseat and align properly. If the problem persists, go to Step 4. Go to Step 5.
5-22
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 5 Is the Transfer Roller scratched? Yes Replace the roller (page 8-86). If the problem persists, go to Step 6. Complete No Go to Step 6.
Replace the following units, listed in order, until the problem is eliminated: Transfer Belt Unit (page 8-33) Transfer Roller (page 8-86) Laser Unit (page 8-15) High Voltage Unit (page 8-50)
Gradation Reproduction Failure

The overall image becomes less and less clear with each copy.
Initial Actions


Laser Unit, PL4.14.1 Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 High Voltage Unit, PL4.19.6 Toner Cartridge (See consumables parts list)
Example Print
s6115-241
s6115-242
5-23
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Is the outside of the unit dirty? Yes No
Clean the unit. If Go to Step 2. problem persists, go to Step 2
Inspect the laser window. Carefully clean the Go to Step 3. Is the outside of the surface surfaces. If the dirty? problem persists, go to Step 3. Check the Transfer Belt Unit. Is the transfer belt dirty or scratched? Has the problem been eliminated? Clean the unit with a soft cloth. If the transfer belt is scratched, replace the unit (page 8-33). Complete Go to Step 3.
Replace the following units, listed in order, until problem is eliminated: Toner Cartridge (page 7-11) Laser Unit (page 8-15) High Voltage Unit (page 8-50)
Foggy Background
Background image of copy is distorted or foggy.
Initial Actions

5-24

Toner Cartridge (See consumables parts list) Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Laser Unit, PL4.14.1
Example Print
Background Contamination
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Are there scratches on the photo conductor surface? Yes Replace the Imaging Unit (page 8-13). No Go to Step 2.
Is the outside of the surface Carefully clean the dirty? surface. If the problem persists, go to Step 3. Is the developing bias contact terminal of the Toner Cartridge in good contact? Check the connectors and terminal contacts of the Laser Unit. Are the connectors, window surface, and contact terminals connected properly? Has the problem been eliminated? Go to Step 4.
Go to Step 3.
Clean the contact terminal.
Go to Step 5.
Reseat the connectors and clean the terminal contacts. If the problem persists, go to Step 5.
Complete
Replace the following units, listed in order, until problem is eliminated: Laser Unit (page 8-15) Toner Cartridge (page 7-11) Transfer belt Unit (page 8-33)
5-25
Poor Color Reproduction

The colors in the copy is not a good reproduction of the original.
Initial Actions


Transfer Belt Unit, PL4.15.5 Engine Control Board, PL4.19.15 High Voltage Unit, PL4.19.6
Example Print
Unexpected Colors
Troubleshooting Procedure Table Step Actions and Questions 1 2 Check the media. Is the paper damp? Inspect the Transfer Belt Unit. Is the terminal dirty? Has the problem been eliminated? Yes Replace with new, unwrapped paper. Clean the contacts. If the problem persists, go to Step 3. Complete No Go to Step 2. Go to Step 3.
Replace the following units, listed in order, until problem is eliminated: Transfer Belt Unit (page 8-33) Engine Control Board (page 8-57) High Voltage Unit (page 8-50)
5-26
Void Areas and White Spots

Missing spots or areas on the copy.
Initial Actions


Imaging Unit, PL4.15.9 Toner Cartridge (See consumables parts list) Transfer Belt Unit, PL4.15.5 Fusing Unit, PL4.18.12
Example Print
Partial Band
Repeating Defects
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Imaging Unit. Is the outside of the surface dirty? Are there scratches on the photo conductor surface? Yes Clean the surface. If the problem persists, go to Step 2. Replace the Imaging Unit. No Go to Step 2.
2 3
Go to Step 3. Reseat and align properly. If the problem persists, go to Step 4. Go to Step 5.
Check the Transfer Belt Go to Step 4. Unit. Are the mounting shafts on the assembly fully seated and installed Is the transfer belt dirty or scratched? If the surface is dirty, wipe the surface clean with a soft cloth. If the transfer belt is scratched, replace the unit (page 8-33).
5-27
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 5 Is the Transfer Roller scratched? Yes Replace the roller (page 8-86). If the problem persists, go to Step 6. Remove the object and reprint the test sheet. If the problem persists, go to Step 7. Close the green nip release levers and go to Step 8. Complete No Go to Step 6.
Check the paper path. Is there a foreign object or obstruction in the path? Inspect the Fusing Unit. Are the green nip release levers in the closed position? Has the problem been eliminated?
Go to Step 7.
Go to Step 8.
Colored Spots
Random colored spots on copies.
Initial Actions

Troubleshooting Reference Table Applicable Parts Imaging Unit, PL4.15.9 Toner Cartridge (see Consumables Parts List) Transfer Belt Unit, PL4.15.5 Fusing Unit, PL4.18.12

Example Print
White Portion is Colored
5-28
Troubleshooting Procedure Table Step Actions and Questions 1 Does the paper size loaded in the tray match the selected paper size? Inspect the Imaging Unit. Are the spots in a single color? Is there dirt or scratches on the photo conductor surface? Yes Go to Step 2. No Correct the paper size mismatch. If problem persists, go to Step 2. Go to Step 3.
Replace the Imaging Unit (page 8-13). If the problem persists, go to Step 3.
If there is dirt on the Go to Step 4. surface, carefully clean the surface. If there are scratches, replace the Imaging Unit (page 7-11). If the problem persists, go to Step 4. If the surface is dirty, wipe the surface clean with a soft cloth. If the belt is scratched, replace the Transfer Belt Unit (page 8-33) then go to Step 5. Replace the roller (page 8-84). If the problem persists, go to Step 6. Remove the object and reprint the test sheet. If the problem persists, go to Step 7. Replace the Fusing Unit (page 8-36). If the problem persists, go to Step 8. Complete Go to Step 5.
Check the Transfer Belt Unit. Is the Transfer Belt dirty or scratched?
Go to Step 6.
Check the paper path. Is there a foreign object or obstruction in the path? Inspect the Fusing Unit. Is the Fuser Roller dirty or scratched? Has the problem been eliminated?
Go to Step 7.
Go to Step 8.
Replace the problem toner cartridge (page 7-11).
5-29
Blurred Image
The overall image density is blurry.
Initial Actions

Troubleshooting Reference Table Applicable Parts Laser Unit, PL4.14.1 Imaging Unit, PL4.15.9 Toner Cartridge (See consumables parts list)

Example Print
nthemum nthemum xx
Chrysanthemum x morifolium nthemum

Fuzzy Text
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the Laser Unit. Is the window surface dirty? Yes Carefully clean the window surface. If the problem persists, go to Step 2. No Go to Step 2.
Inspect the Imaging Unit. Clean the surface. If Is the outside of the surface the problem persists, dirty? go to Step 3. Has the problem been eliminated? Complete
Go to Step 3.
Replace the following units, listed in order, until problem is eliminated: Toner Cartridge (page 7-11) Laser Unit (page 8-15) Imaging Unit (page 8-13)
5-30
Black or Blank Copy

Black or blank copy due to a faulty image reproduction system.
Initial Actions


Engine Control Board, PL4.19.15 Imaging Unit, PL4.15.9 Laser Unit, PL4.14.1 High Voltage Unit, PL4.19.6
Example Print
Blank Print
Black Print
Troubleshooting Procedure Table Step Actions and Questions 1 Check the image. Does a blank print occur? Yes Check the connectors to the Laser Unit. If seated properly, go to Step 2. No If the image is black, go to Step 2.
Inspect the Imaging Unit. Is Go to Step 3. the gear of the Imaging Unit drive mechanism installed properly? Is the charge corona voltage contact or photoconductor ground contact of the Imaging Unit connected properly? Are connectors and cables securely connected to the High Voltage Unit? Go to Step 4.
Check or correct the drive transmitting section. If the problem persists, go to Step 3. Check, clean, or correct the contact. If the problem persists, go to Step 4. Reseat the connectors. If the problem persists, go to Step 5.
Go to Step 5.
5-31
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 5 Has the problem been eliminated? Yes Complete No Replace the following units, listed in order, until problem is eliminated: Imaging Unit (page 8-13) Engine Control Board (page 8-57) Laser Unit (page 8-15) High Voltage Unit (page 8-50)
Incorrect Color Image Registration

The composite color image may be misaligned or present an incorrect color scheme.
Initial Actions


Example Print
Transfer Belt Unit, PL4.15.5 Imaging Unit, PL4.15.9 Transfer Roller, PL4.16.3 Laser Unit, PL4.14.1
Color Registration
5-32
Troubleshooting Procedure Table Step Actions and Questions 1 Check the Transfer Belt Unit. Is the transfer belt dirty or scratched? Yes If the surface is dirty, wipe the surface clean with a soft cloth. If the transfer belt is scratched, replace the Transfer Belt Unit (page 8-33). Clean. If the problem persists, go to Step 3. No Go to Step 2.
2 3
Is the drive coupling to the machine dirty? Is the Transfer Roller scratched?
Go to Step 3.
Replace the roller Go to Step 4. (page 8-86). If the problem persists, go to Step 4. If there is dirt on the Reinstall the Imaging drum, carefully clean Unit. If problem the surface. If there are persists, go to Step 5. scratches, replace the unit (page 8-13). If the problem persists, go to Step 5 Complete Replace the following units, listed in order, until problem is eliminated: Engine Control Board (page 8-57) Laser Unit (page 8-15)
Inspect the Imaging Unit. Is the unit installed in the proper position?
5-33
Fusing System
Poor Fusing Performance or Offset
The fusing process or offset is incorrect.
Initial Actions


Engine Control Board, PL4.19.15 Fusing Unit, PL4.18.12
Example Print
Incomplete Transfer Residual Image/Ghosting
Troubleshooting Procedure Table Step Actions and Questions 1 Check the media. Does the media conform to the specifications of the printer? Inspect the Fusing Unit. Are the green fuser separator levers in the correct position? Yes Go to Step 2. No Replace the paper. If the problem persists, go to Step 2. Close the levers. If the problem persists, go to Step 3.
Clean the original glass and reprint the test sheet. Then, go to Step 3.
5-34
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 3 Has the problem been eliminated? Yes Complete No Replace the following units, listed in order, until problem is eliminated: Engine Control Board (page 8-57) Fusing Unit (page 8-36)
Brush Effect or Blurred Image

The image on the copy appears blurry or smeared.
Initial Actions


Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Fusing Unit, PL4.18.12
Example Print
nthemum nthemum xx
Chrysanthemum x morifolium nthemum

Ink Smears Duplex Fuzzy Text
Troubleshooting Procedure Table Step Actions and Questions 1 Check the media. Is the paper damp or the incorrect media for the printer? Yes Replace with paper that meets the specifications for the printer. If the problem persists, go to Step 2. No Go to Step 2.
5-35
Print-Quality Troubleshooting Troubleshooting Procedure Table (Continued) Step Actions and Questions 2 Inspect the Imaging Unit. Are there scratches on the photo-conductor surface? Check the Transfer Belt Unit. Is the transfer belt dirty with oil or fingerprints, or scratched? Yes Replace the Imaging Unit. If the problem persists, go to Step 3. If the surface is dirty, wipe the surface clean with a soft cloth. If the belt is scratched, replace the Transfer Belt Unit (page 8-33). If the problem persists, go to Step 4. Clean the guide plate. If the problem persists, replace the Fusing Unit (page 8-36). No Go to Step 3.
Go to Step 4.
Inspect the Fusing Unit. Is the fusing entrance guide plate dirty or scratched?
Back Marking
The copy includes markings on the backside of the image.
Initial Actions


Example Print
Transfer Belt Unit, PL4.15.5 Transfer Roller, PL4.16.3 Fusing Unit, PL4.18.12 High Voltage Unit, PL4.19.6
Toner on Back of Print
5-36
Troubleshooting Procedure Table Step Actions and Questions 1 Check the media. Is there a foreign object in the paper path? Inspect the Fusing Unit. Is the fusing entrance guide plate dirty, or is the Fusing Roller scratched? Check the Transfer Belt Unit. Is the unit dirty? Yes Remove the obstruction. If the problem persists, go to Step 2. Replace the Fusing Unit. If the problem persists (page 8-36), then go to Step 3. Clean the surfaces with a clean soft cloth. If the problem persists, go to Step 4. If the roller is dirty, clean the surfaces with a clean soft cloth. If the roller is scratched, replace the Transfer Roller (page 8-86). If the problem persists, go to Step 5. Complete No Go to Step 2.
Go to Step 3.
Go to Step 4.
Check the Transfer Roller. Is the roller dirty or scratched?
Go to Step 5.
Replace the following units, listed in order, until problem is eliminated: Transfer Belt Unit (page 8-33) Fusing Unit (page 8-36) High Voltage Unit (page 8-50)
Uneven Pitch
The pitch along the scan direction is uneven or inconsistent.
Initial Actions

5-37

Toner Cartridge (see Consumables Parts List) Imaging Unit, PL4.15.9 Transfer Belt Unit, PL4.15.5 Transfer Roller, PL4.16.3 Fusing Unit, PL4.18.12
Example Print
Light band
Uneven fill Should see even fill left to right

TP6 Grey Fill
Troubleshooting Procedure Table Step Actions and Questions 1 Inspect the toner cartridge. Is the drive mechanism clean? Are the cartridges for each color in place? Inspect the Laser Unit. Is the unit secured in position with the fixing screw? Inspect the Imaging Unit. Is the photo-conductor surface dirty or scratched? Yes Go to Step 2. No Clean the mechanism and reinstall the cartridge. If the problem persists, go to Step 2. Secure it in position. If the problem persists, go to Step 3. Go to Step 4.
Go to Step 3.
Replace the Imaging Unit (page 8-13). If the problem persists, go to Step 4.
Check the Transfer Roller. Replace the Transfer Is the roller dirty, deformed, Roller (page 8-86). If or worn? the problem persists, go to Step 5. Inspect the Fusing Unit. Are the rollers and drive mechanism dirty, scratched, or worn? Has the problem been eliminated? Replace the Fusing Unit (page 8-36). If problem persists, then go to Step 6. Complete
Go to Step 5.
Go to Step 6.
Replace the following units, listed in order, until problem is eliminated: Toner Cartridge (page 7-11) Transfer Belt Unit (page 8-33)
5-38
Adjustments and Print Function Settings

In this chapter...

Adjust Function Procedures Service Mode Functions Maintenance Mode Functions
Chapter
Adjust Function Procedures

Using the Adjust Functions
The Adjustment Setting section contains detailed information on the adjustment items and procedures for this machine. Throughout this Adjustment/Setting, the default settings are indicated by . 1. Advance Checks Note Before attempting to solve the customer problem, the following advance checks must be made:
The power supply voltage meets the specifications. The power supply is properly grounded. The installation site is environmentally appropriate: high temperature, high humidity, direct sunlight, ventilation, etc.; levelness of the installation site. The original has a problem that may cause a defective image. The density is properly selected. The original glass, slit glass, or related part is dirty. Correct paper is being used for printing. The units, parts, and supplies used for printing (developer, PC Drum, etc.) are properly replenished. Toner is not running out.
2. Precautions for Service Jobs
Unplug the power cord of the machine before starting the service job procedures. If it is unavoidably necessary to service the machine with its power turned ON, use utmost care not to be caught in the Scanner Cables or gears of the exposure unit. Special care should be used when handling the Fusing Unit which can be extremely hot. The Developing Unit has a strong magnetic field. Keep watches and measuring instruments away from it. Take care not to damage the PC Drum with a tool or similar device. Do not touch IC pins with bare hands.
6-2
Service Mode Functions

Service Mode Entry Procedure
Caution Ensure appropriate security for the Service Mode entry procedure. It should NEVER be given to any unauthorized person.
Procedure:
1. On the initial screen, press the Menu/Select key to call [MACHINE SETUP] to the screen. 2. Press the following keys in this order. Stop00Stop01 The window will display the following: SERVICE MODE 1. System default 3. Press the down key to locate all command lines in the function tree (page 6-4). 4. Once you find the desired function, press the Menu/Select again to enter the subcommands. 5. Press the down arrow from the subcommand level to locate the desired subfunction. Pressing the Menu/Select key at this level will execute the selected command. Note Pressing the Cancel key at any level will bring you up to the previous command level.
Exiting:
1. Press the Stop key to exit.
6-3
Service Mode Function Tree

The function tree complies with the following format displayed on the screen (2 pages).
Service Mode 1 System Default Send Speed Receive Speed Send Level Receive Level DTMF Level CNG Level CED Level ECM Mode Coding Scheme TNR Empty Rep Protocol Report GDI Time-Out Energy Save Mode 2 Adjustment PRN Main Regist PRN Sub Regist CCD Main Zoom CCD Sub Zoom CCD Main Regis CCD Sub Regis ADF Sub Zoom ADF Main Regist ADF Sub Regist DMAX 1st Trans. Vol. 2nd Trans. Vol. VPP Offset ROHS Flicker Special 3 Counter Total Print Total Scan Printer Jam ADF Jam Trouble
s6115-355
6-4
4 Configuration
Main F/W Ver. Engine F/W Ver. NC F/W Version Main RAM Size BB CPLD Version NAND Code Version
5 Function Test
Paper Feed Test Print Test Pattern ADF Feed Test Copy ADF Glass Area Park Scan Head FAX Reg Copy Test Scan Test
6 Soft Switch (Internal Only) 7 Report Service Data Test Error Code List Protocol List 8 Fixed Zoom Change 9 Factory Test Signal Test Relay Test Sensor Test Dial Test Volume Test Panel Buzzer Test RAM Test 10 Clear Data SRAM Clear Memory Clear
s6115-542
6-5
1 System Default
Send Speed
Function:
Sets the transmit start speed.
Settings:
Choose the mode from among the following.

V.34: 33600 (default), 31200, 28800, 26400, 24000, 21600, 19200, 16800 V.17: 14400, 12000, 9600, 7200 V.29: 9600, 7200 V.27: 4800, 2400
Receive Speed
Function:
Sets the reception start speed.
Settings:

V.34: 33600 (default), 31200, 28800, 26400, 24000, 21600, 19200, 16800 V.17: 14400, 12000, 9600, 7200 V.29: 9600, 7200 V.27: 4800, 2400
Send Level
Function:
PSK/FSK signal output level.
Setting:
-17 to -10 dBm, -9 dBm (default), or -8 to -2 dBm
Receive Level
Function Reception sensitivity level. 6-6 Phaser 6115MFP Multifunction Product Service Manual
Setting:
DTMF Level
Function:
Dual tone output level.
Setting:
CNG Level
Function:
Calling tone output level.
Setting:
CED Level
Function:
Answer tone output level.
Setting:
ECM Mode
Function:
Select error correction mode.
Setting:
ON (default): When an error occurs during communication, re-send the frame where the error occurs. OFF: Any error is ignored during communication.
6-7
Coding Scheme
Function:
Select compression method in TX/ RX mode.
Settings:

MMR: A compression method. MR: A compression method. MH: The simplest compression method. JBIG (default): The most complex compression method that generates the smallest code than any of following ones.
TNR Empty Rep (Toner Empty Report)

Function: Select to generate a report to a specific destination when toner empty status occurs in the engine. Settings:

ON: Generate a report to report destination. OFF (default): Not to generate report.
1. If ON is selected, select generate report and send to remote side when toner runs out. 2. Enter the telephone number for which the report is to be produced. Note Fax number specifications: An up-to-20-digit number that may consist of [0-9], [*], [#], [pause], and [space]. (0-9, #, *, pause, _) The report will generate after 20 minutes, 24 hours, 48 hours, or 72 hours after the event has occurred or until the condition is gone.
Protocol Report
Function:
Print communication report. Choose one from among the following.
Settings:
1. OFF (default): Disable T.30 communication report. 2. ON: Print T.30 communication report. 3. ON ERROR: Print T.30 communication report when an error occurs.
6-8
GDI Time-out
Function:
Specifies the time for GDI time out.
Settings:
0 (5sec), 1 (10sec), 2 (20sec), 3 (30sec), 4 (40sec), 5 (50sec), 6 (default), or (60sec)
Energy Save Mode

Function:
Set to either activate Energy Save mode when print job receiving, or specify panel operation for a given period.
Setting:

ON (default) OFF
6-9
2 Adjustment
PRN Main Regist
Function:
To vary and adjust the print start position in the main scanning direction.
Use:
If the image on the copy deviates in the main scan direction or when the Laser Unit has been replaced.
Adjustment:
Adjust the amount that widths A and B in the printed test pattern1 are shifted so that the following specification is met.
Specification:
0 2.0 mm
Adjustment Range:
-4.0 (-4.0 mm), ~ 0.0 (0.0 mm default), ~ +4.0 (+4.0 mm)
Step:
0.1 mm
Procedure:
1. Print the test pattern 1 (page 6-27).
s6115-503
2. Check the amount that widths A and B in the test pattern 1 are shifted. If the shift is out of specification, adjust it according to the following procedure. a. Enter the [2. ADJUST] menu in the service mode. b. Select [PRN MAIN REGIST] of [2. ADJUST] and press the Menu Select key twice.
6-10
Adjustments and Print Function Settings c. Using the p/q key, change the setting value and then press the Menu Select key. d. Print a test pattern 1 again and check it.
Adjustment Instructions:

If the width of A is less than the width of B..... Increase the setting. If the width of B is less than the width of A..... Decrease the setting.
PRN Sub Regist

Function:
To vary and adjust the print start position in the sub-scanning direction.
Use:
If the image on the copy deviates in the sub scan direction, or when the Laser Unit has been replaced. Note After the PRN MAIN REGIST adjustment has been performed
Adjustment:
Adjust the width of C in the printed test pattern 1 so that the following specification is met.
Specification:
20 2.5 mm
Adjustment Range:
-6.00 (-6.00 mm, ~ 0 (0 mm default), ~ +6.00 (+6.00 mm)
Step:
0.33 mm
6-11
Procedure:
1. Print the test pattern 1.
s6115-504
2. Check width C on the printed page produced. 3. Check that the width of C in the test pattern 1 meets the specification. If the width of C is out of specification, adjust it according to the following procedure. a. Enter the [2. ADJUST] menu in the service mode. b. Select [PRN SUB REGIST] of [2. ADJUST] and press the Menu Select key twice. c. Using the p/q key, change the setting value and then press the Menu Select key. d. Print a test pattern 1 again and check it.
Adjustment:
Instructions If the width of C in the test pattern is longer than the specified width..... Increase the setting. If the width of C in the test pattern is shorter than the specified width..... Decrease the setting.
CCD Main Zoom

Function:
To adjust for variations in the accuracy of Scanner parts and their mounting accuracy by varying the scanning zoom ratio in the main scanning direction. Use: When the Scanner unit has been replaced. Note After the [PRN MAIN REGIST] and [PRN SUB REGIST] adjustments have been performed
Adjustment:
Adjust the width of D in the copy of the test pattern 1 so that the following specification is met.
6-12
Specification:
100 0.5% (Zoom Ratio = Full Size:100%)
Adjustment Range:
-2.0%, ~ 0% (default), ~ +2.0%
Step:
0.4%
Procedure:
s6115-501
2. Enter the [2. ADJUST] menu in the service mode. 3. Select [CCD MAIN ZOOM] of [2. ADJUST] and press the Menu Select key. 4. Place the test pattern 1 on the Original Glass and make a test copy. Note The test pattern 1 should be positioned vertically. 5. Use A4 or Letter paper loaded into tray1 to make the test copy. 6. Check that the width of D in the copy of the test pattern 1 meets the specification. Calculation: (1 - Width of D in the document Width of D in the copy) 100 If the width of D is out of specification, adjust it according to the following procedure: a. Press the Menu Select key. b. Using the p/q key, change the setting value and then press the Menu Select key. c. Place the test pattern 1 on the Original Glass. Then, make a test copy again and check it.
Adjustment:
Instructions If the width of D in the test pattern is longer than the specified width..... Decrease the setting. If the width of D in the test pattern is shorter than the specified width..... Increase the setting.
6-13
CCD Sub Zoom

Function:
To adjust for variations in the accuracy of Scanner parts and their mounting accuracy by varying the scanning zoom ratio in the sub-scanning direction.
Use:
When the Scanner unit has been replaced. Note Use this command only after the [PRN MAIN REGIST] and [PRN SUB REGIST] adjustments have been performed.
Adjustment:
Adjust the width of E in the copy of the test pattern 1 so that the following specification is met.
Specification:
200 0.5% (Zoom Ratio = Full Size:100%)
Adjustment Range:
-2.0% ~, 0% (default), ~ +2.0%
Step:
0.4%
Procedure:
s6115-502
2. Enter the [2. ADJUST] menu in the service mode. 3. Select [CCD SUB ZOOM] of [2. ADJUST] and press the Menu Select key. 4. Place the test pattern 1 on the Original Glass and make a test copy. Note The test pattern 1 should be positioned vertically. 6-14 Phaser 6115MFP Multifunction Product Service Manual
Adjustments and Print Function Settings 5. Use A4 or Letter paper loaded into tray1 to make the test copy. 6. Check that the width of E in the copy of the test pattern 1 meets the specification. Calculation: (1 - Width of E in the document Width of E in the copy) 100. If the width of E is out of specification, adjust it according to the following procedure: a. Press the Menu Select key. b. Using the p/q key, change the setting value and then press the Menu Select key. c. Place the test pattern 1 on the Original Glass. Then, make a test copy again and check it.
If the width of E in the test pattern is longer than the specified width..... Decrease the setting. If the width of E in the test pattern is shorter than the specified width..... Increase the setting.
CCD Main Regist

Function:
To adjust for variations in the accuracy of Scanner parts and their mounting accuracy by varying the scanning start position in the main scanning direction.
Use:
When the original glass is replaced or when the Scanner unit has been replaced. Note Use this command after the [PRN MAIN REGIST] and [PRN SUB REGIST] and [CCD MAIN ZOOM] adjustments have been performed.
Adjustment Specification:
Adjust the amount that widths A and B in the copy of the test pattern 1 so that the following specification is met. 0 2.0 mm
Adjustment Range:
-5.0 (-5.0 mm), ~ 0.0 (0.0 mm default), ~ +5.0 (+5.0 mm)
Step:
0.5 mm
6-15
Procedure:
s6115-503
2. Enter the [2. ADJUST] menu in the service mode. 3. Select [CCD MAIN REGIST] of [2. ADJUST] and press the Menu Select key. 4. Place the test pattern 1 on the Original Glass and make a test copy. Note The test pattern 1 should be positioned vertically. 5. Use A4 or Letter paper loaded into tray1 to make the test copy. 6. Check the amount that widths A and B in the copy of the test pattern are shifted. If the shift is out of specification, adjust it according to the following procedure: a. Press the Menu Select key. b. Using the p/q key, change the setting value and then press the Menu Select key. c. Place the test pattern 1 on the Original Glass. Then, make a test copy again and check it.
Adjustment Instruction:

If the width of A is less than the width of B..... Increase the setting. If the width of B is less than the width of A..... Decrease the setting.
CCD Sub Regist

Function:
To adjust for variations in the accuracy of Scanner parts and their mounting accuracy by varying the scanning start position in the sub-scanning direction.
6-16
Use:
When the original glass is replaced or when the Scanner unit has been replaced. Note Use this command after the [PRN MAIN REGIST] and [PRN SUB REGIST] and [CCD SUB ZOOM] adjustments have been performed.
Adjustment Specification:
Adjust the width of C in the copy of the test pattern 1 so that the following specification is met: 20 2.5 mm
Adjustment Range:
-5.0 (-5.0 mm), ~ 0 (0 mm default), ~ +5.0 (+5.0 mm)
Step:
0.5 mm
Procedure:
s6115-504
2. Enter the [2. ADJUST] menu in the service mode. 3. Select [CCD SUB REGIST] of [2. ADJUST] and press the Menu Select key. 4. Place the test pattern 1 on the Original Glass and make a test copy. Note The test pattern 1 should be positioned vertically. 5. Use A4 or Letter paper loaded into tray1 to make the test copy. 6. Check that the width of C in the copy of the test pattern are shifted. If the width of C is out of specification, adjust it according to the following procedure: a. Press the Menu Select key. Phaser 6115MFP Multifunction Product Service Manual 6-17
Adjustments and Print Function Settings b. Using the p/q key, change the setting value and then press the Menu Select key. c. Place the test pattern 1 on the Original Glass. Then, make a test copy again and check it.
If the width of C in the test pattern is longer than the specified width..... Increase the setting. If the width of C in the test pattern is shorter than the specified width..... Decrease the setting.
ADF Sub Zoom

Function:
To adjust for variations in the accuracy of all parts and their mounting accuracy by varying the scanning zoom ratio in the sub-scanning direction (when using the Automatic Document Feeder).
Use:
When the original glass is replaced, or when a new Auto Document Feeder Unit is mounted. Note Use this command after the [PRN MAIN REGIST] and [PRN SUB REGIST] and [CCD SUB ZOOM] adjustments have been performed.
Adjustment Range:
-2.0% to +2.0%, Step: 0.4%.
Setting/Procedure
1. Print the test pattern 1(page 6-27). 2. Enter the [2. ADJUST] menu in the service mode. 3. Select [ADF SUB ZOOM] of [2. ADJUST] and press the Menu Select key. 4. Place the test pattern 1 into the Automatic Document Feeder and make a test copy. Note The test pattern 1 should be positioned vertically. Use A4 or Letter paper loaded into tray1 to make the test copy. 5. Check that the width of E in the copy of the test pattern 1 meets the specification.
Calculation: (1 - Width of E in the document Width of E in the copy) 100 If the width of E is out of specification, adjust it according to the following procedure.
6-18
Adjustments and Print Function Settings 6. Press the Menu Select key. 7. Using the ../.. key, change the setting value and then press the Menu Select key. 8. Place the test pattern 1 into the Automatic Document Feeder. Then, make a test copy again and check it.
ADF Main Regist

Function:
To adjust for variations in the accuracy of all parts and their mounting accuracy by varying the scanning start position in the main scanning direction when using the Automatic Document Feeder.
Use:
When the original glass is replaced, or when a new Auto Document Feeder Unit is mounted. Note Use this command after the [PRN MAIN REGIST] and [PRN SUB REGIST] and [CCD SUB ZOOM] adjustments have been performed. After the [ADF SUB ZOOM] adjustments have been performed, perform the adjustment procedure.
Adjustment Specification
Adjust the amount that widths A and B in the copy of the test pattern 1 so that the following specification is met
s6115-503
Settings/Procedure
1. 1. Print the test pattern 1(page 6-27). 2. Enter the [2. ADJUST] menu in the service mode. 3. Select [ADF MAIN REGIST] of [2. ADJUST] and press the Menu Select key. 4. 4. Place the test pattern 1 into the Automatic Document Feeder and make a test copy.
6-19
Adjustments and Print Function Settings 5. The test pattern 1 should be positioned vertically. Use A4 or Letter paper loaded into tray1 to make the test copy.
Check the amount that widths A and B in the copy of the test pattern are shifted. If the shift is out of specification, adjust it according to the following procedure. Press the Menu Select key. Using the ../.. key, change the setting value and then press the Menu Select key. Place the test pattern 1 into the Automatic Document Feeder. Then, make a test copy again and check it. If the width of A is less than the width of B..... Increase the setting. If the width of B is less than the width of A..... Decrease the setting.
ADF Sub Regist

Function:
To adjust for variations in the accuracy of all parts and their mounting accuracy by varying the scanning start position in the sub-scanning direction when using the Automatic Document Feeder.
Use:
When the original glass is replaced, or when a new Auto Document Feeder Unit is mounted. Note After the [PRN MAIN REGIST] and [PRN SUB REGIST] and [CCD SUB ZOOM] adjustments have been performed After the [ADF SUB ZOOM] adjustments have been performed, refer to the Adjustment Range section of the Auto Document Feeder Unit.
DMAX (Manufacturing Only)

Function:
To adjust the density of each color.
1st Transfer Voltage (Manufacturing Only)

Function:
To adjust the voltage applied to the Transfer Roller for each color.
6-20
2nd Transfer Voltage (Manufacturing Only)

Function:
Adjusts image characteristics according to user requirements for each type of media by varying the second transfer voltage.
Use:
To adjust the second transfer voltage when an image problem (void areas, white spots) occurs due to the characteristics of the type of media being used.
If white spots occur, decrease the 2nd transfer voltage (adjust in the minus direction) See page 5-26. If void areas occurs, increase the 2nd transfer voltage (adjust in the plus direction). See page 5-26
Adjustment range:
-1500V ~ +1500V Step: 0 (default), 100V
Types of paper to be adjusted:

PLAIN TRANS., LABELS, LETTERHEAD, J-POSTCARD, THICK STOCK GLOSSY
VPP Offset
Function:
Optimizes the image by varying the output value of the developing bias when an image problem occurs due to the atmospheric pressure at high altitudes.
Use:
To adjust the developing when an image problem (uneven density) occurs in an environment of low atmospheric pressure in places such as at high altitudes.
Adjustment range:
STEP0 (0V default), STEP1 (-100V, STEP2 (-200V), STEP3 (-300V)
6-21
ROHS
Function:
Sets supportability of the temperature/humidity sensor (TEM/HRMS) for ROHS.
Use:
When the temperature/humidity sensor has been replaced with a new one.
Setting:

ON (Sensor not supporting RoHS) OFF (Sensor supporting RoHS - default)
Flicker Special
Function:
Eliminates flickers of a room fluorescent light when it occurs due to power source use environment or similar reason.
Use:
Use when the fluorescent light flickers due to power source use environment or similar reason.
Setting:

ON OFF (default)
6-22
3 Counter Functions
Total Print
Mono Copy Function:
Displays the number of monochrome copies made.
Use:
When checking the number of monochrome copies made
Color Copy Function:

Displays the number of color copies made.
Use:
When checking the number of color copies made
Mono Print Function:

Displays the number of monochrome printed pages produced.
Use:
When checking the number of monochrome printed pages produced
Color Print Function:

Displays the number of color printed pages produced.
Use:
When checking the number of color printed pages produced.
6-23
FAX Print Function:

Displays the number of FAX printed pages produced.
Use:
When checking the number of FAX printed pages produced.
Total Scan
Function:
Display the number of scans made.
Use:
When checking the number of scans made
Printer Jam
Function:
Displays the number of misfeeds that have occurred.
Use:
When checking for the number of misfeeds that have occurred
ADF Jam
Function:
Displays the number of misfeeds that have occurred in the Auto Document Feeder Unit.
Use:
When checking for the number of misfeeds that have occurred in the Auto Document Feeder Unit.
Trouble
Function:
6-24
Adjustments and Print Function Settings Displays the number of malfunctions detected.
Use:
When checking for the number of malfunctions detected.
4 Configuration
Main F/W Version.
Function:
Displays the version of the controller firmware.
When to Use:

When upgrading the firmware When the image processing board has been replaced with a new one.
Engine F/W Version

Displays the version of the engine firmware.
When to Use:
When the printer control board has been replaced with a new one.
NIC F/W Version

Function:
Displays the version of the NIC firmware.
When to Use:
When checking for the Firmware version.
Main Ram Size

Displays the size of the main memory.
When to Use:
When checking for the memory size.
6-25
BB CPLD Version
Function:
Displays the version of the BB CPLD version.
When to Use:
When checking for the BB CPLD version.
NAND Code Version

Function:
Displays the version of the NAND flash code version.
When to Use:
To verify the NAND Code version.
5 Function Test
Paper Feed Test
Function:
To check the paper feeding in the paper take-up/transport sections without printing on the paper.
Use:
When a paper misfeed occurs
Procedure:
1. Select the paper tray. 2. Press the Start key to begin testing paper feeding. 3. Press the Stop key to stop testing paper feeding. Note Do not use this procedure when warming up the printer.
6-26
Print Test Pattern

Pattern 1 Function:
To print the test pattern for adjusting the image.
Use:
If there is tilt or when registration or zoom ratio adjustments are performed
Procedure:
1. Select the paper tray. 2. Select the [PATTERN 1]. 3. Press the B&W key to print the test pattern.
s6115-460
Pattern 2 Function:
To print the test pattern for halftones and gradations.
Use:
When checking density and pitch irregularities, or when checking reproducibility of gradations. Procedure: 1. Select the paper tray. 2. Select the [PATTERN2].
6-27
Adjustments and Print Function Settings 3. Press the Start key to print the test pattern.
s6115-461
ADF Feed Test

Function:
To check the paper feeding in the paper take-up/transport sections in the Automatic Document Feeder.
Use:
When a document misfeed occurs
Procedure:
1. Load paper into the Automatic Document Feeder. 2. Press the Start key to begin testing paper feeding. 3. Press the Stop key to stop testing paper feeding.
Copy ADF Glass Area

Note This command is currently inoperable. Refer to the Users Guide for using this command in the customer mode.
Function:
To check for dirt in the scanning section of the Automatic Document Feeder.
Use:
If spots appear in the copies
6-28
Procedure:
1. Load A4S or LetterS paper into Tray1. 2. Press the Start key to start the [COPY ADF GLASS AREA] function. Two copy samples are fed out. 3. Check that no spots appear in the copy samples. 4. Press the Stop key to stop the [COPY ADF GLASS AREA] function.
Park Scan Head

Function:
Moves the scanner unit to its home position for locking.
Use:
Use when transporting the machine.
Procedure:
1. Enter the user service mode. 2. Select [Park Scan Head] and press the Menu Select key. 3. The Scanner Unit moves to the home position when the start key is pressed. 4. Turn OFF the machine's main switch.
6-29
Adjustments and Print Function Settings 5. Open the Scanner unit. Then, inserting a pin or similar object into the hole at portion [1], lower the lock lever [2].
Pinhole
Lock Lever
s6115-360
Note After the transportation of the machine, make sure to unlock the scanner unit by raising the lock lever before turning on the machine's main switch.
FAX Reg Copy Test

Function:
Stores a FAX image in memory and provides a printed copy.
Use:
To test the creation of a FAX image.
Procedure:

Press the Menu key to begin the FAX Reg copy test. Command delivers a printed copy to the output tray.
6-30
Scan Test
Function:
To check the lighting of the Exposure Lamp and the movement of the Scanner Unit.
Use:
If the scanner malfunctions.
Procedure:

Press the Start key to begin the scanner test. Press the Stop key to stop the scanner test.
6 Soft Switch Functions (Internal Only)

Soft Switch Information unavailable. Used for internal development.
7 Reports
Service Data List
Function:
Print service data list report and Error log history list.
Service Data List:

Includes the following items:

COMMUNICATION HISTORY and COUNTER ADJUST RX IN MEMORY MAIN RAM SIZE ROM ID
Retrieving the Service Data List:

1. Enter the [SERVICE MODE]. 2. Select [REPORT] and press the Menu Select key. 3. Select [SERVICE DATA LIST] and press the Menu Select key.
6-31
SERVICE DATA LIST

NAME TEL DATE : : :JUN. 05. 2006 13:58
--SOFT SWITCH SW01-SW16 SW17-SW32 SW33-SW48 SW49-SW64
00 00 C0 01
20 00 82 00
80 68 10 00
0C 00 8A 00
00 80 00 00
00 07 61 00 81 00 80 06 00 00 00 28 00 A7 C1 00 08 00 00 00 04 B0 00 00 00 00 00 21
10 00 01 03 14 68 00 00 00 06 00 89 0F 00 80 10
--COMMUNICATION HISTORY & COUNTER 000001: ECM RX TIME 000008: G3 RX TIME 000000: V.17 14.4K 000000: V.17 9.6K 000000: V.29 9.6K 000000: V.27 4.8K 000001: G3 TX TIME 000000: V.17 14.4K 000000: V.17 9.6K 000000: V.29 9.6K 000000: V.27 4.8K 000027: V.34 RX TIME 000002: 33.6K 000000: 28.8K 000000: 24.0K 000000: 19.2K 000000: 9.6K 000000: 4.8K 000000: V.34 TX TIME 000002: 33.6K 000000: 28.8K 000000: 24.0K 000000: 19.2K 000000: 9.6K 000000: 4.8K 000007: JBIG TX TIME 000000: TOTAL COUNTER 000849: COPY PRINT 000127: REPORT PRINT -- ADJUST -PRN MAIN REGIST: +0.4 CCD MAIN ZOOM: 0 CCD MAIN REGIST: +1.0 ADF MAIN REGIST: +1.0 ADF SUB REGIST: -2.0 RX IN MEMORY: MAIN RAM SIZE: 128MB -- ROM ID -2006/06/05 V0.38
000000: ECM TX TIME 000000: G3 RX PAGE 000000: V.17 12K 000000: V.17 7.2K 000000: V.29 7.2K 000001: V.27 2.4K 000000: G3 TX PAGE 000000: V.17 12K 000000: V.17 7.2K 000000: V.29 7.2K 000000: V.27 2.4K 000007: V.34 RX PAGE 000005: 31.2K 000000: 26.4K 000000: 21.6K 000000: 16.8K 000000: 7.2K 000000: 2.4K 000015: V.34 TX PAGE 000005: 31.2K 000000: 26.4K 000000: 21.6K 000000: 16.8K 000000: 7.2K 000000: 2.4K 000007: JBIG RX TIME 000000: FAX PRINT 000000: PC PRINT
PRN SUB REGIST: CCD SUB ZOOM: 0 CCD SUB REGIST: -1.0 ADF SUB ZOOM: 0
s6115-462
Error Log History List:

Includes the following items:

Index: Index number from 0 - 9999 Error: Error code number Maker: NSF frame maker code Tell.: Remote side or TX side telephone number for that transaction
Retrieving the Error Log History List:

1. Enter the [SERVICE MODE]. 2. Select [REPORT] and press the Menu Select key.
6-32
Adjustments and Print Function Settings Select [ERROR Log History List] and press the Menu Select key.
ERROR LOG HISTORY LIST Index 0001 0002 0003 0004 0005 0006 0007 0008 0009 Error :00A0 :00A0 :0070 :0070 :0070 :0070 :0070 :0070 :0070 Maker 4230 49EE 0000 0000 0000 0000 0000 0000 0000 123 Tele. 88634733507
Error Code List

Function:
Print error code (CODE) and error occurrence time (ERROR TIMES).
Procedure:
1. Enter the [SERVICE MODE]. 2. Select [REPORT] and press the Menu Select key. 3. Select [ERROR CODE LIST] and press the Menu Select key.
Protocol List
Function:
Print out T.30 or V8 protocol after communication with the following data:.

SESSION: Session number FUNCTION: Function Name DESTINATION STATION: Destination Name/Tel. No. DATE/TIME: Communication Date & Time PAGE: Total page number for this session MODE: Communication speed and ECM mode RESULT: Communication result TX: T.30 command sent by local Fax RX: T.30 command received from remote Fax DATA: T.30 frame that include address & control & Data
6-33
Procedure:
1. Enter the [SERVICE MODE]. 2. Select [REPORT] and press the Menu Select key. 3. Select [T.30 PROTOCOL LIST] and press the Menu Select key.
8 Fixed Zoom Change

Function:
The fixed zoom ratios can be changed.
Procedure:
1. Enter the [SERVICE MODE]. 2. Select [FIXED ZOOM CHANGE] and press the Menu Select key. 3. Select the fixed zoom ratio that you wish to change and press the Menu Select key. 4. Use the 10-Key Pad to type in the following metric (or inch) fixed zoom ratio.
Metric Values
Setting name REDUCTION2 REDUCTION1 EXPANSION1 EXPANSION2
Initial fixed zoom ratio 70% 81% 115% 141%
Setting range 51% to 70% 71% to 99% 101% to 140% 141% to 199%
Inch Values
I Setting name REDUCTION2 REDUCTION1 EXPANSION1 EXPANSION2 Initial fixed zoom ratio 64% 78% 129% 154% Setting range 51% to 64% 65% to 99% 101% to 153% 154% to 199%
6-34
9 Factory Test
The following tests are only for factory adjustment only and should not be used.
Signal Test
This test is for factory adjustment only and should NOT be used.
Relay Test
Sensor Test
Dial Test
Volume Test
Checks the volume of the speaker.
Panel Buzzer Test

Checks the operation of the display and all indicators and buttons. When the panel buzzer test is finished, press the panel reset key twice.
RAM Test
Tests reading and writing of RAM memory.
6-35
10 Clear Data Functions

SRAM Clear
Function:
To clear the errors and reset settings for the functions listed below to their default settings.

MENU: Set to default USER SERVICE MODE: Set to default DISPLAY: [Print Report] - [TX/RX Result] Clear FAX function: Clear SERVICES CHOICE: Set to default
Notes:
Before executing [SRAM CLEAR], be sure to record the setting values that are to be initialized through [SRAM CLEAR]. For the record of the setting values, it is a good idea to have reports and lists printed. Some setting values are not included any of these reports or lists. Be sure to make a note of them separately. After [SRAM CLEAR] has been executed, make necessary entries of data again based on the setting values recorded.
6-36
Memory Clear
Function:
To clear the settings for the functions listed below and return the functions to their default settings:

SERVICES CHOICE: Set to default FIXED ZOOM CHANGE: Set to default
Notes:
Before executing [MEMORY CLEAR], be sure to record the setting values that are to be initialized through [MEMORY CLEAR]. For the record of the setting values, it is a good idea to have reports and lists printed. Some setting values are not included any of these reports or lists. Be sure to make a note of them separately. After [MEMORY CLEAR] has been executed, make necessary entries of data again based on the setting values recorded.
6-37
Maintenance Mode Functions

Maintenance Mode Entry Procedure
Caution Ensure appropriate security for the Maintenance Mode entry procedure. It should NEVER be given to any unauthorized person.
Procedure:
1. On the initial screen, press the Menu/Select key to call [MACHINE SETUP] to the screen. 2. Press and hold down the Left Arrow key (for at least 2 seconds).
Left Arrow Key

Error Display
Phaser 6115MFP
ABC
DEF
MIX
Function Quality
x1.00 A4
Y M C
01 EMPTY
K
1
GHI
2
JKL
3
MNO
4
PQRS
5
TUV
6
WXYZ
2 in 1 Reduce / Enlarge Collate Light / Dark Menu Select

C
8 0
9 #
s6115-544
3. The window will display the following: MAINTENANCE 1. FAX Maintenance 4. Press the down key to locate all command lines in the displayed function tree (page 6-39). 5. Press the down arrow from the subcommand level to locate the desired subfunction. Pressing the Menu/Select key at this level will execute the selected command. Note Pressing the Cancel key at any level will bring you up to the previous command level.
Exiting:
1. Press the Stop key to exit.
6-38
Maintenance Mode Function Tree

The following Maintenance Function tree complies with the format displayed on the control panel screen.
Maintenance Mode 1 Fax Maintenance Send Speed Receive Speed Send Level Receive Level DTMF Level CNG Level CED Level ECM Level Coding Scheme TNR Empty Rep Protocol Report 2 SVC Part Life Transfer Belt Fuser Unit Transfer Roller 3 Reset Count Transfer Belt Fuser Unit Transfer Roller 4 Park Scan Head
s6115-543
1 FAX Maintenance
Send Speed
Function:
Transmit start speed setting.
Settings:
Choose the mode from among the following.
V.3 (default): 33600 (default), 31200, 28800, 26400, 24000, 21600, 19200, 16800 V.17: 14400, 12000, 9600, 7200, V.29: 9600, 7200, V.27: 4800, 2400
6-39
Receive Speed
Function:
Sets the reception start speed.
Settings:
V.3 (default) 33600 (default), 31200, 28800, 26400, 24000, 21600, 19200, 16800 V.17: 14400, 12000, 9600, 7200 V.29: 9600, 7200 V.27: 4800, 2400
Send Level
Function:
Sets the PSK/FSK signal output level.
Settings:
-17 to -10 dBm or -9 dBm -8 to -2 dBm. The default setting is -9 dBm.
Receive Level
Function:
Sets the reception sensitivity level.
Setting:
-49 to -44 dBm, -43 dBm, or -42 to -36 dBm. The default setting is -43 dBm.
DTMF Level
Function:
Sets the Dual tone output level.
Setting:
6-40
CNG Level
Function:
Sets the Calling tone output level.
Setting:
-17 to -12 dBm, -11 dBm, or-10 to -2 dBm. The default setting is -11 dBm.
CED Level
Function:
Sets the Answer tone output level.
Setting:
ECM Mode
Function:
Selects the error correction mode.
Settings:
ON (default): When an error occurs during communication, re-send the frame where the error occurs. OFF: Any error is ignored during communication.
Coding Scheme
Function:
Selects compression method in the TX/ RX modes.
Settings:

MMR: A compression method. MR: A compression method. MH: The simplest compression method.
6-41
JBIG (default): The most complex compression method that generates the smallest code than any of following ones.
Toner Empty Report

Function:
Generates a report to a specific destination when the toner empty status occurs in the engine.
Settings:

ON: Generate a report to report destination. OFF (default): Not to generate report.
If ON is selected, select generate report and send to remote side when toner runs out. Enter the telephone number for which the report is to be produced. Fax number specifications: An up-to-20-digit number that may consist of [0-9], [*], [#], [pause], and [space]. (0-9, #, *, pause, _) Note The report will generate after 20 minutes, 24 hours, 48 hours, or 72 hours after the event has occurred or until the condition is gone.
Protocol Report
Function:
Prints a communication report.
Setting:

OFF (default): Disable T.30 communication report. ON: Print T.30 communication report. ON (ERROR): Print T.30 communication report when an error occurs.
2 SVC Part Life

Transfer Belt
Function:
Displays the remaining life of the transfer belt.
6-42
Use:
Use To check the remaining life of the maintenance service parts.
Fusing Unit
Function:
Displays the remaining life of the Fusing Unit.
Use:
Checks the remaining life of the maintenance service parts.
Transfer Roller
Function:
Displays the remaining life of the Transfer Roller.
Use:
Checks the remaining life of the maintenance service parts.
6-43
3 Reset Count
Transfer Belt
Function:
Resets the counter value of the transfer belt unit and executes the image stabilization sequence.
Use:
Use after the Transfer Belt Unit is replaced.
Procedure:
1. Enter the Maintenance Mode and call [3. RESET COUNT] to the screen. 2. Select [TRANSFER BELT] and press the Menu/Select key. 3. Press the Menu Select key. 4. Turn OFF the machine's main switch. When the machine's main switch is turned ON, the image stabilization is automatically executed.
Fusing Unit
Function:
Resets the counter value of the Fusing Unit.
Use:
Use after the Fusing Unit is replaced.
Procedure:
1. Enter the Maintenance Mode and call [3. RESET COUNT] to the screen. 2. Select [FUSER UNIT] and press the Menu Select key. 3. Press the Menu Select key.
6-44
Transfer Roller
Function:
Resets the counter value of the Transfer Roller and executes the image stabilization sequence.
Use:
Use after the Transfer Roller is replaced.
Procedure:
1. Enter the Maintenance Mode and call [3. RESET COUNT] to the screen. 2. Select [TRANSFER ROLLER] and press the Menu Select key. 3. Press the Menu Select key. 4. Turn OFF the machine's main switch. When the machine's main switch is turned ON, the image stabilization is automatically executed.
4 Park Scan Head

Function:
Moves the scanner unit to its home position for locking.
Use:
When transporting the machine
Procedure:
1. Enter the Maintenance Mode. 2. Select [Park Scan Head] and press the Menu/Select key. 3. The scanner unit moves to the home position when the start key is pressed. 4. Turn OFF the machine's main switch.
6-45
Adjustments and Print Function Settings 5. Open the Scanner unit. Then, inserting a pin or similar object into the hole at portion [1], lower the lock lever [2].
Pinhole
Lock Lever
s6115-360
Note After the transportation of the machine, make sure to unlock the scanner unit by raising the lock lever [2] before turning on the machine's main switch.
Additional Scanner Adjustment Procedures

Scanner CD Registration
Adjusts for variations in machining and installation accuracy of different Scanner parts. The adjustment varies the scanning zoom ratio in the main scanning direction.
When to Use:

When the original glass is replaced. When the scanner unit is with a new one.
6-46
Specification:
20mm +/- 1.0mm
Adjustment Range:

The default setting is 0.00. Adjustment range: -5.00 (-5.00 mm) ~ 0.00 (0.00 mm) ~ +5.00 (+5.00 mm).
Procedure:
1. Complete PRN Main Regist on page 6-10. 2. Prepare a chart (A4S or 11 x 8 1/2S) by drawing a reference line on a sheet of paper at a position 20 mm away from the edge as illustrated below. Width B: 20 mm
s6115-363
3. Enter the Service mode. 4. Select [SCANNER CD REGIST] of [1 ADJUST] and press the Menu/ Select key. 5. Place the chart on the original glass and press the Start key. 6. Measure dimension A on the copy produced to check to see if it falls within the specified range. 7. Press the Menu/Select key, adjust using the +/- key, and then press the Menu/Select key to validate the setting. 8. Repeat steps 5 to 7 until the measurement of dimension A falls within the specified range. 9. If dimension A on the copy falls outside the specified range: a. Increase the setting value if dimension A falls short of the specified range. b. Decrease the setting value if dimension A exceeds the specified range.
6-47
Scanner FD Registration
Adjusts for variations in machining and installation accuracy of different Scanner parts. The adjustment varies the scanning zoom ratio in the sub scanning direction.
When to Use:

When the original glass is replaced. When the scanner unit is with a new one.
Specification:
20mm +/- 1.0mm
Adjustment Range:

The default setting is 0.00. Adjustment range: -5.00 (-5.00 mm) ~ 0.00 (0.00 mm) ~ +5.00 (+5.00 mm).
Procedure:
1. Complete PRN Sub Regist on page 6-11. 2. Prepare a chart (A4S or 11 x 8 1/2S) by drawing a reference line on a sheet of paper at a position 20 mm away from the edge as illustrated below.
Width A: 20 mm
s6115-362
3. Enter the Service mode. 4. Select [SCANNER FD REGIST] of [1 ADJUST] and press the Menu/ Select key. 5. Place the chart on the original glass and press the Start key. 6. Measure dimension B on the copy produced to check to see if it falls within the specified range. 7. Press the Menu/Select key, adjust using the +/- key, and then press the Menu/Select key to validate the setting. 8. Repeat steps 5 to 7 until the measurement of dimension A falls within the specified range.
6-48
Adjustments and Print Function Settings 9. If dimension B on the copy falls outside the specified range: a. Increase the setting value if dimension B falls short of the specified range. b. Decrease the setting value if dimension B exceeds the specified range.
Scanner Function Setting Procedure

Use this procedure to lock in all scanner functions 1. Open the Scanner unit. Then, inserting a pin or similar object into the hole at portion, lower the lock lever
Pinhole
Lock Lever
s6115-360
6-49
Additional ADF Adjustment Procedures

ADF FD Magnify
Adjusts the scanning zoom ratio in the FD (feed) direction of the Auto Document Feeder Unit.
When to Use:
When
a new Auto Document Feeder Unit is mounted.
Specification:
200 mm 1.4 mm
Adjustment Range:

The default setting is 0%. Adjustment Range: -5% ~ +5%
Procedure:
1. Prepare a test chart (A4 or 11 x 8 1/2) as shown below:
Draw a 200-mm-long straight line A, starting with a point 20 mm from the left edge and 105 mm from the top edge
20 mm
105 mm A
200 mm
s6115-361
2. Enter the SERVICE MODE. 3. Select [ADF FD MAGNIFY] of [1 ADJUST] and press the Menu/Select key. 4. Load the test chart in the ADF and press the Start key. 5. Measure the length of line A on the copy to check that it falls within the specified range. 6-50 Phaser 6115MFP Multifunction Product Service Manual
Adjustments and Print Function Settings 6. Press the Menu/Select key, adjust the setting value using the +/- key, and then press the Menu/Select key to validate the setting. 7.Repeat steps 4 through 6 until the length of line A falls within the specified range. 8. If dimension A on the copy falls outside the specified range: a. Increase the setting value if dimension A falls short of the specified range. b. Decrease the setting value if dimension A exceeds the specified range.
ADF CD Registration
Adjusts the image scan start position in the CD direction of the Auto Document Feeder Unit.
When to Use:
When a new Auto Document Feeder Unit is mounted.
Specification:
20mm +/- 1.0mm
Adjustment Range:

The default setting is 0.00. Adjustment Range: -5.00 (-5.00 mm) ~ 0.00 (0.00 mm) ~ +5.00 (+5.00 mm)
Procedure:
1. Prepare a chart (A4S or 11 x 8 1/2S) by drawing a reference line on a sheet of paper at a position 20 mm away from the edge as illustrated below
Width A: 20 mm
s6115-362
2. Enter the SERVICE MODE. 3. Select [ADF CD REGIST] of [1 ADJUST] and press the Menu/Select key. 4. Load the test chart in the ADF and press the Start key.
6-51
Adjustments and Print Function Settings 5. Measure the length of width A on the copy to check that it falls within the specified range. 6. Press the Menu/Select key, adjust the setting value using the +/- key, and then press the Menu/Select key to validate the setting. 7. Repeat steps 4 through 6 until the length of width A falls within the specified range. 8. If dimension A on the copy falls outside the specified range: a. Increase the setting value if dimension A falls short of the specified range. b. Decrease the setting value if dimension A exceeds the specified range.
ADF FD Registration
Adjusts the image scan start position in the FD direction of the Auto Document Feeder Unit.
When to Use:
When a new Auto Document Feeder Unit is mounted.
Specification:
20mm +/- 1.0mm
Adjustment Range:

The default setting is 0.00. Adjustment Range: -5.00 (-5.00 mm) ~ 0.00 (0.00 mm) ~ +5.00 (+5.00 mm)
6-52
Procedure:
1. Prepare a chart (A4S or 11 x 8 1/2S) by drawing a reference line on a sheet of paper at a position 20 mm away from the edge as illustrated below.
Width B: 20 mm
s6115-363
2. Enter the SERVICE MODE. 3. Select [ADF FD REGIST] of [1 ADJUST] and press the Menu/Select key. 4. Load the test chart in the ADF and press the Start key. 5. Measure the length of width B on the copy to check that it falls within the specified range. 6. Press the Menu/Select key, adjust the setting value using the +/- key, and then press the Menu/Select key to validate the setting. 7. Repeat steps 4 through 6 until the length of width B falls within the specified range. 8. If dimension B on the copy falls outside the specified range: a. Increase the setting value if dimension B falls short of the specified range. b. Decrease the setting value if dimension B exceeds the specified range.
Leading Edge Skew Adjustment

Adjusts problems associated with leading skew images.
When to Use:
when image skew occurs.
Specification:
10mm +/- 2.0mm
6-53
Adjustment Range:

The default setting is 0.00. Adjustment range: -4.00 (-4.00 mm) ~ 0.00 (0.00 mm) ~ +4.00 (+4.00 mm)
Procedure:
1. Prepare a chart (A4S or 11 x 8-1/2S) by drawing a reference line on a sheet of paper at a position 20 mm away from the edge as illustrated on the left. 2. Load the chart in the Auto Document Feeder Unit and make five 1-sided copies of the chart.
20 mm
s6115-364
3. Align each copy sample as shown and check the deviation. 4. If the deviation is outside the specified range, perform the adjustment within the specification range of 0 1.0 mm.
s6115-365
6-54
Adjustments and Print Function Settings 5. Loosen the one screw (wide top, 10mm) in the back to the right.
Rea
Fro
nt
s6115-366
6. If the deviation is as shown to the left, move the graduations of the duplexing document feeder to the front.
6-55
Adjustments and Print Function Settings 7. Tighten the screw that has been loosened in step 5.
s6115-367
8. If the deviation is as shown to the left, move the graduations of the duplexing document feeder to the back.
6-56
Adjustments and Print Function Settings 9. Tighten the screw that has been loosened in step 5.
s6115-368
6-57
6-58
Cleaning and Maintenance

In this chapter...

Service Maintenance Procedures Consumables/Routine Maintenance Items Cleaning Procedures Maintenance Replacement Procedures
Chapter
Service Maintenance Procedures

Perform the following procedures whenever you check, service, or repair a printer. Cleaning the printer, as outlined in the following steps, assures proper operation of the printer and reduces the probability of having to service the printer in the future. The frequency of use, Average Monthly Print Volume (AMPV), type of media printed on, and operating environment are factors in determining how critical cleaning the machine is and how often it is necessary. Record the number of sheets printed.
Consumables/Routine Maintenance Items

To ensure that the machine produces good print quality and to extend its service life, it is recommended that the maintenance procedures described in this section are followed. The maintenance parts should be replaced following the quoted page counts in the life expectancy column in the following table. Note Maintenance conditions are based on A4 or Letter, Standard mode, and Energy Saver. User Replaceable and Maintenance Parts
No Classification Part Name Number of prints Clean Replace
Processing section
Toner Cartridge * (C, Y, M, K) Imaging Unit
1,500 Standardcapacity 4,500 High-capacity Monochrome 45,000 (continuous printing) Monochrome 20,000 (3-4 pages per job) Full Color 11,250 (continuous printing) Full Color 10,000 (3-4 pages per job)
7-2
No Classification
Part Name
Number of prints
Clean Replace
Image Transfer section
Transfer Belt
Monochrome 135,000 (continuous printing) Monochrome 75,000 (3 pages per job) Full Color 33,700 (continuous printing) Full Color 28,000 (3 pages per job)
4 5 Tray1 paper pick-up section
Laser Unit Window Pick-Up Roller
When a print-quality defect is visible. When a paper jam occurs
* The high capacity toner cartridges have a life expectancy of 4,500 printed pages at 5% coverage. Maximum life for the toner cartridge is 6,000 prints. There are components in the cartridge that degrade beyond 6,000 prints. Service Replaceable Maintenance Parts (FRU)
No Classification Part name Number of prints Clean Replace
1 2
Image Transfer section Fusing section
Transfer Roller Fusing Unit
120,000 120,000
Maintenance Parts Life Count Explanation

Component Description Near Life Value Life Value
Imaging Unit The period of time during which the Main Motor is energized is counted. Fusing Unit Transfer Roller Transfer Belt The number of printed pages is counted. The number of printed pages is counted. The period of time during which the Main Motor is rotated and the number of printed pages are both counted. The number of printed pages compared with the pixel counter value, whichever reaches the life specifications value, is detected.
43,200 prints 45,000 continuous prints 120,000 prints 120,000 prints
Toner Cartridge C,M,Y,K *
135,000 continuous prints 1,200 prints 1,500 prints** 3,600 prints 4,500 prints**
* Standard-Capacity Toner Cartridges (C,M,Y), High-Capacity Toner Cartridges (C,M,Y,K). ** In the Quality menu you can specify whether to continue or stop printing when there is a toner empty condition.
7-3
Cleaning Procedures
Note This section uses detailed artwork to highlight specific parts. For photographic views of the basic wiring views for this machine, refer to page 10-25.
Recommended Tools

Toner vacuum cleaner Clean water Clean, dry, lint-free cloth Black, light protective bag
Perform the following general cleaning steps as indicated by the printers operating environment. Caution Never apply alcohol or other chemicals to any parts in the printer. Never use a damp cloth to clean up toner. If you remove the Imaging Unit, place it in a light protective bag or otherwise protect it as exposure to light can quickly degrade performance and result in early failure. 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, Imaging Unit, and side covers before cleaning. 5. Ensure that all cover vents are clean and free of obstructions. 6. Remove any debris or foreign objects from the Transfer Roller, Fusing Unit, and Imaging Unit. 7. Vacuum loose toner from the printer interior using a Type II toner vacuum only. 8. Remove and clean the paper trays. 9. Clean all rubber rollers with a lint-free cloth slightly dampened with cold water. This section describes regular maintenance procedures.
7-4
Paper Feed Roller

1. Pull the lever to release the Scanner Unit. Note The Scanner Unit cannot be opened with the Auto Document Feeder unit in the raised position. 2. Open the Top Cover (page 8-4) 3. Remove the Imaging Unit (page 8-13). 4. Position the removed Imaging Unit as shown.
s6115-254
Note Be sure to keep the Imaging Unit horizontal and place it where it will not become dirty. Note Do not leave the Imaging Unit removed for more than 15 minutes, and do not place the removed Imaging Unit in a location where it will be exposed to direct light (such as sunlight).
7-5
Cleaning and Maintenance 5. Using a soft cloth dampened with alcohol, wipe any dirt or dust from the pick up roller.
s6115-255
Laser Window
1. Pull the lever to release the Scanner Unit. Note The Scanner Unit cannot be opened with the Auto Document Feeder unit in the raised position. 2. Open the Top Cover (page 8-13).
7-6
Cleaning and Maintenance 3. Remove the Imaging Unit (page 8-13).
s6115-257
4. Position the removed Imaging Unit as shown below. Note Be sure to keep the Imaging Unit horizontal and place it where it will not become dirty.
s6115-254
7-7
Cleaning and Maintenance 5. Using a soft cloth dampened with alcohol, clean the Laser window.
s6115-369
7-8
500-Sheet Feeder Paper Pick-up Roller

1. Remove the 500-Sheet Feeder Unit from the main unit (page 8-125). 2. Wipe the Paper Pick-up Roller clean of dirt using a soft cloth dampened with alcohol.
s6115-370
ADF Pick Up Roller

1. Open the Top Cover. 2. Wipe the Pick-up Roller clean of dirt using a soft cloth dampened with alcohol.
s6115-359
7-9
ADF Registration Roller

1. Open the Top Cover. 2. Wipe the Registration Rollers clean of dirt using a soft cloth dampened with alcohol.
Rollers
s6115-371
Duplexer Transport Roller

1. Open the duplex door. 2. Using a soft cloth dampened with alcohol, wipe the transport roller clean of dirt.
s6115-372
7-10
Maintenance Replacement Procedures

Toner Cartridge Removal
1. Check the color of the Toner Cartridge to be replaced on the control panel. 2. Press the TC Changer key until the color of the toner cartridge to be replaced with a new one is displayed. 3. Open the top cover (page 8-4). 4. Open the front cover and make sure that the specific Toner Cartridge to be replaced is in the front.
s6115-258
7-11
Cleaning and Maintenance 5. Hold onto the handle of the Toner Cartridge and pull to remove it.
s6115-259
Note When you use the remaining instructions to reinstall a new Toner Cartridge, do not let the cartridge stand on end or keep it in that position. 6. Prepare a new Toner Cartridge.
s6115-260
7-12
Cleaning and Maintenance 7. Shake the cartridge a few times to distribute the toner.
s6115-261
8. Remove the protective cover.
s6115-262
7-13
Cleaning and Maintenance 9. Aligning the shaft on both sides of the Toner Cartridge with the rails in the machine, install the cartridge.
Laser Unit Shutter Lever
s6115-314
10. Press down on the Toner Cartridge until it snaps into place. 11. Close the Front Cover. 12. Close the Top Cover.
7-14
Imaging Unit
Replacement Procedure
1. Open the Top Cover (page 8-4). 2. Hold onto the handle of the Imaging Unit and slowly lift the Imaging Unit out of the machine.
Handle
s6115-373
3. To reinstall, reverse the order of removal. Note There is a first-use fuse. Once you have installed the imaging unit, the fuse is blown. If you are using a new imaging unit to troubleshoot a printquality problem, the fuse can be removed until you confirm that the imaging unit is the cause of the defect. Replacement Note Remember to re-install the fuse so the life counter will work.
7-15
7-16
Service Parts Disassembly

In this chapter...

Overview Of Disassembly Procedures Print Engine Disassembly Procedures Duplex Disassembly Procedures 500-Sheet Feeder Options Disassembly Procedures
Chapter
Overview Of Disassembly Procedures

This section contains the removal procedures for field-replaceable parts of the printer listed in the Parts List. In most cases, the replacement procedure is simply the reverse of the removal procedure. In some instances, additional steps are necessary and are provided for replacement of the parts. For specific assemblies and parts, see the "Parts List" on page 9-1. Note This section uses detailed artwork to highlight specific parts. For photographic views of the basic wiring views for this machine, refer to page 10-25.
Preparation
Before you begin any removal and replacement procedure: 1. Switch Off the printer power and disconnect the power cord from the wall outlet. 2. Remove the Imaging Unit and protect it from exposure to light by covering it with a light proof bag or by placing it in a light-tight container. Disconnect all computer interface cables from the printer. 3. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards. 4. Remove the Fusing Unit or wait at least 5 minutes after you have switched Off the printer power for the Fuser to cool before you work on or around the Fuser. Caution Many parts are secured by plastic tabs DO NOT over Flex or force these parts. Do not over torque the screws threaded into plastic parts. Always use the correct type and size screw. Using the wrong screw can damage tapped holes. Do not use excessive force to remove or install either a screw or a printer part. Warning Unplug the AC power cord from the wall outlet before removing any printer part.
8-2
Fastener Types
The following table lists the primary types of Posi-Drive screws used to assemble the printer. The procedures provide dimensional specifications for screws being removed. Posi-Drive Screw Types used in the Printer Type Selftapping, plastic
Parts etc Plastic
Application
Shape
Characteristics 1. Silver colored 2. Screw thread is coarse compared to metal screw. 3. Screw tip is thin. 1. Silver colored 2. It has a flange. 3. Screw thread is coarse compared to metal screw. 4. Screw tip is thin 1. Silver colored 2. Diameter is uniform 3. Typically 6 mm in length
Coarse
Selftapping, plastic with flange
Coarse Parts etc Plastic
Sheet Metal, silver

Parts etc Sheet metal
Caution Use care when installing self-tapping screws in plastic. To properly start the screw in plastic, turn the screw counter-clockwise in the hole until you feel the screw engage the threads, then tighten as usual. Failure to properly align or over tighten the screw can result in damage to previously tapped threads.
Notations in the Disassembly Text
The notation (item X) points to a numbered callout in the illustration corresponding to the disassembly procedure being performed. The notation PLX.X.X indicates that this component is listed in the Parts List. Bold arrows in an illustration show direction of movement when removing or replacing a component. The notation (self-tapping, plastic 10 mm) or (metal, 6 mm) refer to the type of screw being removed.
Note Provides information specific to the replacement of parts or assemblies.
8-3
Cover Disassembly Procedures

Top Cover (PL4.1.3)
1. Pull the lever of the Scanner Unit Cover to open. Caution Keep the platen lid closed or the lever will not operate.
Handle
s6115-263
8-4
Service Parts Disassembly 2. Pull the lever of the top cover and lift to open. Caution When working on the printer with the cover open, be careful not to touch the Transfer Belt.
Top Cover
Transfer Belt Unit
s6115-043
8-5
Rear Cover (PL2.1.1)

Caution Removing the cover also removes one foot from the printer. Be careful not to lean on the printer. 1. Lift the Scanner Unit Cover. This will allow you to free the Rear Cover in a later step. 2. Disconnect the ADF hookup cable.
s6115-284
3. Remove 3 screws (metal, 10mm). 4. Remove the cover. You may need to press in the top left and top right side of the cover to remove.
8-6
Left Cover (PL2.1.13)

1. Lift the Top Cover (page 8-4). 2. Remove the Rear Cover (page 8-6). 3. Remove 4 screws (metal, 10mm). 4. Partially close the Top Cover to expose the tab. Caution Use care not to break the tab during removal and reinstallation of the Left Cover. 5. Release the tab to remove the Left Cover.
Tab
s6115-134
8-7
Right Cover (PL2.1.10)

Caution Use care not to break the tab during removal and reinstallation of the Right Cover. 1. Open the Top Cover (page 8-4). 2. Remove the Rear Cover (page 8-6). 3. Remove 3 screws (metal, 10mm). 4. Pull the cover slightly from the top-right side to release the tab. 5. Remove the Right Cover.
Tab
s6115-135
8-8
Tray 1 and Cover (PL4.21.1)

1. Remove the Tray 1 cover lid (and any paper left in the tray).
s6115-530
2. Push in on each side of the plastic tray to release and remove the Paper Holder.
s6115-531
3. Gently pry one side of the Tray 1 cover hinge to remove the cover.
s6115-286
8-9
Front Cover (PL2.1.12)

Caution When removing and reinstalling the Front Cover, use care not to touch the Developing Roller of the Toner Cartridge. 1. Open the Top Cover (page 8-4). 2. Remove the Rear Cover (page 8-6). 3. Remove the Left Cover (page 8-7). 4. Remove the Right Cover (page 8-8). 5. Before removing the Front Cover, reposition the Tray 1 Paper Guides to provide access to the screws. 6. Remove 2 screws (metal, 10mm) near the bottom of the cover, and 1 more screw (metal, 10mm) on each side of the frame. 7. Remove the Front Cover.
s6115-127
Replacement Note When remounting the Front Cover, make sure that both hooks are properly fitted in position. When tightening the screws, make sure that there is no clearance between the machine frame and Front Cover. If there is any clearance, press the cover against the frame while tightening the screws.
8-10
Unit Disassembly Procedures

Auto Document Feeder Unit (PL1.1.1)
1. If the printer includes a Duplex Unit, follow the instruction for removing it (page 8-134). 2. Disconnect the ADF hookup cable. Caution NEVER disconnect and reconnect the ADF hookup cable with the power switch turned ON, as a damaged Image Processing Board could result.
s6115-381
3. Make sure the Auto Document Feeder Unit is closed.
8-11
Service Parts Disassembly 4. Remove the large silver mounting screw (self-tapping, 12mm).
Pinhole
s6115-382
5. While inserting a pin or small screwdriver into the hole, carefully lift and remove the Auto Document Feeder Unit. Replacement Note Make the following adjustments (in order) when a new Auto Document Feeder Unit has been mounted:
1. Perform an ADF SUB ZOOM (page 6-18). 2. Perform an ADF MAIN REGIST (page 6-19) 3. Perform a ADF SUB REGIST (page 6-20). 4. Perform a ADF FD MAGNIFY (page 6-50). 5. Perform a ADF CD REGIST (page 6-51). 6. Perform a ADF FD REGIST (page 6-51). 7. Perform a leading edge skew adjustment (page 6-53).
8-12
Imaging Unit (PL4.15.9)

1. Pull the lever to release the Scanner Unit. 2. Open the Top Cover (page 8-4). Note The Scanner Unit cannot be opened with the Auto Document Feeder unit in the raised position.
s6115-257
8-13
Service Parts Disassembly 3. Hold onto the handle of the Imaging Unit and slowly lift out of the machine.
s6115-264
4. Position the removed Imaging Unit as shown in the illustration below.
s6115-265
Note Do not expose the Imaging Unit to light for more than 15 minutes, and do not place the unit in a location where it will be exposed to direct light (such as sunlight).
8-14
Laser Unit (PL4.14.1)

Note Ensure that the power is turned off and the power cord is disconnected from the printer before performing this procedure. Do not attempt to disassemble or adjust the Laser Unit. 1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Front Cover (page 8-10). 5. Remove the Scanner Unit (page 8-25). 6. Remove two screws (metal, 10mm) and the fixing base foot.
s6115-434
8-15
Service Parts Disassembly 7. Remove 2 screws (one metal, 10mm, and one metal, 12mm) from the top right cover.
12mm
10mm
s6115-450
8. Lift and remove the top right cover. Note You may need to raise the Top Cover to allow for clearance when removing the top right cover.
8-16
Service Parts Disassembly 9. Remove 9 screws (metal, 8mm) from the right frame.
s6115-451
10. Disconnect the speaker wire, remove it from the retaining clamp, and remove the right frame. 11. Remove the screw (metal, 10mm) from the metal bracket.
s6115-452
8-17
Service Parts Disassembly 12. Remove the metal bracket and plastic guide. 13. Remove 1 screw (self-tapping, 10mm) to remove the harness cover.
Wiring Clamp
s6115-453
14. Disconnect the connector (P/J19) and the flat cable (P/J20) from the Engine Control Board.
P/J20 Engine Control Board
P/J19
s6115-308
8-18
Service Parts Disassembly 15. Disconnect the connector (P/J3) from the Image Processing Board.
P/J3
s6115-454
16. Remove the clamps and cable ties to free the cables. 17. Grab the handle of the Imaging Unit and remove. Note Be sure to keep the Imaging Unit horizontal and place it where it will not become dirty.
8-19
Service Parts Disassembly 18. Press the Rack Release Lever and then rotate the cartridge rack so that the Toner Cartridge is moved to a position where it can be easily removed. Caution When rotating the rack, use care not to touch the Developing Rollers.
Rack Release Lever
Toner Cartridge Rack
Toner Cartridge
19. Hold onto the handle, pull it and remove the Toner Cartridge.
s6115-310
8-20
Service Parts Disassembly 20. Repeat steps 18 and 19 to remove all Toner Cartridges. Caution Do not leave the Imaging Unit or the cartridges removed for more than 15 minutes. Also, do not place the Imaging Unit or the Toner Cartridges in a location where it will be exposed to direct light (such as sunlight).
s6115-311
8-21
Service Parts Disassembly 21. Remove the right and left Laser Unit covers. Note Through the hole at the location shown on the left, push the tab of the unit cover and remove. Caution Use care not to pull the right cover with an excessive force, so you dont break the connector wiring.
Right Laser Unit Cover Tabs
Left Laser Unit Cover
s6115-312
22. Pull the 3 unplugged harnesses through the chassis. 23. Press the Rack Release Lever and turn the toner rack so that the screw securing the Laser Unit to the chassis can be accessed through the hole in the metal cross plate.
8-22
Service Parts Disassembly 24. Remove 3 screws (metal, 10mm) and the Laser Unit. Caution When you lift the Laser Unit free from the chassis, take care when pulling any connected cables through the routing holes.
s6115-313
8-23
Precautions for Reinstallation of the Laser Unit

Replacement Note When reinstalling the Laser Unit, make sure that you insert the lever of the Laser shutter into the lever of the machine. Be sure to use the original screws and that the gear is in place when reinstalling the unit. To reinstall the laser covers, insert the two back tabs before the front tab to align properly. Reconnect the blue connector before you reinstall the cover. To reinstall the ribbon cable, loosen the lower tab on the plastic air duct to provide access to the route.
Laser Unit Shutter Lever
s6115-314
8-24
Scanner Unit (PL3.1.1)

1. Remove the Auto Document Feeder Unit (page 8-11). 2. Remove the Rear Cover (page 8-6). 3. Remove the Left Cover (page 8-7). 4. Remove the Right Cover (page 8-8). 5. Close the Top Cover and the Scanner lid. 6. Remove the ADF Unit (page 8-11). 7. Remove 11 screws (metal, 8mm), disconnect the connector P/J21, and remove the Image Processing Board metal protective cover. Note Lift up on the metal hooks to remove.
P/J21
s6115-426
8-25
Service Parts Disassembly 8. Remove 3 screws (metal, 8mm) to remove the LAN (and FAX Modem) board and protective film.
Protective Film
s6115-440
8-26
Service Parts Disassembly 9. Remove 4 screws (metal, 8mm) to remove the NCU (Network Card) Board.
CN5
s6115-445
10. Remove 3 screws (metal, 8mm) and two standoffs to remove the board holding bracket.
s6115-427
8-27
Service Parts Disassembly 11. Remove 1 screw (metal, 10mm) to remove the cable holding bracket.
s6115-524
12. Disconnect connector CN10 and 2 flat cables from the Image Processor Board.
CN10
P/J7
P/J6
s6115-447
13. Open 4 cable clamps to allow access to the wiring harnesses. 8-28 Phaser 6115MFP Multifunction Product Service Manual
Service Parts Disassembly 14. Disconnect 2 connectors (MP/J1 and MP/J4) from the Image Processing Board and pull the wiring harness out of the clamps.
MP/J1
MP/J4
s6115-448
15. Open the Scanner Unit.
8-29
Service Parts Disassembly 16. Remove 2 screws (self-tapping, 10mm), to remove the Scanner Unit left cover and right cover. Caution With the ADF Unit removed, you must press the Interlock Switch in order to open the scanner cover.
s6115-527
Caution The plastic Scanner Unit cover latch will become loose when the right cover is removed. Note Be sure to note the alignment notch of the latch when reinstalling. Note To unhook the tab, insert your finger into the hole below the hinge and push the cover outward.
8-30
Tabs
s6115-467
17. Remove the left hinge C-clip and right hinge C-clip of the Scanner Unit.
s6115-468
8-31
Service Parts Disassembly 18. Release the tab to free the stopper. 19. You can now rotate the holding tab of the stopper, then lift to remove the stopper. Note Be careful to hold the Scanner Unit securely while you pull it free from the printer.
Tab
s6115-449
Replacement Note After replacing the Scanner Unit, be sure to perform the following adjustment procedures: 1. Perform an CCD MAIN ZOOM (page 6-12). 2. Perform an CCD SUB ZOOM (page 6-14) 3. Perform a CCD MAIN REGIST (page 6-15). 4. Perform a CCD SUB REGIST (page 6-16). 5. Scanner CD Registration (page 6-46). 6. Scanner FD Registration (page 6-48).
8-32
Transfer Belt Unit (PL4.15.5)

1. Pull the lever to release the Scanner Unit. Note Note that the Scanner unit cannot be swung up with the Auto Document Feeder Unit in its raised position.
Handle
s6115-263
2. Open the Top Cover (page 8-4).
8-33
Service Parts Disassembly 3. Disconnect the connector.
CN1
s6115-266
4. Remove the two shoulder screws (silver metal, 12mm).
8-34
Service Parts Disassembly 5. Lift and slide the Transfer Belt Unit out of the metal slots to remove. Note When replacing the Transfer Belt Unit, use care not to touch the surface of the belt. A scratchy or dirty belt could result in image problems.
Shoulder Screw
Shoulder Screw
s6115-267
6. To reinstall, reverse the order of removal. Note After the transfer belt unit has been replaced with a new one, reset the maintenance counter of the Transfer Belt Unit (page 6-44).
8-35
Fusing Unit (PL4.18.12)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the ADF (page 8-11). 4. Remove the Scanner Unit (page 8-25). 5. Remove the Transfer Belt Unit (page 8-33). 6. Remove 1 screw (metal, 8mm) and remove the top left cover. Raise or lower the Top Cover as necessary to allow for clearance.
s6115-270
7. Disconnect two connectors (P/J6 and P/J7) from the Engine Control Board.
s6115-271
8-36
Service Parts Disassembly 8. Remove 1 screw (metal, 6mm) holding the DC Power Supply 2.
CN2
Hooks
CN11
s6115-272
9. Open the 2 clamps and disconnect 2 connectors (CN2 and CN11). Then, remove the DC power supply 2 and protective cover. Note Depress the plastic release on CN11 to release the connector. Replacement Note When replacing, be sure to place the 2 cover tabs in the hook slots.
8-37
Service Parts Disassembly 10. Remove 1 screw (metal, 8mm) from the Power Switch holder.
3 1 2 4
1 Wht Blk 2 Red Blk
3 Wht Wht 4 Red Wht
Connector Color Wire Color Connector Color Wire Color

s6115-273
11. Disconnect 4 connectors and remove the Power Switch. Caution At reinstallation, make sure each connector is in its proper position. Color of connector 1 2 3 4 White Red White Red Color of harness Black Black White White
8-38
Service Parts Disassembly 12. Remove 3 clamps and free the harness.
s6115-274
13. Disconnect 2 connectors (P/J2 and P/J3) from the Image Processor Board.
MP/J3
MP/J2
s6115-275
8-39
Service Parts Disassembly 14. Remove 9 screws (metal, 8mm) and one 6mm screw (and washer), and free the left frame from the chassis.
Tab
s6115-276
Replacement Note Carefully place the hook on the tab when replacing the frame.
8-40
Service Parts Disassembly 15. Remove 2 screws (metal, 8mm) and remove the left guide assembly.
s6115-277
Caution When the left guide assembly is mounted after the Fusing Unit has been installed, make sure that the harness of the Fusing Unit is placed under the left guide assy.
s6115-278
8-41
Service Parts Disassembly 16. Unplug 2 Fuser connectors.
Fuser Connectors
Black
White
s6115-133
17. Swing open the Fusing Unit gear cover.
s6115-280
8-42
Service Parts Disassembly 18. Remove 1 screw (self-tapping, 10mm) and remove the holder.
s6115-281
8-43
Service Parts Disassembly 19. Remove 2 screws (metal, 10mm) and remove the Fusing Unit. Make sure that the docking gear shaft of the Fusing Unit fits in the hole of the fusing frame.
s6115-282
Replacement Note When reinstalling the left cover after reinstalling the Fusing Unit, make sure that the harness of the Fusing Unit is located below the rib of the left cover.
8-44
Paper Take-Up Unit (PL4.20.1)

1. Remove the Rear Cover (page 8-6). 2. Remove the Right Cover (page 8-8). 3. Remove the Left Cover (page 8-7). 4. Remove the High Voltage Unit (page 8-50). 5. Remove 1 screw (metal, 10mm), unlock the tab, and release the wiring harness from the clamp. Then, remove the shield.
Tab
Shield
Clamp
s6115-305
Caution When reinstalling the shield, make sure that no part of the harness is wedged in the mechanism. 6. Remove the Rack Drive Assembly. See the removal procedure steps 4 to 6 when disassembling the Developing Motor (PL4.13.8) on page 98. 7. Remove the Ventilation Fan Motor (page 8-96). 8. Remove 1 screw (metal, 8mm) and unlock two tabs.
8-45
Service Parts Disassembly 9. Loosen the 4 wiring harnesses that feed the laser, and then remove the Ventilation Fan Duct.
Tabs
s6115-315
Caution Be careful not to pinch the wires on the back of the printer. 10. Remove the PJ/22 connector from the Engine Control Board. 11. Disconnect the cooling fan wires from the Engine Control Board and unsnap the fan from the two hooks of the shroud.
Hook
s6115-529
12. unhook 2 tabs of the shroud to pull the fan free from the chassis.
8-46
Service Parts Disassembly 13. Lay the main body of the printer on its back. 14. Remove 3 screws (one metal, 10mm, two self-tapping 10mm) from the right side of the printer, and 2 screws (self-tapping, 10 mm) from the left side.
Right Side
Bottom Edge of Printer
Left Side
Bottom
s6115-316
15. Remove 1 screw (metal, 10mm) and the metal plate from the right side, rear of the printer.
Edge o
8-47
f Printe
Service Parts Disassembly 16. Remove the black plastic guide by pushing the locking tab on the right side, and then allow the guide to fall.
s6115-528
Replacement Note Notice the orientation of the black plastic guide and reinstall it in the same orientation
8-48
Service Parts Disassembly 17. Pull the tray completely towards you and remove the Paper Pick-up Unit.
s6115-142
Notes for Reassembly

1. Ensure that the cams on the take-up assembly are in the up position. 2. Insert the black and red solenoid harness through the opening on the left side of the chassis. 3. Reinsert PJ22 through the opening of the chassis on the right side of the printer. 4. Align the top pin on the left side of the take-up assembly with the groove on the chassis. 5. Pull the tray forward until it rests underneath the cams on the take-up assembly. 6. Using the lower alignment pin, as a reference, reinstall the unit into the printer. 7. Reinstall the springs.
8-49
High Voltage Unit (PL4.19.6)

Warning Make sure the power switch is off and the cord is unplugged prior to starting this (or any other) disassembly procedure. 1. Remove the Left Cover (page 8-7). 2. Remove the DC Power Supply 2 (page 8-68). 3. Remove 1 screw (metal, 8mm) and the bracket.
s6115-439
8-50
Service Parts Disassembly 4. Remove 4 screws (metal, 8mm).
s6115-303
8-51
Service Parts Disassembly 5. Disconnect two connectors and remove the High Voltage Unit.
s6115-304
Replacement Note Make sure that the High Voltage Unit fits underneath the tab as shown in the following illustration. .
s6115-141
8-52
Disassembly/Assembly Procedures (Main Engine)

Control Panel (PL3.1.2)
1. Open the Top Cover. 2. Disconnect the connector from the Transfer Belt. 3. Remove 3 screw caps and screws (metal, 8mm) from the Control Panel Cover.
s6115-488
4. Disconnect the 2-wire ADF set switch connector (P/J701).
P/J701
P/J702
s6115-489
8-53
Service Parts Disassembly 5. Loosen the plastic ribbon cable holder, and then disconnect the ribbon cable connector (P/J702).
s6115-526
6. Remove the ground wire cable. 7. Replace the Control Panel and Assembly.
8-54
Image Processor Board (PL4.19.1)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove 11 screws (metal, 8mm) and disconnect the connectors. 5. Remove the cover of the Image Processor Board.
P/J21
s6115-42
6. Remove the LAN (and FAX Modem) Board (page 8-72). 7. Remove the Network Communication (NCU) Board (page 8-74).
8-55
Service Parts Disassembly 8. Remove 2 screws (metal, 8mm) and two standoff screws to the Rear Panel.
s6115-427
9. Release the 4 plastic cable restraints and disconnect all connectors.
s6115-428
10. Remove 2 screws (metal, 8mm) and remove the bracket on the top portion of the Engine Control Board.
8-56
Service Parts Disassembly 11. Remove 7 screws (metal, 8mm), then disconnect the interconnecting connector from the Engine Control Board to remove the Image Processor Board.
Engine Control Board/ IP Board Connector CN1
s6115-429
Engine Control Board (PL4.19.15)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Image Processing Board (page 8-55). 5. Remove 11 screws (metal, 8mm) and disconnect the connectors. 6. Remove the metal protective covering of the Image Processor Board. 7. Remove 1 screw (metal, 8mm) and the connector protective bracket.
8-57
Service Parts Disassembly 8. Disconnect all connections and flat cables from the Engine Control Board.
Engine Control Board
s6115-431
9. Remove 4 screws (metal, 8mm) and disconnect the connector from the image processing board. 10. Remove the Engine Control Board.
s6115-430
8-58
Service Parts Disassembly 11. Remove the Parameter Chip (NVRAM) from the Engine Control Board and move it to the replacement board.
NVRAM
s6115-432
Replacement Note When removing the NVRAM from the old Engine Control Board and mounting it on the new Engine Control Board, be sure to align the NVRAM chip properly to the mounting socket. Notch
Notch
s6115-433
8-59
DC Power Supply 1 (PL4.19.3)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Scanner Unit (page 8-25). 5. Remove the NCU Board (page 8-74). 6. Remove the Image Processor Board (page 8-55). 7. Remove the Engine Control Board (page 8-57). 8. Remove 2 screws (metal, 10mm) and the remaining printer foot.
s6115-434
8-60
Service Parts Disassembly 9. Remove 1 screw (metal, 6mm) holding the DC Power Supply 2.
CN2
Hooks
CN11
s6115-272
10. Open 2 clamps and disconnect 2 connectors (CN2 and CN11). Then, remove the DC power supply 2 and protective cover. Note Depress the plastic release on CN11 to release the connector. Replacement Note When replacing, be sure to place the two cover tabs in the hook slots.
8-61
Service Parts Disassembly 11. Remove 1 screw (metal, 8mm) from the Power Switch holder.
3 1 2 4
1 Wht Blk 2 Red Blk
3 Wht Wht 4 Red Wht

s6115-273
12. Disconnect 4 connectors and remove the Power Switch. Caution At reinstallation, make sure each connector is in its proper position. Color of connector 1 2 3 4 White Red White Red Color of harness Black Black White White
8-62
Service Parts Disassembly 13. Disconnect the rear white and black connectors of the Fuser Interlock Switch and remove the wire from 2 wiring clamps.
Black
White
AC Connectors
14. Remove the harness protective plate.
s6115-137
s6115-302
15. Disconnect all AC power harnesses to free the left side brace. Note Remove the green grounding wire from the AC Unit.
8-63
Service Parts Disassembly 16. Remove 9 screws (metal, 8mm) and one 6mm screw (and washer), and free the left frame from the chassis.
Tab
s6115-276
Replacement Note Carefully place the hook on the tab when replacing the frame.
8-64
Service Parts Disassembly 17. Remove 9 screws (metal, 8mm) from the right frame.
s6115-451
18. Disconnect the speaker wire and remove it from the retaining clamp, then remove the right frame, leaving only the cross-member of the right frame. Caution Be careful in the following step when freeing the assembly from the wiring harnesses.
8-65
Service Parts Disassembly 19. Remove 9 screws (metal, 8mm) and pull the DC power supply assembly toward you.
s6115-435
8-66
Service Parts Disassembly 20. From the bottom of the chassis, loosen 2 tabs from two hooks and remove the Plastic Paper Guide.
21. To access the connectors, push the exposed wiring through the hole in the plate until you can pull the assembly far enough away from the chassis to reach the connectors. 22. Disconnect 5 connectors from the DC Power Supply 1 board.
P/J4 P/J6
P/J3
P/J5
P/J1
s6115-436
8-67
Service Parts Disassembly 23. Remove 3 screws (metal, 8mm), release two tabs, then remove the DC Power Supply 1.
Tab
Tab
s6115-437
DC Power Supply 2 (PL4.5.4)

1. Remove the Left Cover (page 8-7). 2. Remove 1 screw (metal, 8mm). 3. Remove 2 saddle harnesses and disconnect connectors CN2 and CN11 (see illustration).
8-68
Service Parts Disassembly 4. Remove the power supply cover plate.
CN2
Hooks
CN11 s6115-272 5. Remove 4 screws (metal, 8mm) and the DC Power Supply 2.
s6115-438
8-69
Waste Toner Near Full Detection Board/LED (PL4.6.6)

1. Remove the High Voltage Unit (page 8-50). 2. Remove 1 screw (metal, 10mm), unlock the tab and the wiring clamp, then remove the shield. Caution Use caution when unlocking the tab.
Tab
Shield
Clamp
s6115-305
Note When reinstalling the shield, make sure that no part of the wiring harness is wedged in the mechanism.
Tab
Tab
s6115-306
8-70
Service Parts Disassembly 3. Unlock 3 tabs and disconnect the connector (P/J1) of the Waste Toner Near Full Detection Board/LED to remove.
P/J1
s6115-307
8-71
LAN (and FAX Modem) Board (PL4.19.11)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove 11 screws (metal, 10mm) and disconnect the connector. 4. Remove the protective covering of the Image Processing Board. Caution To avoid damage to the cover, use caution when unlocking the tabs.
P/J21
s6115-426
8-72
Service Parts Disassembly 5. Remove 3 screws (metal, 8mm) from the LAN (and FAX Modem) board and disconnect the board from the connector. Replacement Note When reinstalling the board, be sure to reinstall the protective cover.
Protective Film
s6115-440
8-73
NCU (Network Card) Board (PL4.19.14)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove 11 screws (metal, 10mm) and disconnect the connector. 4. Remove the protective covering from the board. Caution When reinstalling the board, be sure to reinstall the protective covering.
P/J21
s6115-426
8-74
Service Parts Disassembly 5. To provide access to the NCU board, first remove 3 screws (metal, 8mm) from the LAN (and FAX Modem) board and disconnect it from the connector. Note When reinstalling the board, be sure to reinstall the protective cover.
Protective Film
s6115-440
8-75
Service Parts Disassembly 6. Remove the NCU board.
CN5
s6115-445
8-76
AC Inlet Harness (PL4.19.7)

1. Pull the lever to release the Scanner Unit. Note Note that the Scanner Unit cannot be swung up with the Auto Document Feeder Unit in its raised position.
s6115-257
2. Remove the Auto Document Feeder Unit (page 8-11). 3. Remove the Scanner Unit (page 8-25).
8-77
Service Parts Disassembly 4. Remove 1 screw (metal, 10mm) and the top left cover.
s6115-270
5. Remove 1 screw (metal, 10mm) from the protective cover. 6. Remove two clamps and disconnect two connectors (CN1 and CN11). Then, remove the DC power supply 2 protective cover from the hooks.
CN2
Hooks
CN11
8-78
s6115-272
Service Parts Disassembly 7. Remove 1 screw (metal, 10mm) from the Power Switch. 8. Disconnect 4 connectors and remove the Power Switch. Replacement Note At reinstallation, make sure of the correct position of each connector..
3 1 2 4
1 Wht Blk 2 Red Blk
3 Wht Wht 4 Red Wht

s6115-273
Color of connector 1 2 3 4 White Red White Red
Color of harness Black Black White White
8-79
Service Parts Disassembly 9. Remove 3 clamps and release the harness.
s6115-274
10. Remove 3 screws (metal, 8mm) and the NCU board. Then, remove the protective film. Replacement Note Make sure to reinstall the protective film when reinstalling the board.
Protective Film
s6115-440
8-80
Service Parts Disassembly 11. Disconnect 2 connectors (MPJ2, MPJ3) from the Image Processing Board.
MP/J3
MP/J3
s6115-441
8-81
Service Parts Disassembly 12. Remove 9 screws (metal, 10mm) and the left frame.
Tab
s6115-276
13. Remove 1 screw (metal, 10mm) and remove the bracket. 14. Remove 1 screw (metal, 12mm) and the ground.
8-82
Service Parts Disassembly 15. Remove the clamp. Then, holding down the tabs, remove the AC Inlet Harness.
Clamp
s6115-443
Caution Never unplug the faston terminals from the Inlet. If the terminals are unplugged, do not use the AC Inlet Harness. Be sure to use a new harness.
s6115-444
8-83
Paper Feed Roller (PL4.20.17)

1. Open the Top Cover (page 8-4). 2. Remove the Imaging Unit and place it in a horizontal position. Note Do not leave the Imaging Unit removed for more than 15 minutes, and do not place the removed Imaging Unit in a location where it will be exposed to direct light (such as sunlight).
s6115-254
8-84
Service Parts Disassembly 3. Remove the Paper Feed Roller
s6115-256
8-85
Transfer Roller (PL4.16.3)

1. Open the Top Cover. 2. Remove the Imaging Unit (page 7-15). 3. Remove the Transfer Roller Assembly as follows. While squeezing the white tabs of the holders located on both sides, pull out the roller. Caution Use care not to lose the two springs of the assembly. They can easily come off.
Transfer Roller
Tab
Tab
s6115-268
4. Remove the conductive material, gear (PL4.16.7), two springs (PL4.16.5), two holders (PL4.16.6), and two collars (PL4.16.2).
8-86
Service Parts Disassembly 5. To reinstall, move the pieces in Step 4 to the new roller. Caution Do not touch the surface of the roller.
Holder Collar
Collar
Metal Cap
Holder
s6115-269
6. Snap the roller into position. 7. When the Transfer Roller is replaced with a new one, it is necessary to reset the life counter in the Service menu.
Reassembly Procedures
1. Align the spring with the post on the plastic housing. 2. Make sure that the drive gear on the Transfer Roller is aligned with the coupling on the right side of the printer.
8-87
Service Parts Disassembly 3. Make sure that the spring action of the roller is working correctly. Replacement Note Ensure that the High-Voltage Bias Spring is making contact with the Transfer Roller Bias Contact Plate.
s6115-184
8-88
Tray 1 Separation Pad (PL4.20.7)

1. Remove the Paper Pick-Up Unit (page 8-45). 2. Unlock tabs and remove the Separation Pad.
Tabs
3. Unhook the spring.
s6115-317
Note When replacing the Separation Pad, reattach the spring to the new pad. Line the spring up with the locator tab, and then snap the pad into the slots. Push on the pad to confirm that the spring is moving correctly.
s6115-143
8-89
Removal Procedure Shortcut

1. Open the Top Cover (page 8-4). 2. Remove Tray 1. 3. Remove the Imaging Unit (page 8-13). 4. Move the tray to the down position by turning the Pick Roller Shaft. 5. Unlock tabs and remove the Separation Pad.
Print Engine Motors and Fans Disassembly Preparation

Use the following procedure to prepare for the disassembly of the:

Top Right Cover Right Frame Main Motor Power Supply Cooling Fan Ventilation Fan Fusing Motor
1. Remove the Scanner Unit (page 8-25).
8-90
Service Parts Disassembly 2. Remove 1 screw (metal, 10mm) and the Top Right Cover.
12mm
10mm
s6115-450
8-91
Service Parts Disassembly Remove 9 screws (metal, 10mm) and the Right Frame.
s6115-451
8-92
Main Motor (PL4.12.1)

1. Use the procedures for removing the right cover (page 8-8). 2. Remove the Right Frame (page 8-90). 3. Remove four screws (metal, 10mm), disconnect the connector, and remove the Main Motor.
P/J34
s6115-318
8-93
Power Supply Cooling Fan Motor (PL4.8.1)

1. Use the procedures for removing the right cover (page 8-8). 2. Remove the Right Frame (page 8-90). 3. Disconnect the connector (PJ4A) from the Engine Control Board.
P/J4A
s6115-319
4. Remove 1 screw (metal, 8mm), bracket, and guide.
s6115-452
5. Remove the wiring clamp. 8-94 Phaser 6115MFP Multifunction Product Service Manual
Service Parts Disassembly 6. Remove 1 screw (metal, 8mm) and the harness cover.
Wiring Clamp
s6115-453
7. Unlock tabs and remove the Power Supply Cooling Fan Motor.
Tabs
s6115-320
8-95
Ventilation Fan Motor (PL4.8.2)

1. Use the procedures for removing the Right Cover (page 8-8). 2. Remove the Right Frame (page 8-90). 3. Remove 2 screws (metal, 8mm) and the Fan Cover Bracket.
s6115-455
4. Remove the harness from the wiring clamp and disconnect the connector (CN2) of the Ventilation Fan Motor.
8-96
Service Parts Disassembly 5. Unlock the two hooks and remove the Ventilation Fan Motor from the 2 tabs. Note Notice the position of the fan for reassembly.
Hooks
Tabs
Tabs
CN2
s6115-322
8-97
Fusing Motor (PL4.11.1)

1. Use the procedures for removing the Right Cover (page 8-8). 2. Remove the Right Frame (page 8-90). 3. Remove 2 screws (metal, 10mm) and disconnect the connector. 4. Remove the harness from the wiring clamp and then remove the Fusing Motor.
s6115-323
Replacement Note Be sure to use the original screws and that the gear is in place when reinstalling the motor.
Developing Motor (PL4.13.8)

1. Open the Top Cover (page 8-4). 2. Remove the Right Cover (page 8-8). 3. Remove the Front Cover (page 8-10).
8-98
Service Parts Disassembly 4. Remove the switch bracket with the Safety Switch in place.
s6115-324
Note Precautions for Reinstallation of the Safety Switch Assembly.
Check that the switch is actuated with the Front Cover and the Top Cover closed. If the screw is not in the original position, make sure that the distance between the switch lever and switch case (with the switch in the actuated position) falls within the specified range. Specifications: 0.1 to 1.0 mm
s6115-325
8-99
Service Parts Disassembly 5. Remove 4 screws (metal, 10mm) and remove the Rack Drive Assembly by pulling it straight out of the printer. Note If difficult, depress the gear assembly first before pulling out.
s6115-326
6. Remove 2 screws (metal, 10mm), disconnect the connector, and remove the Developing Motor.
P/J31
s6115-327
8-100
Rack Motor (PL4.13.9)

1. Open the Top Cover (page 8-4). 2. Remove the Right Cover (page 8-8). 3. Remove the Front Cover (page 8-10). 4. Remove 2 screws (metal, 10mm), disconnect the connector (P/J30), and remove the Rack Motor.
P/J30
s6115-328
8-101
Print Engine Solenoids and Sensors

Tray 1 Paper Pick Solenoid (PL4.20.20)
1. Remove the High Voltage Unit (page 8-50). 2. Remove 1 screw (metal, 10mm), unlock the tab, and release the wiring clamp from the saddle. Then, remove the shield.
Tab
Shield
Clamp
s6115-305
Caution When reinstalling the shield, make sure that no part of the harness is wedged in the mechanism. 3. Remove 1 screw (metal, 8mm) and disconnect connector (CN2).
8-102
Service Parts Disassembly 4. Remove the Tray 1 Paper Pick Solenoid. Replacement Note When reinstalling the solenoid, place the back end of the solenoid into the chassis first. Then, apply a small amount of pressure on the actuator arm, sliding it in between the teeth of the gear assembly.
CN2
s6115-330
8-103
Registration Roller Solenoid (PL4.12.3)

1. Remove the Right Cover (page 8-8). 2. Remove the Power Supply Cooling Fan Motor Assembly (page 8-94). 3. Lift upwards on the tab and the guide. 4. Disconnect the connector, remove 1 screw (metal, 8mm), and then remove the Registration Roller Solenoid.
s6115-331
Precaution for Reinstallation
Confirm that the registration roller solenoid is securely seated on the alignment pins, before securing screw to the chassis. Reinstall the solenoid so that the clearance between the gear of the registration roller clutch and flapper falls within the specified range (1.0 0.2 mm).
8-104
s6115-332
Cleaning Blade Solenoid (PL4.11.2)

1. Use the procedures for removing the right cover (page 8-8). 2. Remove the Right Frame (page 8-90). 3. Remove 1 screw (metal, 8mm), disconnect the connector, and remove the Cleaning Blade Solenoid. Replacement Note When reinstalling, make sure the actuator is behind the gear.
CN3
s6115-333
8-105
Image Transfer Solenoid (4.10.14)

1. Remove the Right Cover (page 8-8). 2. Remove the Power Supply Cooling Fan Motor Assembly (page 8-94). 3. Disconnect the connector (CN5) from the solenoid. 4. Move the mylar sheet out of the way, and then remove 1 screw (metal, 8mm) and the Image Transfer Solenoid. Caution Be careful not the damage the mylar.
CN5
s6115-335
8-106
Exit Tray Full Sensor (PL4.1.7)

1. Pull the lever to release the Scanner Unit. Note Note that the Scanner Unit cannot be swung up with the Auto Document Feeder Unit in its raised position.
Handle
s6115-263
2. Open the Top Cover (page 8-4).
8-107
Service Parts Disassembly 3. Disconnect the connector (CN1).
CN1
s6115-266
4. Remove 2 shoulder screws (PL4.15.4).
8-108
Service Parts Disassembly 5. Lift and slide the Transfer Belt Unit out of the metal slots to remove. Note When replacing the Transfer Belt Unit, use care not to touch the surface of the belt. A scratchy or dirty belt could result in image problems.
Shoulder Screw
Shoulder Screw
s6115-267
8-109
Service Parts Disassembly 6. Remove the plastic roller cover.
s6115-490
7. Remove the plastic roller.
s6115-491
8-110
Service Parts Disassembly 8. Remove 6 plastic screws from the plastic sensor cover, exposing the sensor and actuator.
s6115-492
9. Squeeze the tabs to remove the sensor.
s6115-493
8-111
Rack Positioning Sensor (PL4.3.12)

1. Remove the ADF Unit (page 8-11). 2. Remove the Scanner unit (page 8-25). 3. Remove 1 screw (metal, 10mm) and the Top Right Cover.
12mm
10mm
s6115-450
8-112
Service Parts Disassembly 4. Remove 9 screws (metal, 10mm) and the Right Frame.
s6115-451
5. Using a flathead screwdriver, push in the plastic hook of the sensor holder.
s6115-494
6. Pinch the plastic sides of the sensor to free and remove from the holder. Phaser 6115MFP Multifunction Product Service Manual 8-113
Fusing Paper Loop Sensor (PL4.17.2)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Scanner Unit (page 8-25). 5. Remove the Transfer Belt Unit (page 8-33). 6. Disconnect the 3-wire connector (P/J42). 7. Remove a single screw (metal, 8mm), release the plastic hook on the left side of the actuator to remove. Note This step will also expose the actuator underneath the sensor.
s6115-495
8-114
Service Parts Disassembly 8. Release the flexible plastic actuator from one side to remove.
s6115-496
8-115
Registration Sensor (PL4.17.2)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Scanner Unit (page 8-25). 5. Remove the Transfer Belt Unit (page 8-33). 6. Disconnect the 3-wire connector (P/J39).
P/J39
s6115-505
7. Remove 1 screw (metal, 8mm) to remove the sensor. 8. Pinch the plastic release hook to remove the actuator.
8-116
Transparency Sensor (PL4.17.16)

1. Remove the Rear Cover (page 8-6). 2. Remove the Left Cover (page 8-7). 3. Remove the Right Cover (page 8-8). 4. Remove the Scanner Unit (page 8-25). 5. Remove the Transfer Belt Unit (page 8-33). 6. Remove 1 screw (metal, 8mm) to remove the sensor.
P/J40
s6115-506
7. Pinch the plastic release hook to remove the sensor and actuator.
8-117
Temperature/Humidity Sensor (PL4.20.37)

1. Remove the Front Cover (page 8-10). 2. Rotate the printer on its back and remove the C-clip.
s6115-336
3. Remove the clip on the left side of the tray. 4. From the right side of the tray, lift the tray free from the boss.
8-118
Service Parts Disassembly 5. Remove the springs from between the feed unit and the paper tray.
s6115-507
Caution Use care not to lose the two springs. Also, be careful not to damage the actuator of the Tray 1 No Paper Empty Sensor. 6. Push in the tab that secures the housing to the frame. 7. Release the tab of the sensor holder. 8. Disconnect the 4-wire connector (P/J43), then release the plastic hooks to remove the sensor.
P/J43
s6115-338
8-119
Notes for Reassembly
When re-attaching the paper tray, make sure that the cam lobes are in the up position, pointing into the printer. If the tray or cams have slipped out of position, rotate the pick roller to position the cams in relation to the tray. When reinstalling, place the actuator in through the hole before reinstalling the C-clip.
Tray 1 No Paper Sensor (PL4.20.39)

1. Remove the Front Cover (page 8-10). 2. Rotate the printer on its back and remove the C-clip.
s6115-336
3. Remove the clip on the left side of the tray. 4. Remove the springs from between the feed unit and the paper tray.
8-120
Service Parts Disassembly 5. From the right side of the tray, lift the tray free from the boss.
s6115-507
Caution Use care not to lose the 2 springs. Also, be careful not to damage the actuator of the Tray 1 No Paper Empty Sensor. 6. With the tray removed, pinch the plastic hooks to release the sensor. 7. To remove the actuator, first rotate the actuator to align with the key, then remove.
8-121
Exit Sensor (PL4.18.9)

1. Remove the Fusing Unit (page 8-36).
s6115-514
2. Remove the C-ring to remove the plastic cover.
s6115-515
3. Unlace the wiring. This will allow you to pull the side holder free from the Fusing Unit. 4. Remove 2 screws (metal, 8mm) and carefully remove the side holder.
8-122
Service Parts Disassembly 5. Release the plastic tabs to remove the sensor.
P/J33
6. Remove the stop tab.
s6115-516
s6115-517
8-123
Service Parts Disassembly 7. To gain access to the actuator, remove the metal cover.
s6115-518
8. Rotate the flexible plastic actuator to the keyed slot and remove.
s6115-519
8-124
Disassembly/Assembly Procedures (500-Sheet Feeder Tray)

500-Sheet Feeder Unit (PL5.1.17)
Caution Whenever removing or reinstalling the feeder, be sure to first unplug the power cord of the printer from the power outlet. 1. Lift the printer main body and then remove the 500-Sheet Feeder Unit from the printer.
s6115-393
8-125
Tray Removal (PL5.3.1)

1. Remove the 500-Sheet Feeder Unit from the main unit (page 8-125). 2. Slide out the tray.
s6115-392
Rear Cover (PL5.1.1)

1. Slide out the tray (page 8-126).
8-126
Service Parts Disassembly 2. Remove 4 screws (plastic, 10mm), and remove the rear cover.
s6115-394
Pick Roller and Holder (PL5.2.10)

1. Remove the Rear Cover (page 8-126). 2. Using a screwdriver, release two tabs to free the plastic cover.
8-127
Service Parts Disassembly 3. Push down on plastic clips to release the cover.
s6115-395
4. Remove the actuator. To do this, flex the plastic free from the tabs, lift and remove the actuator.
s6615-398
8-128
Service Parts Disassembly 5. Remove 1 screw (plastic, 10mm) and the metal plate.
s6115-399
6. Remove 5 screws (plastic, 10mm), disconnect the connector, remove the metal plate holder and Pick Roller. .
s6115-400
8-129
Paper Feed Drive Board (PL5.2.9)

1. Remove the Pick Roller and Holder (page 8-127). 2. Disconnect 2 connectors from the Paper Feed Drive Board. 3. Remove 1 screw (metal, 8mm) and the protective cover.
s6115-401
4. Remove two screws (metal, 8mm) and the Printer Feed Drive Board.
s6115-402
8-130
Paper Pick-Up Solenoid (PL5.2.16)

1. Remove the Pick Roller and Holder (page 8-127). 2. Disconnect the connector. 3. Remove 1 screw (metal, 10mm) and the protective cover.
s6115-404
8-131
Service Parts Disassembly 4. Remove 1 screw (metal, 8mm) and the Paper Pick-Up Solenoid.
s6115-403
8-132
Paper Size Switch (PL5.2.12)

1. Remove the Paper Pick Roller and Holder (page 8-127). 2. Unlock two tabs, disconnect the connector and remove the Paper Size Switch.
s6115-405
8-133
Disassembly/Assembly Procedures (Duplexer)

Duplex Unit Replacement (PL6.1.27)
1. Open the Duplex Cover. 2. Turn the two locking levers (PL6.1.2) to unlock the Duplex Unit.
s6115-389
3. Remove the Duplex Unit.
s6115-390
8-134
Service Parts Disassembly 4. To reinstall a new Duplex Unit, open the Duplex Cover and turn the two locking levers to unlock.
s6115-391
8-135
Service Parts Disassembly 5. Mount the Duplex Unit onto the printer main body.
s6115-456
8-136
Service Parts Disassembly 6. Turn the two locking levers to lock the Duplex Unit into position. Note When locking the Duplex Unit into position, you may need to hold the unit with one hand and, at the same time, press it up against the printer main body.
s6115-457
Note After the Duplex Unit has been locked into position, check that the two locking levers are in the correct locked position.
8-137
Service Parts Disassembly 7. Close the Duplex Cover.
s6115-458
Duplex Right Cover (6.1.13)

1. Remove 1 screw (plastic, 10mm). 2. Unlock three tabs and remove the Duplex Right Cover.
s6115-406
8-138
Duplex Drive Board Removal (PL6.1.19)

1. Remove the right cover (page 8-138). 2. Remove the screw (metal, 8mm) and the Duplex Drive Board cover.
s6115-522
8-139
Service Parts Disassembly 3. Disconnect all connectors from the board.
P/J2
P/J1
P/J3
P/J4 P/J5
s6115-523
4. Remove 3 screws (metal, 8mm) and the Duplex Drive Board Cooling Fan Motor (PL6.2.3) 5. Remove the right cover (page 8-138).
8-140
Service Parts Disassembly 6. Open the Duplex door and disconnect the connector.
s6115-407
7. Remove 1 screw (plastic, 10mm).
s6115-408
8. Unhook the 2 dowel pins and remove the Duplex Door.
8-141
Service Parts Disassembly 9. Disconnect one connector. 10. Remove 1 screw (plastic, 10mm), unlock the tab and remove the harness cover. Replacement Note Be sure to place the tab into the slot first before replacing the screw.
Tab
s6115-409
11. Remove 2 screws (plastic, 10mm), unlock two tabs and remove the Duplex Door upper cover.
s6115-410
8-142
Service Parts Disassembly 12. Unlock 4 tabs and remove the Cooling Fan Motor assembly.
s6115-411
13. Remove the Cooling Fan Motor cover.
s6115-412
8-143
Service Parts Disassembly 14. Release 3 tabs and remove the Cooling Fan Motor.
s6115-413
8-144
Transport Motor (PL6.1.6)

1. Remove the Duplex Right Cover (page 8-138). 2. Remove 2 screws (metal, 10mm) and disconnect the connector. 3. Release the harness from the holder and remove the Transport Motor.
s6115-414
8-145
Reverse Motor (PL6.1.6)

1. Remove the Duplex Right Cover (page 8-138). 2. Remove 2 screws (metal, 10mm), disconnect the connector, and remove the Reverse Motor.
s6115-415
8-146
Registration Solenoid (PL6.3.15)

1. Remove the Duplex Right Cover (page 8-138). 2. Disconnect the connector. 3. Remove 1 screw (metal, 10mm) and the protective cover.
s6115-416
4. Remove the Registration Solenoid.
8-147
Tray Set Actuator (PL6.1.17)

1. Remove the cover door (page 8-138). 2. Pressing the holding tab, remove the Tray Set Actuator. Replacement Note Be sure to hook the spring around the plastic nodule.
Cover
1 2
Holding Tab
s6115-417
8-148
Parts Lists
In this chapter...

Using the Parts List Automatic Document Feeder Parts Scanner Parts Print Engine Parts 500-Sheet Feeder Parts Duplex Module parts FAX Parts
Chapter
Parts Lists
Serial Number Format

Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information:

Component's part number Product type or model number Serial Number of the printer
The serial number is found on a label located on the frame of the printer, inside the Tray 2 opening. Tray 2 must be removed to locate the Serial Number. The nine-digit serial number has the following format: PPP-SSSSSS PPP = product code, as shown in the following table. Product Code Product 6115MFP/N 6115MFP/DN Configuration Phaser 6115MFP, 110 V, Base Phaser 6115MFP, 110V, Duplex
SSSSSS = Numeric serial number. For example, a printer having PMT219638 as its Serial Number:

Is a 110 V Phaser 6115MFP Printer Has a 219638 serial number
9-2
Parts Lists
Using the Parts List

Only those parts listed with part numbers are available for order. Parts listed without a corresponding part number are only available as part of a parent assembly.

No.: The callout number from the exploded part diagram. Part Number: The material part number used to order that specific part. Name/Description: The name of the part to be ordered and the number of parts supplied per order. Parts identified throughout this manual are referenced PL#.#.#; For example, PL3.1.10 means the part is item 10 of Parts List 3.1. Note The spares list for this product is limited, Therefore, not all disassembly procedures have an associated PL number. The procedures without a part number are necessary to reach other parts that do have PL number.
A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly, made up of the individual parts called out in parentheses. The notation with X~Y following a part name indicates an assembly that is made up of components X through Y. For example, 1 (with 2~4) means part 1 consists of part 2, part 3, and part 4. An asterisk (*) following a part name indicates the page contains a note about this part. The notation (NS) next to a part indicates that particular part is not spared, but contained in a kit or major assembly. The notation J1<>J2 and P2 is attached to a wire harness. It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2.
Abbreviations Abbreviation C E KL S Meaning C-ring E-ring K-clip Screw
9-3
Parts Lists
Parts List Index

Phaser 6115MFP Parts List Index Number PL 1.1 PL 2.1 PL 3.1 PL 4.1 PL 4.2 PL 4.3 PL 4.5 PL 4.6 PL 4.7 PL 4.8 PL 4.9 PL 4.10 PL 4.11 PL 4.12 PL 4.13 PL 4.14 PL 4.15 PL 4.16 PL 4.17 PL 4.18 PL 4.19 PL 4.20 PL 4.21 PL 4.22 PL 4.23 PL 4.24 PL 5.1 PL 5.2 PL 5.3 PL 5.4 PL 6.1 PL 6.2 PL 6.3 PL 6.4 PL 7.1 Title Automatic Document Feeder (1/3) External Parts
Scanner Platen and Drive

Top Cover Top Cover Latch Main Frame Left Side Frame Left Frame Right Side Frame Chassis Fans and Ducts Right Frame Drive (1 of 4) Drive (2 of 4) Drive (3 of 4) Drive (4 of 4) Imaging Transfer Transfer Roller Vertical Transport Fusing Unit Electrical Media Input Tray 1 Wiring Harnesses (1 of 3) Wiring Harnesses (2 of 3) Wiring Harnesses (3 of 3) Feeder Housing Feeder Feeder Tray Tray Wiring Harnesses Duplex Assembly Cover and Fan Transport Wiring Harnesses Xerox Supplies
9-4
Parts Lists
Automatic Document Feeder Parts

Parts List 1.1 ADF
s6115-001
9-5
Parts Lists
Parts List 1.1 Automatic Document Feeder - Service Parts List No. 1. Part Number 059K59130 Name/Description ADF Assembly
9-6
Parts Lists
Covers
PL 2.1 External Parts
10
12
11
14
14
15
13
s6115-004
9-7
Parts Lists
Parts List 2.1 External Parts - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 848K12230 848E17460 848E17470 848K12240 893E86110 017E11810 017E11820 Part Number 848K12220 Name/Description Rear Cover Assembly Rear Cover Assembly Stay (Support foot) Supporter Rubber Foot Bracket Instructions Shoulder Screw Regulating Plate Right Cover Assembly Front Lower Cover Front Cover Left Cover Assembly Screw Holder
9-8
Parts Lists
Scanner Parts
PL 3.1 Scanner Platen and Drive
2 3 1
a 8
9 b 9
s6115-006
9-9
Parts Lists
Parts List 3.1 Scanner Base - Service Parts List No. 1. 2. 3. Part Number 062K22690 848K12210 650K27650 650K27660 650K27670 Name/Description Scanner Assembly Control Panel Assembly (Overlays not included) Overlay Kit (French) Overlay Kit (Portuguese) Overlay Kit (Spanish) Scanner Right Cover Cap Scanner left Cover 017E11810 Rubber Foot
4. 5. 6. 7.
9-10
Parts Lists
Print Engine Parts

PL 4.1 Top Cover
3 2 1 a a 27 20 1 a a
4 5
a 17 24 b 23 25 22 20 19 a 18 15 a 14 13 12 21 a 17 16 a 11 a a 28 29 26 19 18 30
10 a
s6115-007
9-11
Parts Lists
Parts List 4.1 Top Cover - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 05OE23630 050E23610 050E23620 130E11800 120E30930 848K12250 Part Number Name/Description Guide Roller Top Cover Assembly Cover Holder Seal Exit Tray Full Sensor Actuator Lever Tray Tray Cover Label Earth Ground Holder Lever Sound Shield Cam Pressure Spring Bracket Holder Lever Tension Spring Reinforce Plate Contact Lid Lid Shield Plate Earth Ground Tray
9-12
Parts Lists
PL 4.3 Main Frame
a 1 2 3 3 5 8 4 6
9 10
a b 7 17 16 13 PS3 12
11
15 14 13
10
13 9 13
s6115-009
9-13
Parts Lists
Parts List 4.3 Main Frame - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 019E74390 130E11800 017E11810 Part Number Name/Description Seal Member Earth Ground Seal Seal Seal Label, consumables reorder Duct Lever Tension Spring Holder Rack Positioning Sensor Rubber Foot Duct Assy Guide Seal Spacer
9-14
Parts Lists
PL 4.4 Side Plates
2 1
3
s6115-010
9-15
Parts Lists
Parts List 4.4 Side Plates - Service Parts List No. 1. 2. 3. 4. 5. Part Number Name/Description Guide Guide Protection Protection Screw
9-16
Parts Lists
PL 4.5 Left Side Frame
b 1
2 a
14 13 15
DC Power Supply 2 4 5 Power Switch
12
16 7 8 11 10 9
s6115-011
9-17
Parts Lists
Parts List 4.5 Left Side Frame - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 110E19910 105E23940 105E23950 Part Number Name/Description Pressure Spring Left Cover Pawl DC Power Supply 2 (100V) DC Power Supply 2 (200V) Protection Power Switch Pin Friction Sheet Holder Pressure Spring Pin Tension Spring Lever Pressure Spring Holder Rail
9-18
Parts Lists
PL 4.6 Left Frame
11 10 9 12
2 8 5 7 Waste Toner Board/LED 6 3 4
b
s6115-012
9-19
Parts Lists
Parts List 4.6 Left Frame - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 960K25450 Part Number Name/Description Tension Spring Earth Ground Contact Contact Torsion Spring Waste Toner Near Full Board/LED Pawl Torsion Spring Lever Contact Contact Contact
9-20
Parts Lists
PL 4.7 Left Side Frame
a 1 2
3 16 9 15 10 4
11 5 6 8 7
12
c Loudspeaker 14
s6115-013
9-21
Parts Lists
Parts List 4.7 Left Side Frame - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Part Number Name/Description Right Cover Pressure Spring Lever Tension Spring Pin Pressure Spring Holder Friction Sheet Pressure Spring Holder Rail Pin N/A Loudspeaker Pawl Bushing
9-22
Parts Lists
PL 4.8 Right Frame (1 of 2)
Power Supply Cooling Fan 1 a
2 Ventilation Fan 3 4
Interlock Switch 7
s6115-014
9-23
Parts Lists
Parts List 4.8 Right Frame (1 of 2)- Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 053E07470 110K15620 Part Number 127E15240 127E16150 Name/Description Power Supply Cooling Fan Motor Ventilation Fan Motor Lever Pressure Spring Pawl Filter Safety Switch Seal
9-24
Parts Lists
PL 4.9 Right Frame (2 of 2)
a 14 1 2 3 4 5 13 b 7 11 b 10
s6115-015
b 6
12
9-25
Parts Lists
Parts List 4.9 Right Frame (2 of 2) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Part Number Name/Description Gear 22/64t Lever Tension Spring Pawl Torsion Spring Torsion Spring Lever Tension Spring Lever Seal Torsion Spring Holder Friction Sheet Seal
9-26
Parts Lists
PL 4.10 Drive (1/4)
2 1 c 15 14 Image Transfer Solenoid
5 17 b 16
6 7
12 13 11 10
s6115-016
9-27
Parts Lists
Parts List 4.10 Drive (1/4) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 121E20250 Part Number Name/Description Gear 16t Gear 19t Shaft Drum Torsion Spring Gear 108t Gear 31t Gear 25/42t Gear 60t Gear 15/90t Gear 19t Torsion Spring Lever Image Transfer Solenoid Cam Gear 20t Ratchet
9-28
Parts Lists
PL 4.11 Drive (2/4)
a Fusing Motor 10 1
b 10 Cleaning Blade Solenoid 2
8 c
7 6
s6115-017
9-29
Parts Lists
Parts List 4.11 Drive (2/4) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 023E31210 008K02240 Part Number 127E16160 121E20250 Name/Description Fusing Motor Cleaning Blade Solenoid N/A Cam Assembly N/A Gear 14/32T Gear 27/40T Gear 14/55T Timing Belt 134L Screw
9-30
Parts Lists
PL 4.12 Drive (3/4)
Main Motor a
13
14
12
a 3 Registration Roller Solenoid b 5 7 6 8 4
11
10
s6115-018
9-31
Parts Lists
Parts List 4.12 Drive (3/4) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 121E26000 Part Number 127E15270 Name/Description Main Motor Guide Registration Roller Solenoid Gear 20/117t Drum Ratchet Torsion Spring Gear 24t Gear 24t Shaft Gear 52t Gear 14/33t Gear 20/117t Gear 91t
9-32
Parts Lists
PL 4.13 Drive (4/4)
5 3 4 1 3 b c
7 d
c 6 8
a 2
c c 10 9 Rack Motor c Developing Motor
s6115-019
9-33
Parts Lists
Parts List 4.13 Drive (4/4) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 127E16170 127E15290 Part Number 807E17730 Name/Description Rack Gear 24t Tension Spring Ball Bearing Lever Gear 35t Gear 20/35T Gear 35t Developing Motor Rack Motor Gear 19/48t
9-34
Parts Lists
PL 4.14 Laser Imaging

Push Button Switch 4
3 2 9 9 9 1
Laser 6
5 9
8 7
s6115-020
9-35
Parts Lists
Parts List 4.14 Laser Imaging - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 011E20120 110E19940 Part Number 122K02590 Name/Description Printer Head Assy (Laser) Pressure Spring Holder Push button Switch Lever Cover Lever Tension Spring Lever
9-36
Parts Lists
PL 4.15 Transfer
a 4 8
3 4 6
5 9
s6115-021
9-37
Parts Lists
Parts List 4.15 Transfer - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 108R00691 826E27450 023E30891 Part Number Name/Description Spacer Lever Tension Spring Shoulder Screw Transfer Belt Unit Holder Lever Holder Imaging Unit
9-38
Parts Lists
PL 4.16 Transfer Roller
6 1 3 5
2 19
8 4
17 a a
18
11 9 20
a 16 15 5 11 14 13 12
8 12 10
s6115-022
9-39
Parts Lists
Parts List 4.16 Transfer Roller - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 809E71910 019E74410 101E23500 809E71890 019E74400 807E17740 809E71900 Part Number 826E33710 005E23460 059E05450 Name/Description Shoulder Screw Collar Transfer Roller Neutralizing Member Pressure Spring Holder Gear 16t Pressure Spring Spacer Guide Cushion Roll Transfer Roller Holder Conductive Member Contact Pressure Spring Contact Resistor Resistor Contact
9-40
Parts Lists
PL 4.17 Vertical Transport
1 2 Fusing Paper Loop Sensor a 19 2nd Image Transfer Sensor 2 3 4 5 6
9 18
8 16 17 Transparency Sensor 15 Registration Sensor 9
10
b 12
11
14 c a
13
s6115-023
9-41
Parts Lists
Parts List 4.17 Vertical Transport- Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 120E29270 130E11820 120E29280 130E11800 Part Number Name/Description Holder Registration and Fusing Loop Sensors Contact Contact Contact Holder Slider Earth Ground Torsion Spring Roller Gear 28t Guide Guide Duct Actuator Transparency Sensor Actuator Tension Spring Seal
9-42
Parts Lists
PL 4.18 Fusing Unit
c a 11 1 b b 7 8 a d 3 6 1 1
Thermistor
d a 5
3 9 Exit Sensor
12
s6115-024
9-43
Parts Lists
Parts List 4.18 Fusing Unit - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 120E29290 126K23192 126K23202 130E11800 Part Number Name/Description Roll Thermistor Collar Bushing Seal Transfer Roller Bracket Bushing Exit Sensor N/A Actuator Fusing Unit 110v Fusing Unit 220v
9-44
Parts Lists
PL 4.19 Electrical
LAN/Fax Board 12 a 2 11 14 a NCU Board a a 1 13
Image Processor Board
15 DC Power Supply 1
10 10 9 10 6 High Voltage Power Supply b
8 Switch 3 7 a a 4
5 a
s6115-025
9-45
Parts Lists
Parts List 4.19 Electrical - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 960K41480 960K41490 960K41470 055E61390 105E18520 962K63450 110E19920 105E18501 105E18511 802K94021 Part Number 960K41460 Name/Description Image Processor Board Bracket DC Power Supply 1 (100V) DC Power Supply 1 (200V) Rack Terminal Assy Shield High Voltage Power Supply Inlet Assembly Switch Bracket Screw LAN (and FAX Modem) Board Protection Sheet Bracket NCU Board Network Board Engine Control Board
9-46
Parts Lists
PL 4.20 Media Feeder Assembly (1/2)
a 6 1 3 2 5 28 b 27 a 26 29 30 31 32 33 16 17 15 b 21 23 25 24 22 b 19
s6115-027
3 5 4 4 7 8 9 10 11 12
13 14
18 Pick Solenoid 20 18
9-47
Parts Lists
PL 4.20 Media Input (2/2)
34
a b 35 40 Tray 1 39 No Paper Sensor 40 Temperature/ Humidity Sensor 37 38

s6115-026
36
9-48
Parts Lists
Parts List 4.20 Media Feeder Assembly - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 130E11800 809E71920 130E11840 120E29300 121E20250 059E05460 019K13070 Part Number 130K74271 Name/Description Paper Take-up Assy Roller Guide Pressure Spring Holder Bushing Tray 1 Separation Pad Gear 28t Cam Tension Spring Lever Tension Spring Friction Sheet Plate Spring Gear 27t Cam Paper Feed Roller Stopper Gear 27t Tray 1 Paper Pick Solenoid Drum Ratchet Torsion Spring Gear 35t Washer Gear 21/25t Gear 14/20t Gear 14t Tension Spring Gear 17/26t Gear 20t Cam Pressure Spring Bracket Actuator Bracket Temperature/Humidity Sensor Holder Tray 1 No Paper Sensor Pressure Spring
9-49
Parts Lists
PL 4.21 Tray 1
1 5 2 3 4 6
b 12
9 a 11 10 10 8
13
14
s6115-028
9-50
Parts Lists
Parts List 4.21 Tray 1 - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 019E74430 109E74420 153K04740 Part Number 050E23640 Name/Description Tray 1 and Cover Regulating Plate Friction Sheet Lifting Plate Regulating Plate Assy Regulating Plate Lever Holder Gear 14t Rack Holder
9-51
Parts Lists
PL 4.22 Wiring Harnesses
SW2-1 (SW2) SW2-2 (SW2) PJ4PU (DCPU1) PJ6PU (DCPU1) PJ33 (PC7)
PJ3PU (DCPU1)
PJ13A
(PRCB)
PJ1C
(WTDTB/LE) PJ1PU (DCPU1) PJ44 (PS9) PJ41 (PS5) PJ5A (PRCB)
SW1-2 (SW1) SW1-4 (SW1) PJ1PU2 (DCPU2)
PJ2A (PRCB)
PJ16A (PRCB)
PJ2PU2 (DCPU2) PJ17A (PRCB)
PJ3A (PRCB) PJ6A (PRCB) CN4 (M4)
PJ14A (PRCB)
PJ42 (PS8) PJ21A (PRCB) PJ6 (PS10) PJ43 (TEM/HUMS) PJ22A (PRCB) CN7 (FM1) PJ15A (PRCB)
CN7 (DUPLEX UNIT)
PJ10A (PRCB)
CN3 (SD3) PJ15A (PRCB) CN2 (FM2) PJ31 (M3)
PJ5A (PRCB) PJ30 (M2) PJ8A (PRCB) PJ11A (PRCB) PJ32 (PS3) PJ34 (M1) CN5 (SD4) CN6 (SD2) PJ39 (PS1) PJ12A (PRCB) PJ40 (PS2)
CN8 (2ND CASETTE) PJ22A (PRCB) PJ9A (PRCB) DC1 DC2 PJ17A (PRCB) PJ18A (PRCB) PJ46 (SW5) PJ5PU (DCPU1) DC3 PJ1HV (HV) PJ2D PJ23A (PRCB) PJ1CNT (CNT) H1 CN1
CN1 PJ53 (TRANSFER UNIT) (PS11) CN2 CN6p H2
s6115-029
9-52
Parts Lists
Parts List 4.22 Wiring Harnesses - Service Parts List No. 1. Part Number 604K48230 Name/Description Wire Harness Kit
9-53
Parts Lists
PL 4.24 Accessory Parts
SW1-2 (SW1) SW1-4 (SW1)
PJ1PU (DCPU1) PJ1PU2 (DCPU2) 2
PJ22A (PRCB) 5
CN7 (FM1)
PJ5A (PRCB)
PJ2PU2 (DCPU2)
PJ9A (PRCB)
CN1 PJ53 (PS11) (TRANSFER UNIT)
PJ17A (PRCB) 3 PJ6 (PS10) PJ15A (PRCB)
CN1
CN2
s6115-031
9-54
Parts Lists
Parts List 4.24 Wiring Harnesses (3/3) - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Part Number 117E29500 117E29520 802E99630 050E23650 848E17480 Name/Description Power Cord (Europe) Power Cord (USA/Canada) Cover Tray Cover Wire Harness Assy Label Label Label Face Sheet Kit (USA/Canada)
9-55
Parts Lists
500-Sheet Feeder
PL 5.1 Feeder Housing
a 5 a 15
a 2 a 4 3 3 16 8 10 3 9 3 8 a 7
9 a
11
13
3 c 12 14 b 14 3 c b
s6115-212
9-56
Parts Lists
Parts List 5.1 Feeder Housing - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 059K59620 059K59630 017E11450 Part Number Name/Description Rear Cover Bracket Assy Rubber Foot Bracket Frame Right Cover Actuator Pressure Spring Roll Shaft Base Frame Reinforce Plate Left Cover Holder Plate Spring Washer Feeder (letter size) Feeder (A4 Size)
9-57
Parts Lists
PL 5.2 Feeder
b b
8 b
6 2 4 4
a 5 a 3 4 Tray 1 Paper Size Switch a 22 21 20 e 17 18 b b Registration Roller Solenoid 16 15 19 6 d 13 10 12 11 4
Feeder Control Board 9
10
14 e
s6115-213
9-58
Parts Lists
Parts List 5.2 Feeder - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 807E17790 121E20310 110E19930 960K25600 059E05470 Part Number Name/Description Roller Guide Earth Ground Guide Guide Bushing Earth Ground Cover (500-Sheet Feeder Control Board) Pick Roller Shaft Switch (Tray Detect) Bracket Shaft Bushing Paper Pick-Up Solenoid Gear 38t Tension Spring Cover Gear 20/26t Gear 22t Gear 17t
9-59
Parts Lists
PL 5.3 Tray
1 2 8 20 21 a 3 20 B 4 6 19 A 14 c 10 11 18 16 14 14 14 A B 14 14 15 7 14 14 c 13 b 7 12 5 6 c 12 9 10 11
17
s6115-214
9-60
Parts Lists
Parts List 5.3 Tray - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Part Number 050E23380 050E23390 Name/Description Cassette Assy (AA) Cassette Assy (Letter) Cover Collar Cam Torsion Spring Pressure Spring Cushion Regulating Plate Separator Washer Pin Cushion Regulating Plate Spacer Label Cassette Regulating Plate Separator Lifting Plate Friction Plate Lock Lever
9-61
Parts Lists
PL 5.4 Feeder Wiring Harness
CN22S (SW1)
CN24B (PFDB)
CN3A (PFDB)
CN4S (SD1)
9-62
Parts Lists
Parts List 5.4 Wiring Harnesses - Service Parts List No. 1. 2. Part Number Name/Description Wire Harness Assy Wire Harness Assy
9-63
Parts Lists
Duplex Module
PL 6.1 Duplex Assembly
Duplex Motor 1 4 1 2 2 3 d 16 b 18 7 8 9 Duplex Exit Sensor 3 5
a 6 b Duplex Motor 2 11 12 b 6 a 10
13
26
25 15 19 20 c Duplex Control Board c 14
24
d 17
10 Duplex Jam Sensor
b 22 17 10 Duplex Entrance Sensor b 16 23 b
21
s6115-149
9-64
Parts Lists
Parts List 6.1 Duplex Assembly - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 084K36390 960K25590 120E29310 130E11800 127E15300 011E20130 Part Number Name/Description Top Cover Locking Lever Pressure Spring Gear 33/50t Gear 12/47t Motor (Duplex Reverse and Transport Motors) Gear 16/27t Gear 16t Collar Photo Interrupter Bracket Assy Bracket Right Cover Shoulder Screw Plate Spring Torsion Spring Tray Set Actuator Shield Duplex Drive Board Regulating Plate Cover Lower Cover Cover Frame Shoulder Screw Stopper Duplex Unit
9-65
Parts Lists
Pl 6.2 Duplex Cover and Fan
Duplex Fan 4
1 4
5 6
s6115-150
9-66
Parts Lists
Parts List 6.2 Cover and Fan - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 127E15240 Part Number Name/Description Cover Holder Fan Motor Seal Cover Seal Cover
9-67
Parts Lists
PL 6.3 Duplex Transport
4 a 2 3 1
5 6 6 7 8
3 20
19 6 18 17
9 10 12 13 11
b 20 16 Duplex Transport 15 Solenoid 14 23 24 a c
21 18 b 17 a 16 22
8.5 11.2
7.3 4.8
s6115-151
9-68
Parts Lists
Parts List 6.3 Transport - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 121E20270 Part Number Name/Description Bushing Roller Roll Plate Spring Gear 20t Gear 28t Gear 13/53t Gear 33/50t Gear 23/29t Drum Ratchet Wheel Torsion Spring Gear 26t Shield Duplex Registration Solenoid Tension Spring Bushing Bushing Plate Spring Spring Roller Roller Edge Cover 8.5h Wiring Saddle
9-69
Parts Lists
PL 6.4 Duplex Wiring Harnesses
1
PJ1A (ADDB) CN7 (Main)
4
PJ2A (ADDB)
CN12 (M1) CN13 (M2) PJ52 (PS3)
2
PJ4A (ADDB) PJ51 (PS2)
5
PJ5A (ADDB)
3
PJ13A (ADDB) CN11 (SD1) PJ50 (PS1)
PJ14 (FM1)
s6115-152
9-70
Parts Lists
Parts List 6.4 Wiring Harnesses - Service Parts List No. 1. 2. 3. 4. 5. Part Number Name/Description Wire Harness Assy Wire Harness Assy Wire Harness Assy Wire Harness Assy Wire Harness Assy
9-71
Parts Lists
PL 7.1 Xerox Supplies

Parts List 7.1 Xerox Toner and Maintenance Kit Supplies - Service Parts List No. 1. 2. 3. 4. 5. 6. 7. 8. Part Number 113R00689 113R00691 113R00690 113R00693 113R00695 113R00694 113R00692 604K35500 Name/Description CYAN STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115mfp MAGENTA STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP YELLOW STANDARD CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP CYAN HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/ 6115MFP MAGENTA HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP YELLOW HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP BLACK HIGH CAPACITY PRINT CARTRIDGE, PHASER 6120/6115MFP HARDWARE MAINTENANCE KIT, PHASER 6120/6115MFP
9-72
Wiring Diagrams
In this chapter...

Plug Jack Designator Diagrams Plug/Jack Locator Diagrams
Chapter
10
Wiring Diagrams
Plug/Jack Locator Diagrams

The P/J Locator diagrams show the location of primary connections within the printer. and optional sheet feeders. Use these illustrations to locate connections called out in the troubleshooting procedures presented in Sections 3, 4, and 5. To find the location of a Plug or Jack: 1. Locate the P/J connector designator in the first column of the table. 2. With this information, go to the map listed in the second column. 3. Use the coordinates to quickly locate the connection indicated on the map with its P/J designation number.
10-2
Wiring Diagrams
Print Engine Board Plug/Jack Designators

Print Engine Plug/Jack Designators Map P/J 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 P/J1 P/J2 P/J3 P/J4 P/J5 P/J6 P/J7 P/J8 P/J9 P/J10 P/J11 P/J12 P/J13 P/J14 P/J15 P/J16 P/J17 P/J18 P/J19 P/J20 P/J21 P/J22 P/J23 P/J1 P/J2 P/J3 P/J4 P/J6 P/J7 P/J8 Coordinates J-137 B-137 B-135 C-141 G-135 H-134 I-134 D-135 F-134 C-135 C-141 D-141 E-141 F-141 D-138 C-138 G-141 H-141 B-139 C-140 I-139 C-141 C-140 B-139 A-140 D-141 E-136 I-135 J-135 H-134 Remarks Connects the Engine Control Board to CN1 of the Image Processor Board. Connects the Engine Control Board to CN4 of the DC Power Supply 1. Connects the Engine Control Board to CN6 of the DC Power Supply 1. Connects the Engine Control Board to the Power Supply Cooling Fan. Connects the Engine Control Board to the Rack Positioning sensor, and the Rack and Developing motors. Connects the Engine Control Board to the Exit Sensor. Connects the Engine Control Board to the Thermistor. Connects the Engine Control Board to the Main Motor. Connects the Engine Control Board through CN1 to the IDC, Belt Positioning, and cleaning Blade Sensors. Connects the Engine Control Board to the Fusing and Ventilation Motors, and the cleaning blade solenoid. Connects the Engine Control Board to the Registration Solenoid and the 2nd Image Transfer Solenoid. Connects the Engine Control Board to the Registration and Transparency Sensors. Connects the Engine Control Board through to the Fusing Paper Loop and 2nd Image Transfer Sensors. Connects the Engine Control Board through CN1 to the Waste Toner Detect Board and the DC Power Supply 1. Connects the Engine Control Board to the Temperature/Humidity Sensor. Connects the Engine Control Board to the Tray 1 Paper Empty Sensor. Not connected. Connects the Engine Control Board to the High Voltage Power Supply. Connects the Engine Control Board to the Laser Unit through connector P/J1 on the Laser. Connects the Engine Control Board directly to the Laser Unit. Connects the Engine Control Board to the Duplex Control Board. Connects the Engine Control to the 500-Sheet Feeder Control Board. Not connected. Connects the Image Processor Board to the speaker. Connects the Image Processor Board to DC Power Supply 1. Connects the Image Processor Board to the Laser Unit. Connects the Image Processor Board to the NCU Board. Connects the Image Processor Board to the Scanner Board. Connects the Image Processor Board to the Control Panel Board. Connects the Image Processor Board to the Scanner Motor through Connector CN10. 10-3
Wiring Diagrams Print Engine Plug/Jack Designators (Continued) Map P/J 2 2 2 2 2 2 2 2 2 3 3 3 3 3 4 4 5 5 6 7 PJ/10 MP/J1 MP/J2 MP/J3 MP/J4 CN/1 CN/3 CN/4 CN/5 CN/1 CN/3 CN/4 CN/5 CN/6 CN/2 CN/11 CN/1 CN/2 P/J2 P/2 Coordinates E-133 A-135 B-140 G-134 H-134 A-138 J-138 C-141 J-140 A-138 K-138 J-138 K-135 K-137 C-139 J-135 E-137 F-136 B-137 B-138 Remarks Connects the Image Processor Board to the Document Feeder Control Board. Connects the Image Processor Board to the Scanner Cooling Fan. Connects the Image Processor Board to the DC Power Supply 2. Connects the Image Processor Board to the DC Power Supply 2. Connects the Image Processor Board to the NCU Board. Connects the Image Processor Board to the Engine Control Board. Not connected. Connects the Image Processor Board to the USB Board (not available). Connects the Image Processor Board to the LAN (Fax) Board. Connects the DC Power Supply 1 Board to the Power Switch. Connects the DC Power Supply 1 Board to the Safety Switch. Connects the DC Power Supply 1 Board to the Engine Control Board. Connects the DC Power Supply 1 Board to the Image Processor Board. Connects the DC Power Supply 1 Board to the Engine Control Board. Connects the DC Power Supply 2 to the Image Processor Board. Connects the DC Power Supply 2 to the Power Switch. Connects the High Voltage Power Supply to the Engine Control Board. Connects the High Voltage Power Supply to the Tray 1 Paper Pick-up Solenoid. Connects the LAN (and FAX) Board to the Image Processor Board. Connects the NCU Board to the Image Processor Board.
10-4
Wiring Diagrams
Map 1 - Engine Control Board Plug/Jack Locator
131
132
133
P/J10
134
P/J8
P/J9
P/J6 P/J5 P/J7
135
P/J3
136
P/J1
137
P/J2 P/J16 P/J15
138
139
P/J19 P/J20 P/J23 P/J21 P/J13 P/J17 P/J14 P/J18
140
141
P/J4 P/J22 P/J11 P/J12
142
143
144
145 s6115-482
10-5
Wiring Diagrams
Map 2 - Image Processor Board Plug/Jack Locator
131
132
133
MP/J1
134
P/J4
MP/J3
P/J8 P/J6 MP/J4
P/J7
135
136
137
CN1 P/J10
138
139
P/J1 MP/J2 P/J2 CN4 P/J3
CN3
140
141
CN5
142
143
144
145 s6115-481
10-6
Wiring Diagrams
Map 3 - DC Power Supply 1 Board Plug/Jack Locator
131
132
133
134
135
136
CN6 CN3
137
138
139
140
CN5
141
CN1
CN4
142
143
144
145 s6115-483
10-7
Wiring Diagrams
Map 4 - DC Power Supply 2 Board Plug/Jack Locator

A B C D E F G H I J K L
131
132
133
134
CN11
135
136
137
138
139
140
CN2
141
142
143
144
145 s6115-484
10-8
Wiring Diagrams
Map 5 - High Voltage Power Supply Board Plug/Jack Locator
131
132
133
134
135
136
CN1
CN2
137
138
139
140
141
142
143
144
145 s6115-485
10-9
Wiring Diagrams
Map 6 - LAN (and FAX) Board Plug/Jack Locator
131
132
133
134
135
P/J807
136
137
138
139
140
141
142
143
144
145 s6115-486
10-10
Wiring Diagrams
Map 7 - NCU Board Plug/Jack Locator
131
132
133
134
135
136
137
138
P/J2
139
140
141
142
143
144
145 s6115-509
10-11
Wiring Diagrams
Print Engine Wiring Diagrams

Print Engine Wiring Map
Registration Roller Solenoid 2nd Image Transfer Solenoid Transparency Sensor Registration Sensor Waste Toner Near Full Detect Board Fusing Paper Loop Sensor 2nd Image Transfer Sensor Imaging Unit Tray 1 Paper Pick-up Solenoid Fusing Safety Switch Fusing Unit Safety Switch Power Switch Plug
CN11 P/J2 CN1 CN14 CN3 PJ40
CN6 P/J11 CN5
P/J19 P/J20 P/J4
P/J1
Laser Unit Power Supply Cooling Fan Motor
P/J15 P/J12 P/J16
P/J43 P/J44
Temp/Hum Sensor Tray 1 Paper Empty Sensor Fusing Motor Cleaning Blade Solenoid Ventilation Fan Motor
PJ39
P/J1
P/J13 CN4
PJ42 P/J14 PJ41 P/J10
CN3

P/J8 P/J13
CN2
P/J34 P/J45
Main Motor Exit Tray Full Sensor
High CN1 CN1 Voltage Power Supply DC Power Supply 1

CN6 CN4 CN5
P/J18
P/J9
CN1 P/J3 P/J2
Transfer Belt Unit Cleaning P/J38 Blade Sensor

P/J37
Belt Positioning Sensor IDC Sensor Rack Positioning Sensor Developing Motor Rack Motor Exit Sensor Thermistor
P/J35 CN1 P/J23 P/J32
P/J5 CN2 MP/J3 MP/J2 P/J2 CN5 P/J4
P/J31 P/J31
DC Power Supply 2 LAN Board

P/J801 P/J802
P/J1
P/J6 P/J7
P/J34
NCU Board P/J807
P/J21
CN7A CN7B
Duplex Board 500-Sheet Feeder Board
Scanner Cooling Fan Motor Scanner Unit Open/Close Sensor Scanner Motor
P/J1
Image Processing Board

CN9 MP/J1 P/J1 MP/J4 P/J3 P/J7 CN10 P/J8 P/J6 CN4 P/J702
P/J22
CN8
Speaker Control Panel Board P/J701 Scanner Board Document Feeder Control Board Original Cover Set Switch
CN3
P/J10
P/J04
P/J05 P/J03
Door Set Switch Paper Leading Edge Detection Sensor Paper Feed Sensor Paper Feed Clutch
s6115-487
Original Detection Sensor Main Motor
P/J02 P/J06 P/J01 P/J07
10-12
Wiring Diagrams
Engine Control Board to Solenoid and Sensor Wiring
Engine Control Board +24VDC

1 2
PJ11
24VDC SD4_REM
CN5
2 1 1 2
2nd Image Transfer Solenoid Registration Roller Solenoid
3 4 5
24VDC SD2_REM
CN6
2 1 1 2
+5VDC P/J12
1 2 3 +5VDC GND PS1_ON
P/J39
3 2 1
Registration Sensor
4 5 6
+5VDC PS2_LED_REM PS2_ON
P/J40
3 2 1
Transparency Sensor
+5VDC P/J13
1 2 3 4 5 +5VDC WTDTB/LED_ON GND WTDTB/LED_LED_ON
P/J1
4 3 2 1
WTDTB/LED Waste Toner Near Full Detect Board/LED
NC
+5VDC P/J14
P/J41
3 2 1
2nd Image Transfer Sensor
4 5 6
+5VDC GND PS8_ON
P/J42
3 2 1
Fusing Paper Loop Sensor
+24VDC
P/J17
1 2 3 +24VDC +24VDC 1 2 3
Imaging Unit
s6115-469
10-13
Wiring Diagrams
Engine Control Board to Power Supply and Laser Unit Wiring
Engine Control Board +5VDC P/J18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2ND I.T._I_MONITOR*1 2ND I.T._V_MONITOR*1 2ND I.T._PWM*1 1ST I.T._I_MONITOR*1 1ST I.T._V_MONITOR*1 1ST I.T._PWM*1 D.B._AC_MONITOR*2 D.B.(AC)_CLK*2 D.B.(AC)_PWM*2 D.B.(DC)_PWM*2 GRID_MONITOR GRID_ANA P.C._MONITOR*3 P.C._PWM*3 GND +5VDC +24VDC SD1_REM 2ND_I.T._P.C.*1*3
P/Jxx
19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
High Voltage Unit
Tray 1 Paper Pick-Up Solenoid

1 2 +24VDC SD1_REM
P/J19
1 2 3 4 5 6 7 8 9 10 11
+5VDC
SOS GND LD_POWER GND S/HB2 S/H2 S/HB1 S/H1 LD_EN +5VDC +5VDC
P/J1B
11 10 9 8 9 6 5 4 3 2 1
Laser Unit
P/J20
1 2 3 4 5
+24VDC GND ST LOCK CLK

s6115-470
10-14
Wiring Diagrams
Engine Control Board to Motor Wiring
Engine Control P/J4 Board 1

2 3
FM1_REM GND FM1_LOCK
Power Supply Cooling Fan Motor
+5VDC P/J15
1 2 3 4 +5VDC TEM/HUMS ON TEM/HUMS ON GND
P/J43
4 3 2 1
Temperature/ Humidity Sensor
+5VDC P/J16
1 2 3 4 +5VDC GND PS9_ON
P/J44
3 2 1
Tray 1 Paper Empty Sensor
NC
P/J10
1 2 3
CN2
FM2_REM GND FM2_LOCK 3 2 1
Ventilation Fan Motor
+24VDC
4 5 SD3_REM +24VDC
CN3
2 1
Cleaning Blade Solenoid Fusing Motor M

s6115-471
6 7 8 9
M4_A M4_B M4_*A M4_*B
CN4
4 3 2 1
10-15
Wiring Diagrams
Engine Control Board to Main Motor and Positioning Sensor Wiring

1 2 3 4 5 6 7 8
P/J8
+24VDC M1_CLK NC M1_REM +5VDC GND GND +24VDC
Main Motor M
+5VDC
1 2 3 4 5
P/J9
IDC_CONTROL +5VDC GND IDC_VO2 IDC_VO1
CN1
11 10 9 8 7
P/J35
5 4 3 2 1
IDC Sensor
6 7 8
+5VDC GND PS4_ON
P/J37
6 5 4 3 2 1
Belt Positioning Sensor Cleaning Blade Sensor
9 10 11
+5VDC GND PS6_ON
P/J38
3 2 1 3 2 1
12 13 14 15 16
+5VDC GND PS11_ON NC NC
P/J45
3 2 1

s6115-472
10-16
Wiring Diagrams
Engine Control Board to Miscellaneous Motor and Sensor Wiring

1 2 3 4
P/J5
M2_*B M2_B M2_*A M2_A
P/J30
4 3 2 1
Rack Motor M
+5VDC
5 6 7 8
M3_*B M3_B M3_*A M3_A
P/J31
4 3 2 1
Developing Motor M
9 10 11
+5VDC GND PS3_ON
P/J32
3 2 1
Rack Positioning Sensor
+5VDC P/J6
P/J33
3 2 1
Exit Sensor
P/J7
1 2
GND TH_ON
Thermistor
s6115-473
10-17
Wiring Diagrams
Engine Control Board to DC Power Wiring
P/J3
1 2 3 4
HEATER_REM SLEEP_REM MAIN_COVER_SENS FUSER_WDT_RESET +24VDC GND +24VDC GND GND +5VDC +3.3VDC
CN6
4 3 2 1
DC Power Supply 1 Board

1 2
Fusing Safety Switch CN2 Fusing Unit
P/J2
1 2 3 4 5 6 7
CN4
7 6 5 4 3 2 1
+5VDC +3.3VDC
CN3
1 2 3
Safety Switch
+24VDC (SW2_IN)
NC +24VDC (SW2_OUT)
CN3 Image Processor Board +5VDC P/J2 +5VDC

6 5 4 3 2 1 +5VDC GND GND GND +3.3VDC +3.3VDC 1 2 3 1 2 3 4 5 6 NC
Power Switch
L N
CN5
L N
DC Power Supply 2
CN1
1 2
CN11
1 2
s6115-474
10-18
Wiring Diagrams
Engine Control Board to Duplex Unit and Feeder Wiring

1 2 3 4 5 6 7
P/J21
+24VDC
REVERSE_MOTOR_CLK +5VDC +5VDC GND TRANSPORT_SENSOR_ON GND +24VDC
CN7A
7 6 5 4 3 2 1
Optional Duplex Unit
8 9 10 11 12 13 14
DOOR_SENSOR_ON REGISTRATION_SOLENOID_REM PAPER_LOOP_SENSOR_ON TRANSPORT_MOTOR_EN TRANSPORT_MOTOR_CLK REVERSE_MOTOR_EN REVERSE_MOTOR_F/R
CN7B
7 6 5 4 3 2 1
+24VDC P/J22 +5VDC

1 2 3 4 5 6 7 8 9 10 +24VDC PAPER_PICK-UP_SOLENOID_REM NC +5VDC GND PAPER_EMPTY_SENSOR_ON SET3 SET2 SET1 SECOND_UNIT_SET
CN8
12 11 10 9 8 7 6 5 4 3 2 1
Optional 500-Sheet Feeder Unit
s6115-475
10-19
Wiring Diagrams
Engine Control Board to Image Processor Board Wiring
Engine Control Board P2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GND VDATA1 GND VDATA2 GND NC STS TOD EPRDY ETBSY GND SRCLK CTBSY GND TEST GND EDATA1 GND EDATA2 GND DATAEN NC PRRDY HSYNC NC GND CPRDY CMD GND RESET
CN1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
s6115-476
10-20
Wiring Diagrams
Image Processor Board to Laser and Scanner Wiring
Image Processor Board +24VDC MP/J3

1 2 +24VDC GND
CN2
2 1
DC Power Supply 2
+24VDC MP/J2
1 2
MP/J1
1 2 3
CN9
FM3_ON GND FM3_LOCK 3 2 1
Scanner Cooling Fan Motor
+5VDC MP/J4
P/J1
3 2 1
Scanner Unit Open/Close Sensor Scanner Motor M
P/J8
1 2 3 4
M5_BM5_B+ M5_AM5_A+
CN10
4 3 2 1
P/J3
1 2 3 4 5 6
VIDEO1 VIDEO1/ GND VIDEO2 VIDEO2/ GND
Laser Unit
s6115-477
10-21
Wiring Diagrams
Image Processor Board to Scanner and Control Panel Wiring
IP Board P/J7
1
P/J702
1
Control Panel P/J1

1 2
GND SW4_ON
Cover Set Switch
20
20
P/J6
1 1
Scanner Unit
32
32
s6115-478
10-22
Wiring Diagrams
Document Feeder Control Board to Optional Feeder Tray Wiring
Document Feeder Control Board
P/J01
1 2 3 4
M1_B M1_*B M1_*A M1_A
P/J30
4 3 2 1
Main Motor M
P/J02 +5VDC
1 2 3 4
PS1_ON GND GND +5VDC
Original Detection Sensor
P/J03 +5VDC
1 2 3 4
PS3_ON GND GND +5VDC
Paper Leading Edge Detection Sensor P/J10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P/J04 +5VDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
+24VDC +24VDC +5VDC GND GND ADF_MODE SW1 PS1 PS3 CL1 M1_CONTROL AMP0 AMP1 AMP2 AMP3
NC
P/J05
1 2
SW1_ON GND
Door Set Switch
+5VDC
P/J06
1 2 3
PS2_ON +5VDC GND
Paper Feed Sensor
P/J07
1 2 GND CL1_ON
Paper Feed Clutch

s6115-479
10-23
Wiring Diagrams
Image Processor Board to LAN and NCU Board Wiring
Image Processor Board +3.3VDC
CN5
1 2 3 4 5 6 7 RESET +3.3VDC +3.3VDC GND HO_DM HO_DP GND
P/J2
1 2 3 4 5 6 7
LAN/Fax Board
P/J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 GND CI2/ DCSEL DCLIM CI1/ GND TXRX1 ANIN VREF PRL HDTD HOOK1/ HOOK2/ CMLRL HRL GND GND +3.3VDC
P/J807
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
NCU Board
+3.3VDC
FG1
P/J1
1 2
SP_ON GND
Speaker
s611
10-24
Wiring Diagrams
Service Wiring Views

Front View: Covers Removed
Control Panel
Automatic Document Feeder (ADF) Scanner Unit
Output Tray Top Cover
Safety Interlock Switch Cyan Toner Cartridge Magenta Toner Cartridge Developer Roller
Tray 1/MPT
s6115-532
10-25
Wiring Diagrams
Rear View: Covers Removed
Image Processing Board Cover Duplex Connector
s6115-534
10-26
Wiring Diagrams
Rear View: Image Processor Board Cover Removed
Image Processing Board Engine Control Board
NCU Board
s6115-535
LAN/Fax Board
10-27
Wiring Diagrams
Right Rear View: Covers Removed
ADF Cable
s6115-533
10-28
Wiring Diagrams
Left Side View: Covers Removed
Fax Line In
DC Power Supply 2
Scanner Cable Left Frame
Fax Line Out Ethernet Port Scanner Serial Port Power Switch
s6115-536
10-29
Wiring Diagrams
Left Side View: Scanner Removed
Transfer Belt Unit
DC Power Supply 2 Wiring
s6115-537
10-30
Wiring Diagrams
Left Side View: Left Frame Removed
High Voltage Power Supply
Fuser Connectors
Power Switch Wiring
DC Power Supply 2 Wiring
s6115-538
10-31
Wiring Diagrams
Right Side View: Covers Removed
Right Frame
Speaker
s6115-539
10-32
Wiring Diagrams
Right Side View: Scanner Removed
Rack Release Lever
s6115-540
10-33
Wiring Diagrams
Right Side View: Right Frame Removed
Fusing Motor Main Motor Ventilation Fan Safety Interlock Switch
Developing Motor
Rack Motor Power Supply Cooling Fan
s6115-541
10-34
Index
Numerics
500-Sheet Feeder Unit, 1-18, 2-55 Control Board part number, 9-59 disassembly, 8-125 Paper Feed Drive Board removal, 8-130 Paper Pick-up Roller cleaning, 7-9 Paper Pick-Up Solenoid removal, 8-131 Paper Size Switch removal, 8-133 part number, 9-57 Pick Roller and Holder removal, 8-127 Rear Cover removal, 8-126 Tray removal, 8-126 life counts, 1-21 Control Panel, 1-12 buttons, 1-12 disassembly, 8-53 display, 1-13 error code, 3-32 LED, 1-12 part number, 9-10 troubleshooting, 3-32 counters life counts, 1-21
D
DC Power Supply 1 disassembly, 8-60 part number, 9-46 plug/jack locator, 10-7 troubleshooting, 3-13, 3-33 DC Power Supply 2 disassembly, 8-68 part number, 9-18 plug/jack locator, 10-8 troubleshooting, 3-28 Developing Motor disassembly, 8-98 operation, 2-22 part number, 9-34 developing process, 2-2 disassembly overview, 8-2 Document Feeder Control Board wiring to optional feeder tray, 10-23 Duplex Reverse Motor, 2-52 disassembly, 8-146 part number, 9-65 Duplex Transport Motor, 2-53 disassembly, 8-145 part number, 9-65 Duplex Unit, 2-52 disassembly, 8-134 Drive Board disassembly, 8-139 Feeder Control Board, 2-56 misfeed, 4-14 part number, 9-65 Registration Solenoid disassembly, 8-147 Right Cover disassembly, 8-138 Transport Roller cleaning, 7-10 Tray Set Actuator disassembly, 8-148 troubleshooting, 4-13, 4-14 Duplexer Registration Solenoid, part number, 9-69
A
AC Inlet Harness disassembly, 8-77 part number, 9-46 ADF Unit disassembly, 8-11 functional components, 2-49 part number, 9-6 Pick Up Roller cleaning, 7-9 Registration Roller cleaning, 7-10 specifications, 1-11 transport operation, 2-50 troubleshooting, 4-9, 4-10, 4-11 Automatic Transfer Voltage/Density Control, 2-35
B
button functions, 1-12
C
Cassette part number, 9-61 Chassis Fan, 2-41 Cleaning Blade error code, 3-19 home position, 2-32 Position Sensor, 2-32 Cleaning Blade Solenoid, 2-30, 3-18 disassembly, 8-105 part number, 9-30 troubleshooting, 3-20 cleaning procedures, 7-4 color print operation, 2-26 connector representation, 3-9 connector designators, 10-2 consumables, 1-20
E
energy saver mode, 2-40 Engine Control Board
Index 1
disassembly, 8-57 error code, 3-11 part number, 9-46 plug/jack locator, 10-5 print quality problems, 5-25, 5-30, 5-33 troubleshooting, 4-14 wiring to DC power, 10-18 wiring to duplexer and feeder, 10-19 wiring to Image Processor Board, 10-20 wiring to main motor and positioning sensor, 10-16 wiring to miscellaneous motors and sensors, 10-17 wiring to motors, 10-15 wiring to power supply and laser, 10-14 wiring to solenoid and sensors, 10-13 entry procedure maintenance mode, 6-38 error message summary, 5-5 error messages, 3-2 jam errors, 3-8, 5-5 Ethernet Port, 1-2 Exit Roller, 2-48 Exit Sensor disassembly, 8-122 operation, 2-48 part number, 9-44 troubleshooting, 4-6, 4-7 Exit Tray Full Sensor disassembly, 8-107 part number, 9-12 troubleshooting, 4-7 exposure lamp error code, 3-29 exposure process, 2-2 external parts list, 9-8
disassembly, 8-10 part number, 9-8 function tree Maintenance Mode, 6-39 service mode, 6-4 functional specifications, 1-8 Fuser Interlock Switch, 8-63 fusing, 2-4 Fusing Loop Sensor, 2-8 part number, 9-42 Fusing Motor, 2-48 disassembly, 8-98 operation, 2-7 part number, 9-30 Fusing Paper Loop Sensor detecting misfeed, 4-5, 4-14 disassembly, 8-114 troubleshooting, 4-5, 4-14 Fusing Unit disassembly, 8-36 error code, 3-23 heater error code, 3-33 life count, 1-21 life expectancy, 7-3 part number, 9-44 print quality problems, 5-33 speed regulation, 2-7 temperature control, 2-39 temperature protection, 2-12 temperature regulation, 2-9 troubleshooting, 3-24, 3-33
G
G-correction control, 2-37
F
Fan Cover Bracket, 8-96 fastener types, 8-3 fasteners precautions, 8-2 screws, 8-3 FAX clear function, 6-36 error messages, 3-3 locator, 10-10 maintenance functions, 6-38, 6-39 overview, 1-2 print function, 6-24 protocol list, 6-33 specifications, 1-9 warnings, 3-3 FAX (and LAN) Board, see LAN (and FAX) Board, 8-72 Feed Roller life count, 1-21 Feeder (A4 Size) part number, 9-57 Feeder Pick Roller part number, 9-59 Flash ROM error code, 3-12 Front Cover
H
Heater Lamp, 2-12 High Voltage Unit disassembly, 8-50 part number, 9-46 plug/jack locator, 10-9 print quality problems, 5-18, 5-19 troubleshooting, 5-25 High-Voltage Bias Spring, 8-88
I
IDC Sensor, 2-36 Image Processor Board disassembly, 8-55 part number, 9-46 plug/jack locator, 10-6 print quality problems, 3-32, 5-31 troubleshooting, 3-17, 3-30, 4-6, 4-8 wiring to LAN and NCU boards, 10-24
Index 2
wiring to laser and scanner, 10-21 wiring to scanner and control panel, 10-22 image transfer, 2-3, 2-34 error code, 3-18 Image Transfer Solenoid, 2-33 disassembly, 8-106 part number, 9-28 retraction, 2-34 Imaging Unit cleaning, 2-35 disassembly, 8-13 life count, 1-21 life expectancy, 7-2 maintenance replacement, 7-15 print quality problems, 5-15, 5-37 troubleshooting, 3-26 waste toner reservoir, 2-42
feeder operation, 2-55 part number, 9-32 transfer drive, 2-29 troubleshooting, 3-13, 3-20 maintenance items, 1-20 maintenance mode entry procedure, 6-38 media fusing temperature, 2-11 microswitches, 2-58 misfeed detection, 4-5 monochrome print operation, 2-26
N
NCU Board disassembly, 8-74 part number, 9-46 plug/jack locator, 10-11 neutralizing cloth, 2-3 NVRAM replacement, 8-59
J
jam errors, 3-8, 5-5
O
options, 1-18 options specifications, 1-11 Original Detection Sensor, 2-49 Output Tray, 1-2 Output Tray Full Sensor, 2-49
L
LAN (and FAX Modem) Board disassembly, 8-72 error codes, 3-3 part number, 9-46 plug/jack locator, 10-10 Laser Assembly, 2-15 laser intensity adjustment control, 2-37 Laser Unit cleaning, 7-6 disassembly, 8-15 error code, 3-17 life expectancy, 7-3 part number, 9-36 print quality problems, 5-21, 5-31 reinstallation, 8-24 troubleshooting, 3-17 Leading Edge Detect Sensor, 2-51 leak detection, 2-36 LED color definitions, 1-12 Left Cover disassembly, 8-7 part number, 9-8 Left Frame removal, 8-40 light intensity, 2-15 loop correction, 2-53
P
Paper Feed Roller cleaning, 7-5 disassembly, 8-84 part number, 9-49 Paper Loop Sensor, 2-53 paper path print media, 2-5 Paper Pick-Up Solenoid part number, 9-59 Paper Take-Up Unit ADF Feed test, 6-28 disassembly, 8-45 paper feed test, 6-26 part number, 9-49 reassembly, 8-49 Solenoid troubleshooting, 4-12 parts life expectancy, 7-2 parts list index, 9-4 photo sensors, 2-57 Pick Roller life expectancy, 7-3 tray 1, 2-44 plug/jack locator, 10-2 Polygon Motor, error code, 3-16 Power Cord part number, 9-55 Power Supply Cooling Fan operation, 2-40 Power Supply Cooling Fan Motor
M
Main Motor disassembly, 8-93 error code, 3-13
Index 3
disassembly, 8-94 error code, 3-15 part number, 9-24 troubleshooting, 3-15 Power Switch connections, 8-38 part number, 9-18 troubleshooting, 3-31 pressure cam, 2-31 print cycle, 2-2 voltage control, 2-36 print engine wiring map, 10-12 print media, 2-5 print quality defect analysis, 5-2 defects by component, 5-3 paper tips page, 5-2 troubleshooting, 5-2 Printer cleaning, 7-4 configurations, 1-4 dimensions, 1-5 options, 1-18 resolutions, 1-4 process control modes, 2-38 product code, 9-2
Retard Rollers, 2-45 Reverse Motor troubleshooting, 4-13 Right Cover disassembly, 8-8 part number, 9-8 Right Frame disassembly, 8-92 routine maintenance life counts, 1-21
S
Safety Switch disassembly, 8-99 part number, 9-24 scan resolutions, 1-4 Scanner Cooling Fan Motor error code, 3-27 Scanner Fan, 2-41 Scanner Latch, 2-15 Scanner Motor error code, 3-28 Scanner Unit, 2-14 disassembly, 8-25 exposure lamp error code, 3-29 Motor troubleshooting, 3-28 part number, 9-10 print quality problems, 5-6, 5-14 troubleshooting, 3-30 screw types, 8-3 sensor types, 2-57 Separation Pad, 2-45, 2-49 service checklist, 4-2 service mode entry procedure, 6-3 service mode function tree, 6-4 service wiring views, 10-25 Shoulder Screw part number, 9-38 space requirements, 1-10 standard memory, 1-6
R
Rack Motor, 2-27 disassembly, 8-101 error code, 3-22 operation, 2-24 part number, 9-34 troubleshooting, 3-22 Rack Positioning Sensor disassembly, 8-112 error code, 3-22 operation, 2-27 part number, 9-14 troubleshooting, 3-22 Rear Cover disassembly, 8-6 part number, 9-8 reflectance measurement control, 2-37 Registration Roller, 2-46 Registration Roller Solenoid disassembly, 8-104 part number, 9-32 troubleshooting, 4-5 Registration Sensor, 2-45 disassembly, 8-116 media size detection, 2-47 misfeed, 4-4 part number, 9-42 troubleshooting, 4-4 Regulating Plate part number, 9-51 replacement preparation, 8-2 residual toner, 2-30
T
temperature error codes, 3-23 Temperature/Humidity Sensor, 2-9 density control, 2-36 disassembly, 8-118 part number, 9-49 thermal control, 2-13 thermal regulation, 2-40 thermistors, 2-58 Timing Belt Unit part number, 9-30 Toner life count, 1-21 toner adherence control, 2-37 Toner Cartridge life expectancy, 7-2
Index 4
maintenace replacement, 7-11 print quality problems, 5-24, 5-37 Top Cover disassembly, 8-4 part number, 9-12 Transfer Belt Position Sensor, 2-32 Transfer Belt Unit, 2-28 Cleaning Blade, 2-30 detection holes, 2-32 disassembly, 8-33 error code, 3-21 life expectancy, 7-3 part number, 9-38 print quality problems, 5-15, 5-37 troubleshooting, 3-18, 3-20, 3-21 Transfer Roller, 2-28, 2-29, 2-33 Bias Contact Plate, 8-88 cleaning, 2-35 Clutch, 2-33 disassembly, 8-86 error code, 3-2 image transfer, 2-34 life count, 1-21 life expectancy, 7-3 part number, 9-40 print quality problems, 5-17, 5-37 reassembly, 8-86, 8-87 Transfer Roller Holder part number, 9-40 Transparency Sensor, 2-46 disassembly, 8-117 error code, 3-25 part number, 9-42 troubleshooting, 3-25 Transport Motor troubleshooting, 4-13, 4-14 transport operations single sheets, 2-54 Tray 1 Cover disassembly, 8-9 part number, 9-51 Tray 1 No Paper Sensor, 2-45, 2-56 disassembly, 8-120
part number, 9-49 Tray 1 Paper Pick Solenoid, 2-44 disassembly, 8-102 feeder operation, 2-55 part number, 9-49 reinstallation, 8-103 troubleshooting, 4-4 Tray 1 Separation Pad disassembly, 8-89 part number, 9-49 Tray Detect Switch, 2-57 part number, 9-59 troubleshooting media-based problems, 4-3 mis-picks, 4-3 printing defects, 5-3
V
Ventilation Fan Motor, 3-14 disassembly, 8-90, 8-96 error code, 3-14 part number, 9-24 voltage measured tolerances, 3-10
W
Waste Toner Full Sensor, 2-42 disassembly, 8-70 error code, 3-26 part number, 9-20 troubleshooting, 3-26 Waste Toner Transfer Unit, 2-42 Wire Harness Kit part number, 9-53 wiring diagrams, 10-1 wiring views, 10-25
Index 5
Index
Index 6
701P45784

Phaser 6115 MFP Service Manual

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Service Manual 701P45784

Phaser 6115MFP Product Color Laser Multifunction

Color Laser Multifunction Product

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Symbols Marked on the Product

Hot surface on or in the printer. Use caution to avoid personal injury.

Do not touch the item.

Phaser 6115MFP Multifunction Product Service Manual

Power Safety Precautions

Moving the Printer

Phaser 6115MFP Multifunction Product Service Manual

Always lift the printer from the designated lift points.

Phaser 6115MFP Multifunction Product Service Manual

Electrostatic Discharge (ESD) Precautions

Phaser 6115MFP Multifunction Product Service Manual

Service Safety Summary

CLASS 1 LASER PRODUCT

Phaser 6115MFP Multifunction Product Service Manual

Servicing Electrical Components

Servicing Mechanical Components

Servicing Fuser Components

Phaser 6115MFP Multifunction Product Service Manual

United States (FCC Regulations)

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

3 Error Codes and Messages

Phaser 6115MFP Multifunction Product Service Manual

6 Adjustments and Print Function Settings

Phaser 6115MFP Multifunction Product Service Manual

7 Cleaning and Maintenance

Phaser 6115MFP Multifunction Product Service Manual

8 Service Parts Disassembly

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Printer Introduction and Overview System Options System Specifications

Printer Introduction and Overview

Phaser 6115MFP Front View (with Optional Sheet Feeder)

Automatic Document Feeder Control Panel

Optional Sheet Feeder

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115 MFP Rear View

Power Switch Duplex

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Frequency: 50/60 Hz 3 Hz Max Power Consumption Dimensions Weight

30%-85% RH, non-condensing

Phaser 6115MFP Multifunction Product Service Manual

Original Scanning Scanning in main scanning direction with a CCD

CPU Standard memory

Embedded RISC processor 48MHz 128 MB on IPB SDRAM 16 MB on LANB

Optional Memory Interfaces

Windows 98SE/Me/2000/XP/Server 2003

Phaser 6115MFP Multifunction Product Service Manual

Phaser 6115MFP Multifunction Product Service Manual

Transparency 42.26 mm/second film

Copy / Print speed Full color (Plain paper) Monochrome

Custom paper sizes