I have a Phaser 6130 (HAT046224) that was working fine with very low page count on it until it started making a clicking sound like gears slipping when trying to print and simultaneously stopped printing. Being a DIY kind of guy, I got a manual for the printer and started to troubleshoot. Here's what I've found:
- there are no error messages shown
In service mode:
- the ESS diagnostics (All Test) passes (Check OK)
- the sensor tests all pass
- the clicking sound occurs during the Main Motor tests (Full1, Full2, and Half)
- the Sub Motor tests all pass (in Full1, Full2, and Half, the clicking sound doesn't occur)
- the K Mode Solenoid test passes
- the Tray Feed Solenoid (Half) test does not seem to pass since the Feed Roller doesn’t make a half-turn (but I hear the solenoid click at the end of the test while the clicking sound occurs throughout the test - because the Main Motor is running)
- the Tray Feed Solenoid (Init) test does not seem to pass since the Feed Roller doesn’t do anything (in this test, I do not hear the solenoid click at the end of the test, but the clicking sound occurs throughout the test because the Main Motor is running)
- the Fan (High) and Fan (Low) both pass
- the Toner Motor tests all pass
- the Regi Clutch test passes (even though the clicking sound occurs because the Main Motor is running)
- the Tray Feed Solenoid (Auto) test appears to pass since the solenoid clicks closed and then opens
- the Drum Erase Lamp tests both pass
The clicking noise seemed to emanate from the Paper Feed Drive assembly, so I pulled it off the unit and with it removed (even still connected), the Main Motor tests no longer created the clicking noise. At this point, I concluded that the Feed Drive assembly was suspect, especially since one of the gears had a segment missing (Gear C). It seemed that when the drive spun one way, the Color Mode Switching Solenoid would catch Gear C and keep it from engaging. If the drive spun the other way, Gear C became the clicking noise as Gear P4-2 sat in the open segment of Gear C. Based on that observation, I decided to replace the Feed Drive assembly (PN 007K94706). When it arrived, I was surprised to see the new Feed Drive assembly looked the same as the one I had, but I put it in and found that I still had the clicking noise.
Somewhere in all of this, I did something while things were running and broke the Feed Gear (another one with segments missing), so I had to replace that as well (PN 675K54150).
So now you can see that I’ve clearly missed the real problem, but I don’t know what it is. I suspect I didn’t give enough weight to the fact that the Feed Roller doesn’t do anything during the Tray Feed Solenoid (Half/Init) tests (mainly because the Tray Feed Solenoid (Auto) test seemed to do something), but I’m stumped now. I sure would appreciate any thoughts anyone has regarding what could be the root cause of this problem and what I should do next. Thanks!
