Xerox Phaser 6300 User manual

Service
Manual
color laser printer
Phaser® 6300/6350

Phaser®6300/6350
Color Laser Printer
Service Manual
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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: March 2005
071-0875-00

Safety iii
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.
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.
ADC: Automatic Density Control MCU: Engine Control Board
BTR: Bias Transfer Roller NCS: Non-Contact Sensor
CRUM: Customer Replaceable Unit
Monitor
PHD: Imaging Unit
CTD: Toner Density Control PL: Corresponds to the FRU Parts List.
ESD: Electrostatic Discharge ROS: Laser Scanning Unit
IDT: Intermediate Transfer Unit RTC: Charge Roller

iv Phaser 6300/6350 Color Laser Printer Service Manual
Symbols Marked on the Product
DANGER high voltage.
Protective ground (earth) symbol.
Hot surface on or in the printer. Use caution to avoid personal
injury.
The surface is hot while the printer is running. After turning off
the power, wait 30 minutes.
Avoid pinching fingers in the printer. Use caution to avoid
personal injury.
Use caution (or draws attention to a particular component).
Refer to the manual(s) for information.
0
30 min.

Safety v
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 de-energize
the printer. You must also disconnect the power cord from the printer’s 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.

vi Phaser 6300/6350 Color Laser Printer Service Manual
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.
■After removing a static sensitive assembly from its anti-static bag, place it on a
grounded conductive surface. If the anti-static bag is conductive, you may ground
the bag and use it as a conductive surface.
■Do not use freon-propelled chemicals. These can generate electrical charges
sufficient to damage some devices.
■Do not remove a replacement component or electrical sub-assembly from its
protective package until you are ready to install it.
■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 IC’s and EPROM’s carefully to avoid bending pins.
■Pay attention to the direction of parts when mounting or inserting them on
Printed Circuit Boards (PCB’s).

Safety vii
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 extreme caution when working on or around the printer.
CLASS 1 LASER PRODUCT
The Phaser® 6300/6350 Color Laser Printer 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.

viii Phaser 6300/6350 Color Laser Printer Service Manual
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.
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Do not touch any electrical component unless you are instructed to do so by a
service procedure.
Servicing Mechanical Components
When servicing mechanical components within the printer, manually rotate drive
assemblies, rollers, and gears.
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Do not try to manually rotate or manually stop the drive assemblies while any
printer motor is running.
Servicing Fuser Components
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This printer uses heat to fuse the toner image to media. The Fuser is VERY HOT.
Turn the printer power off and wait at least 5 minutes for the Fuser to cool before
you attempt to service the Fuser or adjacent components.
S7300-02
S7300-03

Safety ix
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 numérique de la classe B est conforme à la norme NMB-003 du Canada.

x Phaser 6300/6350 Color Laser Printer Service Manual
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:
Low Voltage Directive 73/23/EEC as amended
Electromagnetic Compatibility Directive 89/336/EEC as amended
Radio & Telecommunications Terminal Equipment Directive 1999/5/EC as amended
This product, if used properly in accordance with the user's instructions, is neither
dangerous for the consumer nor for the environment.
A signed copy of the Declaration of Conformity for this product can be obtained from
Xerox.
EN 60950:2000
EN 60825-1:1994+A1:2001+A2:2002
EN 55022:1998 +A1:2000 +A2:2003
EN 55024:1998 +A1:2000 +A2:2003
EN 61000-3-2:2000
EN 61000-3-3:1995 +A1:2001
EN 300 330-2 V1.1.1
EN 300 440-2 V1.1.1
EN 300 489-3 V1.3.1

Safety xi
Manual Organization
The Phaser 6300/6350 Color Laser Printer 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 6300/6350 Color Laser Printer Service Manual contains these sections:
Introductory, Safety, and Regulatory Information: This section contains
important safety information and regulatory requirements.
Section 1 - General Information: This section contains an overview of the
printer’s operation, configuration, specifications, and consumables.
Section 2 - Theory of Operation: This section contains detailed functional
information on print engine components.
Section 3 - Error Codes and Messages: This section provides detailed
troubleshooting procedures for error messages and codes generated by resident
diagnostics.
Section 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.
Section 5 - Print-Quality Troubleshooting: This section focuses on techniques
to correct image quality problems associated with printer output.
Section 6 - Adjustments and Calibrations: This section provides procedures
for the adjustment of print engine components.
Section 7 - Cleaning and Maintenance: This section provides periodic cleaning
procedures for the printer.
Section 8 - Service Parts Disassembly: This section contains removal
procedures for spare parts listed in the Parts List. A replacement procedure is included
when necessary.
Section 9 - Parts List: This section contains exploded views of the print engine
and option FRUs, as well as part numbers for orderable parts.
Section 10 - Wiring Diagrams: This section contains the plug/jack locations and
the wiring diagrams for the print engine.
Appendix A - Reference: This section provides an illustration of the printer’s
menu structure, a listing of printer status codes, and a list of Service Diagnostics tests.

xii Phaser 6300/6350 Color Laser Printer Service Manual

Contents xiii
Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . . vi
Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 General Information
Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Metered Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Printer Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hard Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Additional Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Configuration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
550-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1100-Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Consumable Life Counter Behavior. . . . . . . . . . . . . . . . . . . . . . . 1-11
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Memory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . 1-13
Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Image Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Imaging Unit Cleaning Cycle Intervals . . . . . . . . . . . . . . . . . . . . 1-15
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
First Print Output Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
2 Theory of Operation
Phaser 6300/6350 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Summary of the Printing Process. . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Print Process Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Print-Quality Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

xiv Phaser 6300/6350 Color Laser Printer Service Manual
Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Selective Control; Paper Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
LED Light Density CTD (ADC) Control Sensor . . . . . . . . . . . . . . 2-11
Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Transfer Roller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Toner Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Paper Path Route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Sensor Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Sensors in the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Print Engine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Registration Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Chute Assembly In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Chute Assembly Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Transfer Roller and Fuser Assembly . . . . . . . . . . . . . . . . . . . . . 2-37
Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Tray 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Tray 2 Paper Pick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Toner Cartridge Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . 2-45
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
1100-Sheet Feeder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Paper Pick Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
550-Sheet Feeder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Tray 3 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
3 Error Messages and Codes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Accessing Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Status Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service Usage Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Contents xv
Messages, Codes, and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Error Message Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Error Message Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Using the Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . 3-9
Measurement Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Jam Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Jam at Fuser: Jam F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Jam at Duplex: Jam D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Jam at Registration Roller: Jam RR . . . . . . . . . . . . . . . . . . . . . . 3-15
Misfeed at Tray 1 (MPT): Jam T1 . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Misfeed at Tray 2: Jam T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Misfeed at Tray 3: Jam T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Misfeed at Tray 4: Jam T4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Misfeed at Tray 5: Jam T5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Door and Cover Error Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Close Front Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Consumable/Routine Maintenance Procedures . . . . . . . . . . . . . . . . . . . 3-33
Install or Reseat Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Replace Imaging Unit or
Imaging Unit Is Near End of Life . . . . . . . . . . . . . . . . . . . . . . 3-34
Install or Reseat Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Replace Transfer Roller or
Transfer Roller Is at End of Life . . . . . . . . . . . . . . . . . . . . . . 3-37
Install or Reseat Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Replace Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Install or Lock [Y] [M] [C] [K] Toner Cartridge. . . . . . . . . . . . . . 3-41
Replace [Y] [M] [C] [K] Toner Cartridge or
[Y] [M] [C] [K] Toner Is Low . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Dusty Density Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Remove Ribbon from [Y] [M] [C] [K] Toner Cartridge . . . . . . . . 3-45
Tray 2 Paper Is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Tray [3] [4] [5] Paper Is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Replace [Y] [M] [C] [K] Toner Cartridge. . . . . . . . . . . . . . . . . . . 3-48
Non-Phaser 6300/6350 Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Replace Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Non-Xerox Imaging Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Metered Toner Is not Enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Tray and Media Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Insert Tray [2] or Tray [2] Missing . . . . . . . . . . . . . . . . . . . . . . . 3-54
Insert Tray [3] [4] [5] or Tray [3] [4] [5] Missing. . . . . . . . . . . . 3-55
Out of Paper; Load Tray 1 (MPT) with [size] [type] . . . . . . . . . . 3-57
Out of Paper; Load Tray [2][3][4][5] with [size][type] . . . . . . . . 3-58
Output Tray Is Full, Unload Paper . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Media Mismatch Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Wrong Paper Size; Load Tray 1 (MPT) with [size][type]. . . . . . . 3-61
Wrong Paper Size; Load Tray 2 with [size][type] . . . . . . . . . . . . 3-62

xvi Phaser 6300/6350 Color Laser Printer Service Manual
Wrong Paper Size; Load Tray [3][4][5] with [size][type]. . . . . . 3-63
Configuration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Invalid or Missing Configuration Card . . . . . . . . . . . . . . . . . . . . 3-64
Duplicate IP Address Detected. . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Unsupported Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Fatal Error Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Density Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Fuser Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Rear Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Fuser Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Engine Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Engine Firmware Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Engine NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
[Y] [M] [C] [K] Toner Cartridge Failure . . . . . . . . . . . . . . . . . . . 3-77
Environmental Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Fuser Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Developer Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Main Motor Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Motor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Disk Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Image Density Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
4 General Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
POST Soft Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
POST Hard Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Service Diagnostics Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Service Diagnostics Utilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Diagnostic Fault History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
No Control Panel Display after Power Is Turned On. . . . . . . . . . 4-11
Control Panel LED Is On, Control Panel Display Is Blank . . . . . . 4-11

Contents xvii
Inoperable Printer Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Engine Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Printer Continually Displays Warming Up... . . . . . . . . . . . . . . . . 4-12
Printer Continually Displays Install or Reseat Imaging Unit . . . . 4-12
Printer Displays Reseat Contoller Board . . . . . . . . . . . . . . . . . . . 4-12
Printer Does Not Come to a Ready State . . . . . . . . . . . . . . . . . . 4-13
Paper Size Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
AC Power Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
RAM Memory Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Media Jams and the Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . 4-20
Macintosh Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Windows Printing Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Network Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Network Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
USB Port Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
5 Print-Quality Troubleshooting
Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Defects Associated with Specific Printer Components . . . . . . . . . 5-3
Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Test Print 1: CMYK Sample Page . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Test Print 2: RGB Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Test Print 3: Test Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
600 x 600 Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Engine Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Print-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Light Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Light Print in Only One Color . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Black Prints with White Margin Border. . . . . . . . . . . . . . . . . . . . 5-16
Solid Dark or Dirty Prints, No Border . . . . . . . . . . . . . . . . . . . . . 5-17
Horizontal Bands, Voids Or Streaks in Any or All Colors. . . . . . . 5-18
Vertical Bands, Voids or Streaks in Any or All Colors . . . . . . . . . 5-20
Repeating and/or Random Spots . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Background Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Residual Image, Ghosting or Hot Offset . . . . . . . . . . . . . . . . . . . 5-26
Incomplete Fusing or Cold Offset . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Mis-Registration, Color Layers Not Correctly Registered . . . . . . 5-29
Dirty Vertical Streaks on the Edges of the Page . . . . . . . . . . . . . 5-30

xviii Phaser 6300/6350 Color Laser Printer Service Manual
6 Adjustments and Calibrations
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Color Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Margin Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Vertical and Horizontal Color Registration . . . . . . . . . . . . . . . . . . 6-3
Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Restore Factory Registration Settings . . . . . . . . . . . . . . . . . . . . . 6-4
Restore Factory Color Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Restore Previous Color Settings . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Restore Factory Margins Settings . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Resetting Connection Setup Defaults. . . . . . . . . . . . . . . . . . . . . . 6-5
Resetting Paper Handling Defaults. . . . . . . . . . . . . . . . . . . . . . . . 6-5
Resetting PostScript Setup Defaults . . . . . . . . . . . . . . . . . . . . . . 6-6
Resetting PCL Setup Values to Default . . . . . . . . . . . . . . . . . . . . 6-6
Resetting Control Panel Setup Values to Default . . . . . . . . . . . . . 6-6
Resetting Printer Controls Values to Default . . . . . . . . . . . . . . . . 6-6
Resetting All Printer Defaults (PostScript NVRAM) . . . . . . . . . . . 6-7
Developer Assembly Life Count Resets . . . . . . . . . . . . . . . . . . . . 6-7
Maintenance Kit Life Count Resets . . . . . . . . . . . . . . . . . . . . . . . 6-7
Service Diagnostics NVRAM Utilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Postscript NVRAM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Engine Control Board NVRAM Save/Restore . . . . . . . . . . . . . . . . 6-8
Toner Cartridge Install Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Toner Cartridge CRUM Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
CRU Life Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
CRU Life Read . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
7 Cleaning and Maintenance
Service Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Cleaning the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cleaning the Developer Assemblies . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cleaning the Laser Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
RIP (Repair, Inspect, and Prevent) Procedures . . . . . . . . . . . . . . 7-4
Long-Life Maintenance Kit Installation. . . . . . . . . . . . . . . . . . . . . 7-4
8 Service Parts Disassembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . 8-2
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Notations in the Disassembly Text. . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fastener Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Contents xix
Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Imaging Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Toner Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Print Engine Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Top Main Cover (PL1.1.4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Front Cover (PL1.1.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Control Panel (PL1.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Right Side Cover (PL1.1.20). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Left Side Cover (PL1.1.30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Door C (PL1.1.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Rear Cover (PL1.1.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Right Front Cover (PL1.1.22) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Left Front Cover (PL1.1.28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Front Feeder Frame Cover (PL3.1.1). . . . . . . . . . . . . . . . . . . . . . 8-19
Universal Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Retard Assembly (PL2.1.12). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Feeder Chute (PL3.1.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Tray Rear Cover (PL3.1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Printer Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Paper Size Switch Assembly (PL3.2.24). . . . . . . . . . . . . . . . . . . 8-25
Option Feeder Harness (PL3.2.11) . . . . . . . . . . . . . . . . . . . . . . . 8-26
Paper Pick Assembly (PL3.3.1) . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
No Paper Sensor (PL3.3.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Low Paper Sensor (PL3.3.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Upper Chute (PL3.3.15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Low Paper Sensor Actuator (PL3.3.14) . . . . . . . . . . . . . . . . . . . 8-31
Feed Roller (PL3.3.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
No Paper Sensor Actuator (PL3.3.20) . . . . . . . . . . . . . . . . . . . . 8-33
Retard and Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Registration Chute (PL4.1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Registration Sensor Actuator (PL4.1.1) . . . . . . . . . . . . . . . . . . . 8-35
Registration Sensor (PL4.1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Retard Holder Assembly (PL4.1.16) . . . . . . . . . . . . . . . . . . . . . . 8-37
Registration Roller Assembly (PL4.2.1) . . . . . . . . . . . . . . . . . . . 8-38
Tray 1 (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Tray 1 (MPT) (PL1.1.23). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Tray 1 (MPT) Cover (PL1.1.27) . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Tray 1 (MPT) Feed Solenoid (PL5.3.9) . . . . . . . . . . . . . . . . . . . . 8-41
Tray 1 (MPT) No Paper Sensor and Actuator (PL5.3.14) . . . . . . 8-45
Tray 1 (MPT) Feed Roller (PL5.3.20) . . . . . . . . . . . . . . . . . . . . . 8-49