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1. 9923 115 Test Prints 5 161 4 Reverse Text The print indicates if the printhead is outputting properly sized drops of ink and that the drum temperature is not too high Note This print should be made with the printer covers closed and in place The heat loss without the covers can hide the too hot thermal problem Also print the test print in Standard print mode Look for Legibility in the lines of 6 point text particularly in the primary colors If the letters are closed or badly plugged with ink the printhead is laying down too much ink A good quality print shows five vertical parallel lines of different thicknesses on the left and right side of the print If the thinnest line is missing the printhead is outputting too much ink or the drum temperature is too high Causes Check the thermal regulation of the printhead and of the drum Make sure that the drum temperature sensor is correctly mounted and in proper even contact with the drum If necessary remove the sensor and check it for an accumulation of debris at its contact point Replace the drum temperature sensor Check the printhead to drum gap Phaser 840 only Ensure the printhead drive voltage is set to the default 128 5 Big Bands Hand fed OHP This print allows you to evaluate transparency printing as well as manual feeding It prints two prints one with primary color fills and one with secondary
2. 8 212 Motor and fan FRUs 8 214 Circuit Board FRUs 8 216 Solenoid and Clutch FRUs 8 218 Gear and belt FRUs 8 220 Sensor and flag FRUs 8 222 High capacity Paper Tray 8 224 New ink sticks PA 242 x Phaser 840 850 860 8200 Color Printer Service Manual General Information This service guide contains information used to verify operation troubleshoot repair adjust and maintain the Xerox Phaser 840 Phaser 850 and Phaser 860 Color Printers This guide includes a Field Replacement Unit Parts list Topics such as printer theory of operation detailed removal replacement procedures configuration page details and verifying printer operation are located on the companion Color Printer Service amp Support Resources CD ROM To ensure complete understanding of the product we recommend participation in Phaser 840 850 860 printer service training 0388 01 Fig 1 1 The Phaser 840 850 printer shown with optional High Capacity Paper Tray Assembly P860 001 Fig 1 2 The Phaser 860 printer shown with the optional High Capacity Paper Tray Assembly General Inormation 1 1 Phaser 840 Printer Overview The Phaser 840 Color Printer is an Adobe PostScrip
3. 8 210 Paper path FRUS 8 213 Motor and fan FRUS 8 215 Circuit board FRUS 2 8 216 Solenoid and clutch FRUs 8 219 Gear and belt FRUS E ee 8 221 Sensor and flag FRUs 8 223 High capacity Paper Tray FRUs 8 225 Setvicetools 0 2 co xem tee ee Dee emos 8 226 Supplies and accessories 8 227 viii Phaser 840 850 860 8200 Color Printer Service Manual List of Figures The Phaser 840 850 printer shown with optional High Capacity Paper Tray Assembly 1 1 The Phaser 860 printer shown with the optional High Capacity Paper Tray Assembly 1 1 Internal features of the print engine 1 12 Circuit boards of the print engine right front view of the Phaser 850 1 13 Circuit boards of the print engine left rear view Phaser 850 1 14 Circuit Boards of the print engine right rear view Phaser 860 1 14 The printer s IC b s B cines ahd ool 1 15 Printhead maintenance system of the print engine 1 16 Sensors and switches on the right side ofthe print engine 1 17 Swi
4. 3 89 Color is uneven 3 90 Streaks or lines down the print 3 9 Scratches parallel to the long axis of printing 3 92 Printing too light or too dark 3 93 White portion of print is colored 3 94 Fuzzy Text 3 95 Poor primary color fills 3 96 Ghosting 3 97 Poor small text resolution 3 98 Vertical line appears wavy 3 99 streaks on print 3 100 Incomplete image transfer to paper 3 101 Ink smears on first side of duplex printt 3 102 Repeating print defects on the print 3 103 Wrinkling 3 104 Front Panel Shortcuts 4 119 List of Tables vii Hidden Service Menu eee 4 121 Diagnostic Menu Map 4 123 Check Menu Value Key 4 127 Test Print Ment ee ee eee Pe ee 5 159 Maintenance Kit Life 6 176 Cabinet FRUS 0s 2 eh ee ee 8 209 Imaging FRUS
5. 9 S 0388 09 Fig 1 12 Features of the Phaser 840 printer main board General Information 1 21 EEPROM RAM DIMMs Printer ID Code ROM 0388 76 Fig 1 13 Features of the Phaser 850 printer main board Factory Code ROM ROM Upgrade Code DIMM EEPROM Printer ID RAM SODIMMs Hard Drive P860 002 Fig 1 14 Features of the Phaser 860 Main Board 1 22 Phaser 840 850 860 8200 Color Printer Service Manual Front Panel Phaser 840 850 Printers These front panel features are found on the printer 128 x 64 pixel backlighted graphic display W Two push buttons and four arrow buttons m Two LEDs LCD The backlighted LCD serves two purposes displaying current image processor and print engine status information and displaying an interactive menu Status information includes image processor status such as Ready to print Receiving data and Printing Print engine status includes messages such as Out of paper Paper Jam Add ink as well as error messages Customers can review and modify certain NVRAM I O ports and peripheral parameters Buttons Four of the six buttons are arranged as a diamond shaped keypad The other two buttons are used as Select and Help Refer to Check Value Menu Parameters on page 4 135 for details on using the front panel controls to enter special printer modes The topic Resetting on page 4 156 explains how to use the front panel buttons to reset the NVRAM to its fact
6. a a a a af a 4 4 4 4 4 4 AJ Oo No media at middle tray pick sensor o Middle tray not empty o Middle tray present o No media at lower tray pick sensor 0 Lower tray not empty 0 Lower tray present Diagnostics and Adjustments 4 127 Table 4 4 Check Menu Value Key Paper Path Timing Test ID 17 and 4 This test reports the timing from one sensor or event to the next sensor in the paper path The results are broken into two ID s 17 includes pick events from all trays up to the standard ick sensor ID 4 coves the remaining paper path sensors In the case of the Preheat entry sensor to the A width sensor the locations are so close that skewed paper may result in negative timings Test ID R Definition Results Interpretation Actions The paper is not being picked 0 Tray 3 pick motor gt 850 reliably Ensure that the paper is to tray 3 pick flag not too heavy and the at the tray is loaded properly Paper is not feeding smoothly through the trays Ispect the trays 1 3 feed motor gt 975 for obstructions trays are loaded properly the correct media 2 pick flag weight is used and the tray is properly seated in the printer Paper is not feeding smoothly through the trays Inspect the trays and pick up guide for Mig e ja 000 obstructions Are the trays loaded y with the suppo
7. sse 3 94 Fuzzy Text ss Poor primary Color fills 1i riter tent te ptit su 3 96 Gh stn8 etui date d T ee 3 97 Po t small text fesol tion 5 2i tiec edet etie een eti cepe ge 3 98 Vertical line appear wavy oerte pei PER eet op ee eee 3 99 Oil streaks on prinia e dte een eene eph 3 100 Incomplete image transfer to paper sss 3 101 Ink smears on first side of duplex print 3 102 Repeating print defects on print 3 103 Wrinkling esses 3 104 Image is offset or cut 3 105 Oil streaks on top of print essere 3 105 Poor ink adhesion poor image durability sss 3 105 Evaluating the printhead and cap wipe purge system sss 3 106 Troubleshooting following cap wipe purge installation 3 112 Macintosh printing problems eeeeeeeseeeeeeeene 3 115 Image nev r Printe ertt acre etit tenti rr te e ele de 3 115 Image is rotated 90 degrees sse 3 115 Image prints in black and white sse 3 115 Pririt r sn t in the Chooser ssc seed rete e t de 3 116 Windows printing problems essent 3 117 ii Phaser 840 850 860 8200 Color Printer Service Manual Diagnostics Adjustments and NVRAM 4 119 Front Panel Shortcuts iere rper senses anai 4 119 Hi
8. Problem on Page System Power Up Sequence page 76 Inoperative Printer No Lights No Sound on power up page 80 Verifying Main Board CPU Operation page 80 Verifying Print Engine operation by its startup page page 81 Verifying Power Supply and Measuring Voltages page 81 Inspecting the power supply fuses page 82 Testing for shorted drivers page 83 Testing for a shorted motor page 84 Testing motor and solenoid resistances page 84 Media and Paper Path Problems RAP Table Table 3 2 Media and Paper Path RAP Table Problem on Page Media Based Problems page 85 Paper Pick Errors page 85 Print Transfer Jams page 86 Checking the Process Motor and Drive Train page 86 Media skews passing through the Paper Path page 87 Troubleshooting 3 73 Print Image Quality Problems RAP Table Table 3 3 Print and Image Quality Problems RAP Table Problem on Page Not Printing page 88 Missing ink or light colored ink band running length of print page 89 Color is uneven page 90 Streaks or lines in the prints page 91 Scratches parallel to the long axis of printing particularly with page 92 film Printing too light or too dark page 93 White portion of print is colored or marked page 94 Fuzzy text page 95 Poor primary color fills page 96 Ghosting page 97 Poor small text resolution page 98 Vertical line appears wavy page 99 Oil streaks on print top or bottom page 100 I
9. 04 001 40 PC DEV FAULT HEAD READ Failure reading printhead NVRAM data check the wiring to the printhead 12 bus and other hardware May also be related to ESD 04 002 41 PC DEV FAULT HEAD Z EROS Printhead NVRAM data was all Os has this printhead been through normalization If so check wiring to printhead May also be related to ESD 4 003 42 PC DEV FAULT HEAD ONES Printhead NVRAM data was all 1s has this printhead been through normalization If so check the wiring to the printhead 4 004 43 Printhead NVRAM checksum failure the data within the PC DEV FAULT HEAD printhead NVRAM has been corrupted Check the hardware and CHECKSUM wiring The printhead may need to be renormalized a manufacturing function 4 006 67 This indicates that an undefined message was found by the PC PROG FAULT 0x06 processor This may be caused by ESD Check grounding and media issues Error Codes and Messages 2 45 Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 4 013 43 The printhead is unable to move on its tilt axis The head is PC DEV FAULT GEAR unable to move on its tilt axis because it is colliding with GRIND something head restraint pin cap poorly installed ink loader cee SB399 screwdriver Prior to declaring this fault the engine has attempted to move the process motor through enough revolutions to disengage the
10. Comments 252 Phaser 840 850 860 8200 Color Printer Service Manual 2840 2850 Electronics Troubleshooting Guide This troubleshooting guide is composed of two sections The first section is to be used for printer failures that occur during the printer s power on sequence The second section is to be used for all other failures relating to electronics that can occur at any point other than during the power on sequence Failures Occurring During Power On Sequence l No Lights No Sound ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 Fan twitches lights may flash on for a moment A Short in power system A1 Check for shorted motor drivers on power control board by removing 40V Jumper and replace it with 40V Service Plug A2 If the printer powers up with 40 V Service Plug put 40 V Jumper back in place and systematically remove cables from power control board until it does power up replace appropriate art If printer still does not work after removing cables from power control board replace power control board A3 If it does not power up with 40 V Service Plug replace power supply If it still does not power up with new power supply replace main board 2 No reaction to power switch fan does not move lights don t blink A No wall power B Power supply failed C Short in power system 2A Check wall power for proper voltage 2B Check power supply fuse
11. 4 128 63 PC PROG FAULT 0x80 Bad Command Result waiting for Fault to clear processing of a PostScript command message returned SERVICE NEEDED while waiting go the fault state to clear This should never happen and is flagged by pend waiting for fault to clear as an error 4 243 61 Some Phaser 850 printers were built with printheads that had different set points for different print modes If the printer sees what it believes to be an invalid set point this fault occurs Review the print options that the user is selecting and try a different print quality mode or avoid selecting different page sources within a job Changing the printer defaults may also help turn off 2 sided printing turn on the Startup Page etc If these work arounds are unsuccessful replace the printhead 2 48 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 5 000 Y AXIS PROGRAM FAULT CODES see also SB457 SB461 SF167 5 001 41 YA HOME FAIL Drum home sensor failure The drum has turned a full revolution without seeing the drum home sensor activate Check the Y axis encoder and I O Left board Note The Phaser 840 has a separate drum home sensor The Phaser 850 printer s home sensor is part of the drum position sensor Run the Y axis Encoder Diagnostic Test Phaser 860 only 5 002 42 Y axis position failure The drum i
12. Y Axis Encoder Test ID 10 This test finds the encoder home positon at faster rates with each cycle to find the maximum rate at which the home location can be seen Test ID R Definition Results Interpretation Actions Encoder gap alignment may be 0 Max Home flag lt 106000 Off the encoder disk may be sense velocity scratched or the encoder sensor may be defective Y Axis Encoder ID 10 1 Plus postion loss gt 2 Encoder gap alignment may be during positioning off or the encoder disk may be Minus postion scratched 2 loss during 2 positioning Y axis Geometry Test ID 11 This test measures the amplitude and frequency of vibration peaks in the y axis system The test will identify up to 15 of these peaks and display the results as AMPLITUDE FREQUENCY The frequencies will vary slightly The table below identifies the amplitudues at which key frequencies are exceeding their normal range Results Interpretation Actions Retension Y axis belts then gt 2500 4 9 0 5 replace the y axis pulley assembly Check the drum for binding when gt 2300 6 2 0 6 rotated Replace the drum transfix assembly if it is binding gt 3700 25 4 2 5 gt 500 Q 33 3 3 3 Retension belts then gt 550 66 6 6 7 replace y axis pulley assembly gt 800 87 6 8 8 Replace y axis motor Retension y axis belts and gt 1000 any frequency gt 15 0 insp
13. 0388 78 Fig 4 4 Setting the Y axis belt tension Phaser 850 860 Diagnostics and Adjustments 4 145 Printhead to drum spacing adjustment Phaser 840 Printer Only Tools required m Printhead to drum gap clips and springs m Small 3 16 in flat blade screwdriver Magnetic screwdriver m T 20 TORX tip m 9 64 in hex tip Make this adjustment after removing or replacing the printhead Note The Phaser 850 and 860 printheads should never be adjusted If the printhead is known to be out of adjustment it should be replaced 1 If not already removed remove the top cover and the metal heat cover 2 Tilt the printhead to its print position and if previously removed attach the head tilt spring 3 For the hot adjustment scroll to the printer s hidden service support menu To enter the hidden menu scroll to the Troubleshooting menu and press Select Press and hold the left arrow button While holding the left arrow button press Select Activate the menu s Head to Drum Adjust routine The routine automatically centers the printhead and brings the printhead and drum to their operating temperatures If the printhead fails to tilt back momentarily when Head to Drum Adjust is selected exit and re enter the adjustment mode to ensure the adjustment is performed accurately 4 Lift the ink loader up and back slightly so that the printhead can be accessed Do not unplug the printhead 5 If not already tightened tighten the
14. Declared when the printer is booted and the drum is dirty Cleaning the drum when very cold could increase the chance of gluing media to the drum surface and creating a mess around the stripper fingers 4 023 66 PC PROG FAULT 0x17 Dangerous Process Motor Motion Detected The PC task is about to send a command to the process motor to print chase move the eccentric cam or move the dm cam while the PC task detects that the printer is in a dangerous position from such a move damage could result 4 029 63 PC PROG FAULT 0x1d Head Cal Task Spawn Failed An attempt to spawn the head calibrate task failed This may be due to a low memory condition Error Codes and Messages 2 47 Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 4 032 66 PC PROG FAULT 0x20 Undefined result in pc process result The PC task function pc process result received an undefined inter task communication ITC result message from one of the tasks it communicates with This is typically caused by out of order messages due to fault condtions different than what the software expects 4 035 60 PC PROG FAULT 0x23 Bad Status Message in pc process status The PC task received a inter task communication ITC status message that it did not expect 4 040 65 PC PROG FAULT 0x28 Re entrant call to halt detected This error is generated in pc syshalt seq the soft sh
15. PM FAULT COMPOUND GEAR SENSOR BAD No transistions are observed for the compound gear sensor when the compound gear should be turning Verify that compound gear sensor is not physically broken and is plugged in to the left I O board Run diagnostics to verify operation or change the sensor 2 50 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 07 004 46 The Drum Maintenance home sensor did not actuate or change PM FAULT DM CAM _ state as expected Run diagnostics to verify clutch and sensor State Error operation Also verify that the shaft is properly assembled see SF165 amp SF167 7 004 46 Maintenance blade position sensor right I O board failed to detect transitions of the drum maintenance home flag Observe drum maintenance home flag motion while turning on the printer Does flag Check operation of the Does process rotate during power compound gear belt gear train rotate on sequence and drive train smoothly Replace or reseat gears replace or retension belt Remove maintenance Replace I O drawer and inspect right board drum maintenance cam bushings and cam lifters All parts installed correctly Reinstall or reseat the parts Replace in this order drum maintenance clutch e I O board Power contro
16. Check the transfix solenoid and its cam Ensure they operate correctly and are properly lubricated If lubrication is needed apply a dab of grease to the contact point between the cam and the latch and the cam and the cam advanced spring Refer to Lubrication on page 6 177 A stripper finger or rapid release guide jam can occur because of broken teeth on the small section of the back side of the compound gear The root cause of this may be also be due to a lack of transfix cam grease If you find broken teeth on the compound gear check for proper lubrication of the transfix cam Be careful to ensure that no grease touches the Y axis belts If the belts get contaminated with grease they must be replaced wipe off any excess grease to prevent it from dripping onto the belts Checking the process motor and drive train 1 Determine if the process motor runs If it does not rotate go to Step 2 If it does rotate go to Step 5 Measure to determine if 40 VDC is being supplied to the motor If power is applied go to Step 3 Ifit is not inspect the process motor s wiring harness If the harness is functional then troubleshoot the power control board and power supply Refer back to the topic Measuring power supply voltages on page 3 81 Disconnect the motor s wiring harness Measure the resistance of the motor s windings The expected resistances are listed in Table 3 5 Motor and solenoid resistances on page 3 84 I
17. Disconnect the head tilt spring Remove the top cover Remove the ink loader Disconnect the wiring harness leading from the cap wipe purge assembly to the power supply wiring harness Clip the tie wraps and disconnect the vacuum hose leading to the vacuum pump module 8 Tilt back the printhead and center it 9 Rotate the cap wipe drive gear to position the cap wipe purge assembly 25 mm 1 in from the top of its travel 10 Place a few sheets of paper between the drum and the cap wipe purge assembly to prevent scratching the drum 11 Remove the right timing belt s lower pulley to create slack in the right timing belt 12 Remove the metal vacuum line from the assembly 13 Remove the wiring from the right cap wipe purge assembly bracket 14 Push the wiring through the print engine s frame so that you can unloop it from the cap wipe purge assembly 15 While holding onto the cap wipe purge assembly remove the three pin screws that hold the cap wipe purge assembly in the grooves on each side of the print engine Reverse these steps to reinstall the cap wipe purge assembly Refer to Wiring Diagrams on page 9 235 for details on dressing the cap wipe purge wiring 7 202 Phaser 840 850 860 8200 Color Printer Service Manual Cap wipe purge assembly IS screw Long pin screw N AN 840 4 43 Fig 7 20 Removing the cap wipe purge assembly Phaser 840 printer Removal an
18. Main Board CPU operation 3 80 Verifying print engine operation by printing a built in page 3 81 Verifying power supply operation 3 81 Measuring power supply voltages ccessesseescseceeceeceseseseesecsecsecseeseeas 3 81 Inspecting the power supply fuses sss 3 82 Testing for shorted drivers sss 3 83 Testing for a shorted motor sss 3 84 Testing motor and solenoid resistances 3 84 Paper Path and Media based Problems 3 85 Media based problems sees eene 3 85 Paper pick ertots ace ntt edited id i ee De Hee Print transfer jams e Checking the process motor and drive train sss 3 86 Media skews passing through the paper path sese 3 87 Print Image Quality Problems attt treten estet teet ret n 3 88 Not printing i crises no eroe rer APAAPA RE Ra 3 88 Missing ink or light colored ink band running length of print 3 89 Coloris Ul eVelbuiuiise nt i be nee a Sissi pa ds uu ixi eni eee E Reds 3 90 Streaks or lines down the print esses 3 91 Scratches parallel to the long axis of printing particularly with film 3 92 Printing too light or too dark sese 3 93 White portion of print is colored
19. Run the test a second time before concluding that there is a failure If the tubing is ok replace the vacuum module Vacuum bleed off time lt 3000 ID 8 This test measures the alignment of the Cap Wipe Purge There may be a leak in the vacuum system or inadequate peak vacuum Run the test a second time Inspect and replace the cap wipe purge or tubing as needed If no problem is seen replace the vacuum module ID 9 This runs successive cycles of R Definition Results Interpretation Actions Right belt gt 75 Verify cap wipe purge belt o hysteresis 20 alignment and tension Excessive torque required with 1 Process Motor no gt 61 no load run the Cap Axis Drive load current Test Left belt gt 120 Verify cap wipe purge belt 2 hysteresis 50 alignment and tension Cap tilt gt 160 Verify cap wipe purge belt 3 40 alignment and tension rmine the minimum drive current R Definition Results Paper path motor o drive current at gt 0 87 end scan 1 Scan cycles lt 3 Cap axis gt 0 2 hysteresis 04 gt 0 120 3 Plus position loss lt 0 120 Minus position gt 0 120 4 loss lt 0 120 the Cap Wipe Purge drive system Interpretation Actions All Tests Inspect for obstructions or binding in the cap wipe purge system 4 132 Phaser 840 850 860 8200 Color Printer Service Manual Table 4 4 Check Menu Value Key
20. 115 VAC nominal 174 to 264 VAC 220 VAC nominal Input voltage range is auto sensed Primary voltage frequency range 47 to 63 Hz Power consumption 200 watts standby 300 watts at idle 600 watts during printing Maximum power consumption 1000 watts during warm up Current rating 115 VAC configuration 8 amp max 1 amp min 220 VAC configuration 4 amp max 1 amp min Fusing F1 DC switcher 6 3 amp slo blo F2 Drum heater 1 reservoir heater 1 ink melt chambers cap wipe purge unit 10 amp slo blo F3 Jet stack left and right paper pre heaters reservoir heaters 2 3 and 4 10 amp slo blo Fuses are not user accessible Secondary voltages 5V x 2 596 12 V 5 12 V 5 40 V 5 12 52 V 10 54 10 General Information 1 33 Table 1 11 Electrical specifications Characteristic Specification RF emissions Both 115 and 220 VAC configured instruments pass these standards EC EN60950 1992 Safety of Information Technology Equipment including Business Equipment EC EN55022 1992 Limits and methods of measurement of radio interference characteristic of Information Technology Equipment EC EN50082 1 1997 The Generic Immunity Standard Residential Commercial and Light Industry EN61000 4 3 1995 02 RF Field Immunity EN61000 4 2 1995 01 ESD Electostatic Discharge EN61000 4 4 1995 01 Fast Burst Transient EN61000 4 5 1995 02 Line Surge EN61000 4 6 1996 0
21. 840 replace the power control board with 01 or higher version board 1C See SF152 Replace Lower Tray Assembly connector inside printer Notes 260 Phaser 840 850 860 8200 Color Printer Service Manual ON SITE PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 860 8200 Version 1 3 NAME OUT REQUEST ID DATE SERVICE COMPANY if no OUT REQUEST ID PHONE IMPORTANT This checklist outlines proper printhead troubleshooting procedures and should be performed by all Xerox employees and any other service personnel on any job involving printhead replacement The completed checklist and sample test prints are to be returned with each printhead Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed checklist and a sample print with each returned printhead As the On site Printhead Troubleshooting Checklist is a complex procedure it has been organized into three sections the Initial Checklist the Cap Wipe Purge Checklist and the Non Xerox Tektronix Ink Failure Checklist Please return the following items with the defective printhead Service Print 2 not applicable for system errors On site Printhead Troubleshooting Checklist filled out Inventory control GreenTag filled out Sample prints which clearly show the observed printhead defect not applicable for system errors Initial Checklist 1 Check for use of Non Xerox Tektronix Ink NXTI circle all that apply
22. Fig 3 7 Inadvertently disconnected thermistor cable connector m 13 034 46 error thermistor appears to be shorted Look to see if the 4 pin plug on the top of the driver board is plugged in correctly If it is check the gray data cable If the gray data cable is good replace printhead If the error happens the new printhead replace the power control board m 13 035 47 and 13 036 48 errors reservoir heater is running away or reservoir is not heating With these errors it is most likely a problem with the printhead Note A broken ink loader can cause the cap wipe purge assembly gasket to not seal Look for signs of breakage of the black plastic parts on the ink loader 5 underside especially the bosses that retain the lowest black plastic panel Breakage or separation can interfere with head tilt resulting in a poor seal with the cap wipe purge assembly during the purge process Replace the ink loader if broken or defective 3 114 Phaser 840 850 860 8200 Color Printer Service Manual Macintosh printing problems Image never prints The printer indicates it is receiving data but no print comes out of printer or the printer goes back to Ready to Print mode without printing an image 1 Make sure that the correct printer icon was selected in the Chooser Try printing the job again Try printing a different file or from a different application In the Chooser switch background printing off Try printing the job again With
23. Gear and Belt FRUs 8 220 Sensor and Flag FRUS 2 8 222 High capacity Paper Tray Assembly sss 8 224 Service Supplies and accessories iv Phaser 840 850 860 8200 Color Printer Service Manual Wiring Diagrams 9 235 Phaser 8200 Color Printer Addendum PA 241 Phaser 8200 Printer Configurations eee PA 241 Hardware Updates Internal Pages and Menu Items 5 InkS e dta m Appendix A 243 On site Printhead Troubleshooting Checklist Phaser 340 350 360 380 840 850 sscsseseccsseeeeeseseeseesescseeesesseseneeeeeeaeete A 244 On site Electronics Troubleshooting Checklist Phaser 840 850 A 250 7840 2850 Electronics Troubleshooting Guide sss A 253 On site Printhead Troubleshooting Checklist Phaser 860 8200 3 pereo ca ene dp ID ee e e EROS On site Electronics Troubleshooting Checklist Phaser 860 Contents y vi Phaser 840 850 860 8200 Color Printer Service Manual List of Tables Installed RAM and printer capabilities 1 8 Acceptible SORAMDIMMs 1 9 Acceptible SODIMMs 1 10 Installed RAM and printer capabilities 1 11 Tray switch sensor combinations 1 20
24. PPPRxxxxx C indicates the headquarters of the city or country of the manufacturing company B Beaverton M Malaysia Y numerically indicates the last digit of the year of manufacture ranging from 0 to 9 R indicates the modification level rev of the printer ranging alpha numerically from 0 to Z Phaser 840 850 only an F represents printers for the FreeColorPrinters Program exclusively xxxx numerically indicates the sequence of the printer among the printers produced matching the other parameters PP indicates the product code XC LGP 860 XD LHW 860DPF LTH 8200 LUK 8200DPF M indicates month of manufacture ranging alpha numerically from 1 to C D indicates the day of the month of manufacture ranging alpha numerically from 1 to X S indicates the configuration site for the product W Wilsonville OR V Oostrum Netherlands P Paneng Malaysia FRU Parts List 8 207 Cabinet FRU s Fig 8 1 Cabinet FRUs Phaser 840 850 860 8200 Color Printer Service Manual 208 8 Table 8 1 Cabinet FRUs Parts Part number Serial number Qty Name and description Effective Discont d 1 200 4412 00 1 Right cover 8408 50 200 4591 00 Right cover 840GP Designer Edition 200 4645 00 Right cover 860 8200 2 200 4370 00 1 Front cover jam access Phaser 840 200 4598 00 1 Front cover jam access door 840GP Designer Edition 200 4607 00 1 Front
25. Paper feed motor Drum Vacuum pump module Vacuum pump I Process motor position encoder Air valve solenoid RightVO em Drum temperature sensor 2 J 140 Process Gear 3 Leftl O board Position Sensor board Tray present sensor J 180 A f A A4 size sensor Cap wipe purge Handfeed sensor clutch RA Drumhome j J 150 Paper OHP sensor sensor rum A size sensor Phaser 840 encoder sensor Empty sensor Transfix solenoid only 5 A4 size sensor Sensor Upper feed Preheat entry Exit tray full roller clutch 2 left edge sensor sible iesu EE sensor 2 Transfix exit Drum p 3 Cap wipe purge sensor aneh L Front panel unit home sensor board Pick clutch 9 Preheater Front cover Top cover Duplex paper exit sensor switch switch sensor 0388 57 Print engine wiring diagram Wiring Fold 9 235 The following illustrations detail the proper means of routing and dressing printer wiring Incorrect wiring dressing can result in wires pinched by cabinet panels or damaged by moving parts of the printer Bundle vacuum hose through cable restraint Tie wrap hose and wiring to corner of fan Tie wrap wiring harness Wire routing on the right side of the printer near right I O board 9 236 Phaser 840 850 860 8200 Color Printer Service Manual The power wiring harness for the ink loader is routed through a cable strap located be
26. Rear panel DIP switch settings 1 28 Summary of differences between Phaser 840 850 860 1 29 Physical dimensions 1 31 Printer installation clearances 1 31 Functional specifications 1 32 Electrical specifications 1 33 Environmental specifications 1 34 Main board power up self test error codes 2 37 BIST Rear Panel LED Codes 2 40 POST Power On Self Test Error Messages 2 41 Front Panel amp Fault History Log Error Codes and Messages 2 45 22 LSS TC Error Codes Media Jams 2 59 22 000 Fault Codes and Actions 2 60 Front Panel amp Fault History Log Error Codes and Messages 2 71 Electrical Interface RAP Table 3 73 Media and Paper Path RAP Table 3 73 Print and Image Quality Problems RAP Table 3 74 Macintosh Printing Problems RAP Table 3 74 Motor and solenoid resistances 3 84 Not Printing 3 88 Missing or light colored ink band
27. installing a new Y axis drive assembly or drum transfix assembly then locate any previously placed index marks on the pulleys and proceed as if re using existing parts Allow the system to cool as long as feasible before mounting the Y axis drive assembly onto the chassis Tensioning of the y axis drive assembly without diagnostics increases the risk of failures associated with low belt tension for example a growling sound heard upon cold power ups Place an index mark on the edge of each pulley Mark the Y axis drive pulley and the drum pulley where the edges are closest to one another disregarding previous marks Use a distinct color if the pulleys have been previously marked Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re tighten the screws to 30 in lbs Release the tension tool s lever arm and remove the tool 10 Set the printer s Print Quality Mode to Standard and Duplex Mode to On 11 Print service test print 8 YMCKRGB Solid Filles from the hidden service menu 3 times 12 Repeat the complete tensioning procedure Steps 1 through 9 4 142 Phaser 840 850 860 8200 Color Printer Service Manual y 2 M QJ Mark the Ax pulleys 0 Never loosen O these 3 screws ANOS Attach tension tool to keyholes aA S Y axis belt E assembly Leu lever arm to set tension 0388 30 Tighten 3 mounting screws after setting tension Fig
28. newer LaserWriter printer drivers select Foreground Printing in the Print dialog box Download the Echo showpage snippet which produces a blank sheet of paper to determine if the printer is receiving and processing files 4 Make sure you are printing with the correct PPD file Activate Error Handler using the front panel Advanced Printer Settings menu Alternately download the Error Handler utility and try printing the job again If an error page is printed after printing the job again call the Customer Support Hotline for further assistance Please have the error page in hand If available try printing to a black and white PostScript Level 2 printer such as an Apple LaserWriter If the file does not print on the black and white PostScript printer this may mean that the problem is application or network related Image is rotated 90 degrees 1 In the application s Page Setup make sure that the image is selected to print in Portrait or Landscape orientation as you expect Image prints in black and white 1 In the Chooser ensure a color printer icon is displayed next to the Phaser 840 or Phaser 850 in the list of available printers This indicates the printer s PPD has been selected and configured 2 In the Print dialog box make sure that the Color Grayscale option has been selected Make sure that the Phaser 840 or 850 printer icon was selected in the Chooser Try printing the job again Check t
29. number of sheets is equal to scan cycles R Definition Results Interpretation Actions Inspect the paper path drive 0 current at gt 74 7 components engaged at the time end scan of the paper stall for binding or wear Inspect the paper path drive 1 Scan cycles gt 4 components engaged at the time of the paper stall for binding or wear Sensor ID Codes 0 None 9 Stripper Exit 2 Leading edge 1 Aux2 Pick 10 Exit sensor id 2 Aux1 Pick 11 Duplex Entry 3 Std Pick 12 Duplex Width A 4 Handfeed 13 Duplex Preheat Entry 3 Trailing edge 5 Width A 14 Duplex Width A4 sensor ID 6 Preheat Entry 15 Duplex Preheat Exit 7 Width A4 16 Duplex Stripper Exit 8 Preheat Exit 17 Duplex Exit 4 130 Phaser 840 850 860 8200 Color Printer Service Manual Table 4 4 Check Menu Value Key DM Axis Performance Test ID 6 This test exercises multiple aspects of the drum maintenance system Test ID R Definition Results Interpretation Actions The test could not establish control of the drum maintenance 0 Controllability flag 0 cam shaft Verify that the shaft bushings are properly installed and the shaft is not obstructed Drum 1 Maintenance cam rest to Home sensor distance Home sensor 2 hysteresis Process Motor drive train backlash Drum 4 Maintenance clutch engage time Drum DM Axis 5 Maintenance Perfo
30. perform up to 6 clean cycles As a last resort a new printhead should be installed 3 Install a new printhead only after completing the cap wipe purge assembly check and performing 6 clean cycles If you are not sure the printhead is the problem change the cap wipe purge assembly assembly first Note The front panel Head to Drum Adjust will time out after 20 minutes resulting in a 4 015 45 error To clear the error cycle power on the printer 4 After installing a new printhead be sure to set the front panel hidden service menu item Head Adjust setting to the factory default of 128 5 Check cap wipe purge assembly purge performance After installing a new printhead you must recheck the cap wipe purge assembly system vacuum and decay as described earlier If the printhead is not installed correctly the cap wipe purge assembly gasket may leak 3 112 Phaser 840 850 860 8200 Color Printer Service Manual Check for Service Required errors After installing the printhead you may get one of the following service errors due to mis adjustment or cabling problems 4 002 41 and 4 006 45 errors printhead NVRAM all zeroes If the data cable between the power control board and the printhead is not plugged in properly or damaged this error will occur Reseat or replace the data cable Fig 3 6 Damaged printhead data cable 13 001 40 13 002 41 13 017 47 or 13 018 48 errors Reseat or replace the printhead ribbon cable before replac
31. xxxxx Execute Head Wipe Engine FW Version x xx Head SN xxxxxxxx Print Usage Profile Duplex Oil chase Head Cal Date dd mmm yyyy Print OCR Usage Profile Exit Head Version xx Engine Copy count xxxxx Engine FW Version x xx Head SN 2 sided Printing Oil Chase Head Cal Date Envelope Oil Chase Head Version xx Center Image Engine FW Version x xx Exit 2 sided Printing Oil Chase On Off Envelope Oil Chase On Off Center Image Edge Flush Exit Diagnostics and Adjustments 4 121 Built in Diagnostics Phaser 860 Only The Phaser 860 has three built in diagnostic routines that can be run to troubleshoot printer problems Note The Phaser 860 diagnostics are accessible through the printers front panel menus rather than requiring a laptop connection Auto Diagnostics Selecting auto diagnostics from the service tools menu or via CentreWare IS will run a predefined set of diagnostic tests and then return the printer to ready mode This interface was designed primarily for remote users who did not have immediate access to the printer Report Current Temps Check Voltages Check Paper Path Status Check Y Axis Geometry Check Cap Axis Geometry Check Transfix Axis Loading Check DM Performance m Check Paper Path Timing Customer Accessible Diagnostic Mode This mode gives access to a subset of the service dia
32. 4 3 Pull the lever arm and press the tool firmly against the printer frame to set tension Diagnostics and Adjustments 4 143 Y axis belts tension adjustment Phaser 850 860 printer Perform this procedure after loosening or removing the Y axis belt drive assembly Note the additional steps you must perform for a new Y axis drive assembly Warning It is not necessary to remove the tensioning bracket for this adjustment However if you do follow the procedure Y axis belt drive assembly Phaser 850 860 printer on page 7 201 Improperly removing the tension spring can cause the tension bracket to flip off forcefully causing injury 1 Ensure that the three mounting screws that secure the Y axis drive assembly to the chassis are 1 turn loose and that the Y axis drive assembly slides freely with respect to the chassis Note If there is a situation in which diagnostics are not available when installing a new Y axis drive assembly or drum transfix assembly then locate any previously placed index marks on the pulleys and proceed as if re using existing parts Allow the system to cool as long as feasible before mounting the Y axis drive assembly onto the chassis Tensioning of the y axis drive assembly without diagnostics increases the risk of failures associated with low belt tension for example a growling sound heard upon cold power ups 2 If not in place attach the tension spring between the Y axis drive assembly and the ten
33. 43 dripping Check that the ink stick is able to advance in the chute IL FAULT K JAM An ink stick jam will be reported three times before an ink melter fault is declared Replace the ink loader If the problem persists replace the power supply see SF157 09 009 44 IL FAULT INK UNPLUG Ink well sense cable on the printhead appears to be unplugged 11 000 Digita Motion Control DMC ASIC LIBRARY PROGRAM FAULT CODES 11 001 60 DMC PROG FAULT 1 Timer Event Missed A health check routine is called every 400 milliseconds the A D update period and checks that all the currently pending timer events are for some time in the future It generates this error if it detects a timer event for some time in the past A missed DMC interrupt due to interrupts disabled too long by any region is the probable cause 11 007 66 DMC PROG FAULT 7 Event parameter Block not Prepped The parameter block associated with a DMC event notification was not prepped with a call to dmc prep event parm block before the call to dmc request event notification 11 008 67 PROG FAULT 8 Bad Message ID in Event Request The parameter block for a DMC event notification request contains an inconsistent state field in the ITC status message 11 011 61 DMC event parameter block not found The DMC library was attempting to locate an event parameter block in its linked list The block was not found 11 020 61 DMC
34. 662xx 850 64 Mbytes Micron MT4LSDT864AG 10Exx 850 128 Mbytes Micron MT16LSDT1664AG 662xx 850 128 Mbytes Micron MT16LSDT1664AG 10Exx 850 Note The 32 Mbyte DIMM marked for 850 only are not compatible with the other RAM DIMMs because the 32 Mbyte RAM DIMM is an 6 column type the other DIMMs are 9 column types If one of each type is installed in the Phaser 850 printer only the 9 column DIMM will be enabled General Information Phaser 860 RAM and Printer Capabilities The Phaser 860 printer features two SODIMM connectors which accept off the shelf 64MB or 128 MB SODIMM SDRAM memory modules meeting these specifications 144 pin SODIMM Synchronous DRAM 3 3 volts PC100 compliant Valid on board Serial Presence Detect ROM Built using 64 or 128Mbit SDRAM parts 100MHz operation at CAS Latency 2 Upon power up the image processor interrogates the Serial Presence Detect EEPROM which describes the SODIMM in great detail such as data width clock delay number of address columns and row refresh rate and more If the SODIMM does not meet the required specifications it will be not be used If there are no good SODIMMs you will receive a RAM error If one SODIMM is good you will receive a temporary error message and the printer will continue with power up Print the Configuration Page and check the item Installed RAM to see what type of RAM is installed This is a list of SODIMMs that are branded for use by Xerox in t
35. 850 650 4215 00 1 Ink loader Phaser 860 650 4247 00 1 Ink loader Phaser 8200 12 166 0714 00 1 Vacuum hose rubber 650 4223 00 1 Tubing Kit includes hoses and vacuum filter 13 147 0079 00 1 Vacuum pump assembly 14 166 0713 00 1 Vacuum hose rigid see 12 15 650 3615 00 1 Head maintenance drive belt Part of 650 3615 00 Belt Kit 16 650 3619 00 1 Pulley head maintenance drive Part of 650 3619 00 Gear Kit Phaser 840 850 650 4221 00 1 Part of 650 4221 00 Gear Kit Phaser 860 8200 17 650 3615 00 1 Head maintenance timing belt and ratchet clips Part of 650 3615 00 Belt Kit 18 134 0265 00 1 Plug Maintenance drawer life counter 19 650 4148 00 1 Y axis tensioner Phaser 850 860 8200 200 4379 01 1 Cover heat plate printhead thermal duct 214 4772 00 1 Head tilt return spring refer to SB 541 214 4813 00 1 Tilt arm spring refer to SB 541 FRU Parts List 6 211 Paper Path FRU s 0388 80 Fig 8 3 Paper path FRUs 8 212 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 3 Paper path FRUs Parts Part number Serial number Qty Name and description Effective Discont d 1 351 1045 00 1 Guide media tray right Phaser 840 850 351 1092 00 1 Guide media tray right Phaser 860 8200 2 351 1032 00 1 Guide pick assembly Phaser 840 850 351 1088 00 1 Guide pick assembly Phaser 860 8200 3 351 1046 00 1 Guide media tray left Phaser 840 850 351 1093 00 1 Guide media tray left Phaser 860 8
36. Circuit boards of the print engine left rear view Phaser 850 Printhead Drive Board Power Control Board Board left Power Supply P860 004 Fig 1 6 Circuit Boards of the print engine right rear view Phaser 860 1 14 Phaser 840 850 860 8200 Color Printer Service Manual The printer s IC bus An internal data bus called the rc bus connects all I O boards to the main board Through this single bus the main board can poll the I O boards for the state of the printer s sensors as well as actuate the printer s solenoids This data bus greatly simplifies the wiring that would otherwise be required for monitoring numerous sensors and solenoids The 2 bus also extends down to the High Capacity Paper Trays High capacity Paper Tray connection I2C bus 0388 05 Fig 1 7 The printer s I C bus General Information 1 15 Printhead Maintenance System The printer features a printhead maintenance system used to clean the printhead faceplate and clear clogs from the printhead nozzles The system consists of a vacuum pump assembly the cap wipe purge assembly and the cap wipe purge carriage drive Cap wipe purge carriage drive Vacuum pump assembly Cap wipe purge assembly 0388 06 Fig 1 8 Printhead maintenance system of the print engine 1 16 Phaser 840 850 860 8200 Color Printer Service Manual Sensor Maps Sensors in the printer provide information to the main board to determine th
37. E Failed main board 1A Reseat the Code ROM DIMM 1B Reseat the memory DIMM 1C Replace the Code ROM DIMM 1D Replace the memory DIMM 1E Reseat the main board Replace the main board V Tektronix logo displayed Front Panel error light off PE LED heartbeat ADDITIONAL CLUES Confirm that all DIP switches are up PROBABLE ROOT CAUSE ACTIONS follow in order 1 Printer connected to network or computer A Something external to printer 1A Disconnect printer from network or computer and cycle power 2 Still hung after disconnecting from all external components only power cord is connected A NVRAM corrupt B Internal component C Connection problem with code DIMM D Connection problem with memory DIMM E Failed code ROM DIMM F Failed memory DIMM G Failed main board 2A Reset the NVRAM 840 only Replace the NVRAM 2B Hook up laptop based diagnostics and run System Verification 2C Reseat the Code ROM DIMM 2D Reseat the memory DIMM 2E Replace the Code ROM DIMM 2F Replace the memory DIMM 2G Reseatthe main board Replace the main board 256 Phaser 840 850 860 8200 Color Printer Service Manual VI Display on off LED flash ADDITIONAL CLUES Confirm that all DIP switches are up and printer is isolated from network PROBABLE ROOT CAUSE ACTIONS follow in order 1 Possibly continuous reboot A Power B Connection problem wit
38. Good Board Con nection 2 Reseat main board to insure good contacts and power up printer repeat one time if first try is unsuccessful 3 Remove main board and reseat the code DIMM and power up printer repeat one time if first try is unsuccessful Check the one that applies Failure corrected due to reseat check appropriate box in next column Same failure still exists after trying Actions 2 and 3 goto Action 4 Check the one that applies 2 If error condition is gone after reseat check printer s history m If previous fix was due to a reseat of this board replace main board m f history of a previous reseat record fix as a main board reseat 3 If error condition is gone after reseat check printer s history m If previous fix was due to a DIMM reseat of this board replace code DIMM m f history of a previous reseat record fix as a code DIMM reseat Go to Action 4 Use the Electronics Troubleshooting Guide 4 Power printer on and observe when it fails Check the one that applies __4A Printer is immediately dead when power switch is turned on __4B Failure occurs during printer power on sequence hang or error message __4C Failure occurs after power on sequence front panel message present other than the Tektronix logo print quality problem occurs due to electronics etc Check the one that applies __4A 4B Refer to the following section in the
39. LED very breifly at a fast rate for only 1 3 of a second at a rate of 8 Hz a total of 3 flashes until the end of the next test The Boot loader performs CPU initialization and RAM test RAM test is less than 0 1 seconds even with 256 Mbytes It then sends the boot loader version to the serial port Power on self test POST initializes the front panel front panel LED turns red then green then orange and then off the front panel LCD goes black and then clear The POST version is displayed on the LCD and waits two seconds During this time the operator can press the Back button to bypass the remaining POST test Low level power on self test POST diagnostics are performed The front panel displays status messages as each sub test is performed This test takes about 8 seconds All LEDs are off during the test If POST diagnostics pass the front panel displays the Xerox logo If an error is detected the error message is displayed on the LCD and the printer flashes the LEDs with a repeating error code pattern The VxWorks operating system is initialized and engine code is started This takes about 15 seconds The Xerox logo is displayed The mechanical initialization is conditional on the initial position of the printhead and cap wipe purge assembly Two NVRAM parameters are checked for the last known position If the printhead is in either the Locked or Print position a The cap wipe purge motor is run to ens
40. Perform the procedure Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 The Phaser 850 860 printer should never require this adjustment 12 Manuf x axis scanner This print is used for manufacturing and engineering evaluation of printhead performance Indicates optimum head to drum gap setting 0388 39 5 166 Phaser 840 850 860 8200 Color Printer Service Manual 13 Black Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 14 Red Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak j
41. Phaser 840 850 Service Quick Reference Guide for more information 1 Condition started after recent upgrade A The Memory DIMM not seated correctly B Connection problem with code DIMM C Unsupported or defective memory DIMM D ESD damage to main board 1A Reseat the memory DIMM 1B Reseat the Code ROM DIMM 1C Replace the memory DIMM 1D Replace the main board 2 Was working OK then failed A Connection problem with code DIMM B Memory DIMM became defective 2A Reseat the Code ROM DIMM 2B Replace the memory DIMM NVRAM Error Codes 9 10 See page 30 in the Phaser 840 850 Service Quick Reference Guide for more information 3 Recently swapped A NVRAM 840 only or main board Boot ROM socket empty 9 NVRAM Chip or chip has bent leg 840 only B NVRAM 840 only or 10 8 pin Boot Boot ROM defective ROM 3A Swap part from old board or check for bent leg 3B Replace with new part 4 Other error code Record here A Depends on error code 4A See page 29 of Error Code topic in the Phaser 840 850 Service Quick Reference Guide Appendix 255 IV Tektronix logo displayed Front Panel ready light off PE LED static ADDITIONAL CLUES Confirm that all DIP switches are up PROBABLE ROOT CAUSE ACTIONS follow in order A Connection problem with code DIMM B Connection problem with memory DIMM C Failed code ROM DIMM D Failed memory DIMM
42. Replace the power control board 3 7 004 46 A Mechanical failure or 3A See the Service Quick failed I O Right or power Reference Guide for mechanical control board recommendations first If the drum maintenance home flag rotates during power on sequence replace I O Right board Replace power control board 4 8 001 44 A Mechanical failure or 4A See SB411 and Service Quick failed I O Right or power Reference Guide for mechanical control board recommendations first Possibly replace I O Right or power control board according to SB411 5 5 9 005 40 A Mechanical failure 5A See SF157 Check for a blown 9 006 41 9 007 42 inkload assembly or F3 fuse on the power supply If 9 008 43 840 failed power supply blown replace the power supply AND the cap wipe purge 6 9 005 40 assembly If not blown replace 9 069 41 9 037 42 ink loader 9 101 43 850 258 Phaser 840 850 860 8200 Color Printer Service Manual IX Printer shuts down on its own Loss of power ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 Printershuts down Spurious over current 1A If printer powers back on within with power switch two seconds do nothing still Cycling power brings If printer powers on in about 6 printer back to seconds remove power cord Ready wait 30 seconds and then plug back in If it then powers up within 2 seconds do nothing Otherwise replace power supply If the
43. Screws 2 Remove 4 screws Remove hex screw Pd 840 4 20 Fig 7 10 Removing the drum transfix assembly right side 2 7 190 Phaser 840 850 860 8200 Color Printer Service Manual Reverse these steps to reinstall the drum transfix assembly Upon reassembly install the hex keyed screws first they align the drum transfix assembly to the engine frame Make these adjustments after installing a new drum a b Ensure the drum position encoder sensor gap is correct Lubricate the transfix cam as described in the topic Lubrication on page 6 177 Set the Y belt tension refer to the topic Y axis belt tension adjustment Phaser 840 printer on page 4 142 or Y axis belts tension adjustment Phaser 850 860 printer on page 4 144 Power up the printer in Bypass Mode to skip the startup and mud pages Select service test print 10 Manufacturing Paper Path to verify the paper path and that all ink jets operate Print service test print 9 Seal Drum to seal the new drum Phaser 840 printer only Perform the printhead to drum adjustment described in the topic Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 or Drum position encoder gap on page 4 152 Removal and Replacement Procedures 7 191 Drum position sensor assembly Phaser 840 printer 1 Remove the left and right cover 2 Remove the top cover Caution Unhook the head tilt spring to avoid possible damage to the
44. Token Ring card supporting TokenTalk Novell NetWare NDS and TCP IP When inserted this card also disables the standard 10 100BaseT port LocalTalk and 10Base2 are not supported by the Phaser 850 printer A second rear panel slot accommodates an internal IDE hard drive for print job collation job accounting font storage and PDF direct printing An integral bi directional parallel port IEEE 1284C with ECP mode supports printing and also allows connecting a parallel interface scanner for optical copying support Like the Phaser 840 printer the Phaser 850 printer supports Job Accounting 1 4 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 860 Printer Overview The Phaser 860 Color Printer is an Adobe PostScript Level 3 Version 3010 color solid ink printer It also supports color PCL 5c at 600 x 600 dots per inch resolution The printer can print at the following resolutions W Fast Color mode 16 page per minute ppm W Standard mode 10 ppm mode at 355 x 464 dpi Enhanced mode 6 ppm at 464 x 928 dpi High Resolution Photo mode 3 5 ppm at of 600 x 1200 dpi The printer also includes a 7 ppm Fast Transparency mode and a 4 ppm Standard Transparency Mode double pass Both modes are at 355 x 464 dpi The Phaser 860B The Phaser 860B printer features 136 built in fonts and is equipped with 64 Mbytes of RAM The Phaser 860B can be upgraded to configurations of 64 128 192 and 256 Mbytes of RAM using combinations
45. Transfix Roller Performs a transfix roller oiling cycle Fill Ink Levels Fills the ink levels Park Printhead Moves the printhead into the park position Mechanical Init Initializes all mechanical systems Access Fault History View fault history codes Access Test History View history of test results Access PE NVRAM Parameters Access and change selected NVRAM parameters Diagnostics and Adjustments 4 125 Table 4 3 Diagnostic Menu Map Clear Fault History Erase the fault history Clear PS NVRAM Clear the PostScript NVRAM parameters Clear PE NVRAM Clear the Engine NVRAM parameters Set PE NVRAM to Defaults Set Engine NVRAM parameters to factory default Switch to External Diags Enable external diagnostics Requires Phaser 860 diagnostics software These items are are available in the service diagnostic menus and not available in custormer diagnostic mode Check Menu Value Keys and Descriptions Phaser 860 only Refer to the tables associated with each test for their normal operating ranges the R values and the suggested troubleshooting steps if the test results exceed the given range s In cases where insufficient baseline data is available the results have been left blank All results from tests that move paper through the printer were collected using 24 Ib bond paper Note Collecting 2 or 3 samples of the test data is recommended before deciding on a course of
46. Y axis drum encoder is used encoder assembly which does not use a separate drum home sensor Lower stripper The lower stripper fingers of the blade holder and have been replaced with a stripper blade replaceable stripper blade called a rapid release guide and a guide holder which is backward compatible to the Phaser 840 Color change Rollers and Phaser 850 roller shafts are clutches re tooled for clutches with C clips instead of the Phaser 840 printer s snap fit feature The parts are reversed compatible only if the shaft clutch and e ring combination replace the Phaser 840 parts The bushings for the Phaser 850 s duplex roller are installed with C clips from the inside of the chassis A new Drum Maintenance clutch is used in the Phaser 850 printer to dramatically improve reliability Round pick roller to improve reliablility The pick roller now uses the same clutch as the upper feed roller and the cap wip purge drive New Drum Maintenace Cam to support new Drum Maintenance alogrithms Preheater A new paper preheater designed to accommodate the travel of the paper preheater entry flags is used in the Phaser 850 printer The preheater is reverse compatible into the Phaser 840 printer Inks The Phaser 850 printer uses new Ink is NOT inks using a different formulation interchangeable between models New ColorStix amp II formulation specific to the Phaser 860 Legal Tray w Bail New featur
47. also be due to a bad feed clutch slippery feed roller or misaligned sensor Width 4 flag to preheat exit flag 180 160 Media was not deskewed successfully Ensure proper tray loading and verify front door deskew fingers are not damaged This may also be due to a bad feed clutch slippery feed roller or misaligned sensor Preheat exit flag to transfix strip flag 680 The media was delayed in reaching the strip sense flag Light weight or coated media may tend to stick to the transfix roller This may also occur if the transfix roller is dirty or not properly oiled The rapid release guide may also be bound or damaged Transfix strip flag to paper exit flag 160 Something may be obstructing the exit path Paper exit flag to duplex entry flag 2300 The exit rollers may be slipping on the media or the exit flag may be worn to the point that it catches on the media Duplex entry flag to duplex preheat entry flag gt 1600 This may be due to skewed paper paper path obstructions or media that is too heavy for the duplex path Duplex preheat entry flag to width A flag Paper may be excessively skewed or damaged bent or torn corner Ensure proper tray loading and verify media is in good condition Diagnostics and Adjustments 4 129 Table 4 4 Check Menu Value Key Test ID Paper Path Timing IDs 4 cont d Test ID
48. applicable for system errors On site Printhead Troubleshooting Checklist filled out Inventory control GreenTag filled out Sample prints which clearly show the observed printhead defect not applicable for system errors Initial Checklist 1 Check for use of Non Xerox Tektronix Ink NXTD circle all that apply 1 Did the customer state they have used NXTI ink in this printhead YES NO 1b Did you observe NXTI sticks or related packaging at the site YES NO 1c Are there NXTI sticks in the ink loader YES NO 1d After cooling does the waste ink have a dull and grainy appearance YES NO le Does service history indicate possible use of NXTI YES NO Indicate brands and lot codes of NXTI if used For Xerox personnel only Record ink information in Non Tektronix Ink section of the STS app Note If you answered YES to any of the above perform the Non Xerox Tektronix Ink Failure Checklist after the Initial Checklist and the Cap Wipe Purge Checklist have been completed 2 Enter the printhead serial number Continue with Step 3 on the following page 244 Phaser 840 850 860 8200 Color Printer Service Manual 3 Does the printer display an error code indicating a problem with the printhead YES NO If YES please write down the error code No go to C W P Checklist 3a Is error code 13 035 47 present in the Fault History YES NO If YES replace the power supply continue to 3b No go to 3b 3b Is the printh
49. axis motor fuse has opened Follow the procedure Testing motor and solenoid resistances on page 84 of this manual Try diagnostics to verify X axis movement If there is not any movement it is propable that the fuse is defective The fuse is located in the power control board the whole baord should be replaced See SF146 for more details 6 002 43 Indication that the motor coil s is open or shorted or the X axis motor fuse has opened Follow the procedure Testing motor and solenoid resistances on page 84 of this manual Try diagnostics to verify X axis movement If there is not any movement it is propable that the fuse is defective The fuse is located in the power control board the whole baord should be replaced See SF146 for more details Error Codes and Messages 2 49 Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 6 003 44 Indication that the motor coil s is open or shorted or the X axis motor fuse has opened Follow the procedure Testing motor and solenoid resistances on page 84 of this manual Try diagnostics to verify X axis movement If there is not any movement it is propable that the fuse is defective The fuse is located in the power control board the whole baord should be replaced See SF146 for more details 06 005 68 This error occurs when a printer is in Energy Star mode and a door is opened Instead of just waking the print
50. be sent to the Startup Page m Wrong values in script set scratch registers m Script operation timed out m Script operation returns wrong exit code DMA transfer spills outside buffer DMA transfer data mismatch none IDE hard drive This test verifies that the main board is able to communicate with the IDE drive 2 38 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 1 Main board power up self test error codes cont d PS LED Meaning Details flashes Long flash 5 Short flash 1 2L 1S 11 none 10baseT This test verifies the functionality of the Ethernet LAN Phaser 840 Controller chip Any test failures with this component are only treated as non fatal errors with the error information written to the start page If a failure is detected the message Ethernet with one of the following messages will be sent to the Startup Page m General Failure m MAC internal loopback failure MII internal loopback failure currently disabled none Ethernet This test verifies the functionality of the Ethernet LAN 10 100BaseT Controller chip Any test failures with this component are Option Card treated as non fatal errors with the error information Phaser 840 written to the Startup Page If a failure is detected the only message Ethernet Option Card with one of the following messages will be sent to the Startup Page m General Failure m MAC internal loopback failure MIl internal loopback f
51. blockage disconnect it from the vacuum module Blow through the tube to ensure the cap wipe purge assembly s tube orifice or the tubing is not blocked with ink there will be some natural resistance to the air you blow a blocked tube will be very difficult to blow air through A defective or contaminated solenoid valve can cause ink to be sucked into the tubing If the tubing is blocked replace the vacuum module and any parts cap wipe purge assembly tubing filter that are contaminated Vacuum decays too quickly Generally if the vacuum decays too quickly or immediately drops to zero the cap wipe purge assembly is making poor contact with the printhead faceplate Look for improper cap wipe purge assembly belt alignment printhead to drum gap or obstructions to the printhead tilt mechanism that prevent the cap wipe purge assembly gasket from sealing properly against the printhead faceplate Also inspect the vacuum hoses for leaks and proper fit Ink build up in the cap wipe purge assembly due to poor heating in the assembly can cause poor cap wipe purge sealing as detailed in the next step Alternately the cap wipe purge assembly gasket is bad With a flashlight closely examine the cap wipe purge assembly Inspect the gasket for defects and signs of separation Phaser 840 850 860 8200 Color Printer Service Manual 7 Ensure that the cap wipe purge heater is operational Verify that the heater resistance is about 350 ohms 50 In
52. clutch activation 7 Media found flat in tray chronic problem on Problem with pick clutch Too much pick shaft motion a Reinstall or replace the pick clutch b Check bushings and e clips 8 Media damage in center a Pick pad a Don t load media too close to fill line Replace pick pad if needed 9 Media at lower roller pick a Pick lag problem a Reseat flag flag area o Sensor Problem Lower roller problem b Verify I O right is installed correctly reinstall or replace if needed c Check bushings and e clips 22 322 13 Unknown standard tray event Same as 22 105 01 22 411 01 Handfeed width A or A4 sensor event 1 None a b Media is not pushed far enough into the handfeed slot Media is not the expected size a Feed paper in until the printer grabs b Use a ruler to verify exact media dimensions Phaser 840 850 860 8200 Color Printer Service Manual Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 500 00 Command stop event with media in front door area See SF144 amp SB460 a Inspect the maintenance drawer for worn lift pins replace if needed 1 Media perfect in media path Drum maintenance clutch a front door area b Worn maintenance drawer lift pins b PostScript fault Front panel error Power supply problem Replace drum maintenance clutch Re
53. color fills and a band of 50 blue as this is a popular background for overhead transparencies Look for Uniformity of fill with no scratching Evaluate the print on an overhead projector Some print artifacts visible on the print do not show when projected Likewise some defects do not show until projected Causes The ink drops from the jets are traveling in incorrect trajectories The printhead is incorrectly mounted or its printhead to drum spacing Phaser 840 only is incorrect BCDEFGHUKLMNOPC UVWXYZabedefghijklmnopqrs 9923 116 5 162 Phaser 840 850 860 8200 Color Printer Service Manual 9923 117 6 66 Gray dot size uniformity This print is made up of a 66 black fill It reveals variations in the ink drop spread caused by thermal variations or transfix roller pressure variations or drum oiling variations Look for Large area of differences in the density across the width of the page A slight variation is normal Look for a lighter vertical band about 1 5 the width of the page running the length of the page Also look for small light L spots or irregular white lines vertically aligned with each other in the print every 13 3 cm 5 25 in This pattern is sensitive to the density variations in the paper it is printed on Use a high quality grade of laser printer paper otherwise the print will appear mottled Causes Use the diagnostics t
54. diagnostics on the Color Printer Service amp Support Resources CD ROM Diagnostics and Adjustments 4 155 Resetting NVRAM Resetting returns all the printers s PostScript NVRAM stored parameters including those of the network card to their factory defaults except the print count for images processed through the image processor the Adobe firmware serial number the usage profile and the authorization codes Print engine NVRAM values are not changed by the following procedure See SB419 for the Phaser 840 Resetting NVRAM returns all the image processor s NVRAM stored parameters except the print counts the Adobe firmware serial number and the network address to their factory defaults To reset the printer to its factory default values follow this procedure Phaser 840 850 1 If possible print the Configuration Page for a record of all the printer s port settings and other customer unique settings Enter the Troubleshooting menu Press and hold the Left arrow button While holding the Left arrow button press Select to enter the hidden service menu Scroll to the menu item Reset NVRAM Press OK to reset NVRAM oci Phaser 860 The Phaser 860 has multiple methods of resetting the printer to factory defaults Reset Network Setup This option is available in the Nework Setup Menu and resets all parameters within that menu to factory defaults Reset Printer Setup This option is availab
55. each string When a number is saved any leading 0 is discarded When a string is saved any leading space is discarded this allows the deletion of undesired right most characters Diagnostics and Adjustments 4 135 Adjustments Printing service test prints Refer to Test Prints on page 5 159 which discusses each test print and what printing defect it reveals Phaser 840 850 1 Turn on the printer 2 Allow the printer to complete its power up self tests The front panel displays Ready to Print 3 Scroll to the Troubleshooting menu and press Select 4 Press and hold the left arrow button 5 While holding the left arrow button press Select to enter the hidden service menu 6 Scroll to the menu item Test Prints Selecta test print Phaser 860 1 Turn on the printer allowing the it to complete the power up self tests The front panel should display Ready to Print Press and hold the Scroll Up button and press OK While in the Service Tools Menu press and hold Scroll Up and then press Scroll Down This will take you to the Hidden Service Menu Scroll to the menu item Test Prints and press OK Select a Test Print ak Printing the Configuration Page The Configuration Page shows a great deal of information regarding the data and set up values stored in NVRAM Refer to the topic Configuration Page on the Color Printer Service amp Support Resources CD ROM for an explanation of the Confi
56. event parameter block not found The DMC library was attempting to locate a timer parameter block in its linked list The block was not found 11 022 63 PROG FAULT 22 Invalid Get Device State Argument The ITC message base passed into dmc get device stat was not a valid DMC type DMC STATUS MSG BASE or DMCB STATUS MSG BASE 11 025 66 DMC PROG FAULT 25 Motion Segment Too Late The DMC ASIC interrupt to program the event control hardware for the next segment in a motion control profile occurred too late A motion profile consists of a list of absolute times and motor register values After the hardware writes a DSP value the software must program the event control store hardware for the next segment in the profile This error occurs when any region PostScript Network or engine disables interrrupts for a long period of time preventing the DMC interrupt service routine from running This may be due to an unintentional coding error or because a task took a CPU exception which is processed with interrupts disabled taking a long time to execute 11 029 61 DMC PROG FAULT 29 Motion Segment Too Short Software attempted to program a motion profile with a motion segment shorter than 750 microseconds If this specifcation is violated the DMC interrupt Service routine may not have time to reload the control store hardware event when the system is busy Error Codes and Messages 2 55 Table 2 4 Front Panel amp Faul
57. get better with multiple prints Inspect the Drum Maintenance system Does the Maintenance Roller contain sufficient oil For Drum ghosting replace the Maintenance Kit if neccessary Ensure the left and right Maintenance Drawer lift pins operate correctly when lifted Verify that the Maintenance Drawer blade is not damaged causing the blade to incorrectly wipe the drum Verify that the Maintenance Drawer lift pins do not have excessive wear Improper lift pin actuation can cause the Manitenance Roller to run out of oil prematurely Replace the Maintenance Drawer Run Diagnostics to verify the Maintenance Cam and Drum Maintenance Clutch are operating correctly Replace the defective parts Ensure the drum temperature sensor is clean and properly positioned Clean realign or replace the sensor If none of the above procedures worked it is permanent drum ghosting An image was run numerous times consecutively causing the image to permanently imprint the drum One solution is to run 1 000 2 000 blank prints Replace the Drum Transfix Assembly Troubleshooting 3 97 Poor small text resolution Small characters appear heavy and plug up ABCDEFGHIJKLMNOPQRSTUV abcdetghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 70 Table 3 16 Poor small text resolution Step Question and Actions 1 Verify that the tray is set to Paper 2 Inspect and clean the drum temperatur
58. hnc S 6 176 DDT Cation 6 177 Inspection Key FRU Removal and Replacement 7 179 Main board and its components essent 7 180 Power SUPPLY eco em ici ie ter bee REPE RH ER RENTRER sat N R 7 183 Power control board 7 184 Upper feed roller assembly 7 185 Paper drum heater 7 187 Drum transfix assembly seen 7 188 Drum position sensor assembly Phaser 840 7 192 Drum position sensor assembly Phaser 850 860 7 194 Printhead ia ood eei 7 196 X axis motor and drive assembly a we 7 199 Y axis belt drive assembly Phaser 840 printer 7 200 Y axis belt drive assembly Phaser 850 860 printer M 7 201 Cap wipe purge assembly Phaser 840 7 202 Cap wipe purge assembly Phaser 850 860 7 204 FRU Parts List 8 207 Cabinet FRU GS is 8 208 Imaging 8 210 Papet Path FRU S erecti rer rt itae c e eli eee EO dd 8 212 Motorand Fan isi ibo dr edere a Hae 8 214 Circuit Board FRUS X de 8 216 Solenoid and Clutch FRUs 8 218
59. holes cracks in tubing W Defective vacuum module Inspect and replace the C W P or tubing as needed if the C W P is replaced return to Step 2 Note that a new C W P may take 6 purges before optimal performance If no problem is seen replace the vacuum module 5c Is R2 greater than 8000 YES NO Go to 6 YES there may be a problem with the air solenoid or clogged tubing If the tubing is ok replace the vacuum module NOTE After exiting diagnostics there may be some color mixing as the Cap Vacuum test does not do a complete series of faceplate wipes Performing an Eliminate Light Stripes cycle should resolve this 6 Print Service Test 2 Weak and Missing Jets Are there weak or missing jet s YES NO W NO weak or missing jets and Non Xerox Tektronix ink is used go to Test for Non Xerox Tektronix Ink Failure Checklist on next page NO weak and missing jets and Xerox Tektronix ink is used repair is complete YES and Non Xerox Tektronix ink is used go to Test for Non Xerox Tektronix Ink Failure Checklist YESand Xerox Tektronix ink is used go to Step 8 7 Is the customer is experiencing vertical bands in solid color areas YES NO Complete YES print 10 solid fill pages of cyan If the bands vary in intensity and or location over the 10 prints the customer is experiencing stagnant ink discoloration Continue to print solid fills of the offending color until the output is uniform It may take over 120 solid fill
60. in place with two screws 7 Remove the left and right maintenance drawer guides Each is held in place by a single screw at the front and two frame latches at the rear Removal and Replacement Procedures 7 185 Note If you have trouble removing the right maintenance drawer guide manually rotate the x axis drive to move the printhead in its forward position to the center of its travel 8 Remove the screw securing the right side of the upper feed roller assembly to the inside of the printer frame 9 Disconnect the wiring harness leading from the upper feed roller assembly to the inside the left side of the printer frame 10 Remove the C clip located on the left inside printer frame securing the upper feed roller assembly in place 11 Remove the upper feed roller assembly Separate the assembly into its two halves Keyed bushing C clip 7 7 gt 0 Wiring sti harness Left maintenance drawer guide Right maintenance drawer guide Upper feed roller assembly AZ Keyed bushing Fa Key pin on right frame aligns upper feedroller iaia assembly screw from right side 840 4 14 Fig 7 7 Removing the upper feed roller assembly front 7 186 Phaser 840 850 860 8200 Color Printer Service Manual Paper drum heater Warning Disconnect the power cord AC voltages may be present at the heaters even with the printer turned off Turn off the printer and remove the po
61. la Did the customer state they have used NXTI ink in this printhead YES NO 1b Did you observe NXTI sticks or related packaging at the site YES NO 1c Are there NXTI sticks in the ink loader YES NO 1d Does service history indicate possible use of NXTI YES NO Indicate brands and lot codes of NXTI if used For Xerox personnel only Record ink information in Non Tektronix Ink section of the STS app Note If you answered YES to any of the above perform the Non Xerox Tektronix Ink Failure Checklist after the Initial Checklist and the Cap Wipe Purge Checklist have been completed 2 Enter the printhead serial number Continue with Step 3 on the following page Appendix 261 Initial Checklist cont d 3 Does the printer display an error code indicating a problem with the printhead YES NO If YES please write down the error code No Go toC W P Checklist 3a Is error code 13 035 47 present in the Fault History YES NO YES replace the power supply continue to 3b No Go to 3b 3b Is the printhead thermostat open common leads to all other heater leads YES NO YES replace the power supply and printhead No Go to 3c 3c If one of the specific error codes below is present follow the steps indicated otherwise replace the printhead and perform the C W P Checklist with the new printhead Iferror 13 001 40 13 002 41 13017 47 or 13018 48 reseat or replace printhead ribbon cable before replacing the pri
62. main board and all components on it RAM ID Chip Code DIMM Hard Drive If the Printer ID chip was corrupted resetting NVRAM may resolve the issue Environments prone to static electricity discharges may also cause this type of behavior N2 Does the printer shutdown or reboot on its own YES NO Go to N2a Go to N3 N2a Does the printer turn itself off and stay off YES NO Go to N2b YES when turning the power back on does the printer Begin Power up within 2 seconds and continue to operate Probably due to a power source problem Ensure that the printer is not on a circuit with other high power devices Begins Power up within 2 seconds but shuts down again under certain operating conditions If the shut down follows a paper jam troubleshoot the jam issue Otherwise use diagnostics to test the different subsystems to isolate the component causing the over current condition Begins to Power up after about 6 seconds Unplug the printer for at least 30 seconds before plugging it back in and turning on the power If it still takes 6 seconds replace the power supply Doesn t begin to power up Refer back to the Power Up Checklist N2b Does the printer automatically begin reinitializing YES NO YES identify the codes in the fault history and refer to the Service Quick Reference Guide for troubleshooting recommendations The printer automatically reboots when a fault occurs to minimize customer down time If the fault occurs 3 t
63. media in the main tray Same as 22 101 06 22 303 03 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in the main tray Same as 22 101 06 22 305 05 Unexpected standard tray sensor event with media in the main tray Same as 22 105 01 Error Codes and Messages 2 61 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 306 15 Time out of pick flag on main tray with media picked from the main tray 1 Pick roller is slipping a Media is too heavy and or has high sheet to sheet friction a Try different media b Clean the pick pad and pick roller with packing tape See Pick Roller Cleaning Method on page 6 175 Verify roller motion with diagnostics 2 Last sheet in tray Stuck on media grip a Fill tray more likely with heavier media 3 Media skewed with no noticeable damage 5 Media tray over filled a Fill tray appropriately 4 Media skewed with noticeable damage 5 Problem with pick guide assembly a Reseat or replace if damaged 5 Media wedged in tray 5 Too much friction or lift plate cannot operate correctly bottom sheet may be wedged between lift plate and pick pad a Remove media inspect and reload 6 Media is folded damaged or deformed Media cannot get out of the tray a Use diagnostics to verify pick roller motion and
64. pack plus 2 black sticks 016 1904 01 Phaser 860 Magenta Ink 5 pack plus 2 black sticks 016 1905 01 Phaser 860 Yellow Ink 5 pack plus 2 black sticks 016 1909 01 Phaser 860 Rainbow pack 1 stick each color 016 1906 01 Phaser 860 Cyan Ink 2 pack plus 1 black sticks 016 1907 01 Phaser 860 Magenta Ink 2 pack plus 1 black sticks 016 1908 01 Phaser 860 Yellow Ink 2 pack plus 1 black sticks 016 2040 00 Phaser 8200 Black Ink 5 pack 016 2044 00 Phaser 8200 Black Ink 10 pack 016 2045 00 Phaser 8200 Cyan Ink 5 pack 016 2046 00 Phaser 8200 Magenta Ink 5 pack 016 2047 00 Phaser 8200 Yellow Ink 5 pack 016 2048 00 Phaser 8200 Rainbow pack 1 stick each color 016 2041 00 Phaser 8200 Cyan Ink 2 pack 016 2042 00 Phaser 8200 Magenta Ink 2 pack 016 2043 00 Phaser 8200 Yellow Ink 2 pack Trays 436 0330 00 Tray Paper A size Phaser 840 850 436 0395 00 Tray Paper A size Z840DP Designer Edition Tray Paper A size Phaser 860 436 0409 00 436 0332 00 Tray Paper A4 size Phaser 840 850 436 0396 00 Tray Paper A4 size Z840DP Designer Edition 436 0410 00 Tray Paper A4 size Phaser 860 8 228 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 436 0336 00 Tray High volume transparency A size Phaser 840 850 436 0411 00 Phase
65. pages to refresh all of the ink in the printhead reservoir The repair is now complete 8 Install a new printhead Test performance Comments Xerox US personnel please add all comments in TechLink 264 Phaser 840 850 860 8200 Color Printer Service Manual NON XEROX INK FAILURE CHECK LIST PERFORM THIS CHECKLIST ONLY IF NON TEKTRONIX INK IS IN USE At this time there is insufficient data to support field diagnosis of NXTI failure at the customer site for the Phaser 860 8200 All NXTI work for the Phaser 860 8200 will be done by Xerox Failure Analysis Engineering Service Support Personnel are encouraged to provide FULL AND COMPLETE documentation packages to assist the Failure Analysis Engineers with any potential NXTI cases WHAT TO DO WHEN A NXTI USAGE IS OBSERVED SUSPECTED IN A PHASER 860 8200 PRINTHEAD Provide the customer with the Customer Alert 6 March 2002 letter If there are weak or missing jets replace the printhead per normal procedures Check Non Xerox Tektronix Ink Box on Greentag Be sure to document the brands and lot codes of NXTI being used in the Initial Checklist section Enclose all sample prints ink samples and this checklist with the printhead and return it to Wilsonville for evaluation Enclose a sample of waste ink with the printhead return if possible Xerox Personnel please provide full documentation in TekLink WHAT TO DO WHEN A PHASER 860 8200 PRINTHEAD HAS NXTI LIKE
66. paper path Following this a weak jet test print identical to Test Print 2 is printed to verify that all the printhead jets operate correctly 9923 153 Test Prints 5 165 11 Head to Drum Gap This print indicates if the gap between the printhead and the drum is correct Lines The horizontal lines of the print are made up of long and short dashes Inspect the first and last 1 2 in 12 mm of the black lines for the vertical distance between the short dashes and long dashes m If the short dashes are any distance below inline or slightly above with no separation with the long dashes then the drum gap is correct m f the short dashes are above the long dashes with significant line separation then the drum gap is too wide and must be readjusted a f the short dashes on one side of the print extend farther below the long dashes than on the other side of the print with a noticeable difference 1 64 in 0 4 mm or more or if the short dashes extend below the long dashes on one side of the print and the short dashes extend above the long dashes on the other side of the print with line separation then the printhead is skewed and must be readjusted Text Examine each end of the band of text Look for fuzziness or differences between the quality of the characters on the left and right ends of the print A difference indicates the printhead gaps at each end of the printhead are not equal
67. print Try a different color correction setting 2 Perform the procedure Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 3 Verify that the printhead setting Head Adjust in the hidden service menu is set to 128 Troubleshooting 3 93 White portion of print is colored Color on a print where no color should be printed is often called a latent image A latent image remains on the drum when it should have been transferred to its sheet of paper An insufficient amount of oil on the drum provided by a dirty defective or old maintenance drawer may be the problem See SB439 amp SB445 ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 69 Table 3 12 White portion of print is colored Step Question and Actions 1 Clean the wiper blade of the drum maintenance drawer If necessary replace the maintenance kit 2 Clean the rapid release guide 3 The paper preheater may be contaminated with ink Clean for ink smears using the front panel Troubleshooting function Remove Ink Smears 4 Run diagnostics to ensure that printer temperatures are in tolerance Ensure that the drum heater is properly positioned Print using a smoother laser quality paper Some recycled paper brands may be too rough 5 Dark rectangular marks on transparency film can be caused by an accumulation of paper dust and oil on the feed ro
68. printhead and drum 3 Disconnect the drum home position sensor wiring harness from J180 of left I O board leading to the drum position assembly Disconnect the drum position encoder sensor at the drum position assembly 4 Remove the clear plastic dust cover from the drum position assembly 5 Precisely mark the end of the drum shaft relative to the drum home flag on the drum position sensor assembly this is not necessary if you are also replacing the drum as part of the drum transfix assembly Mark on the drum shaft to align with the home flag Drum home ap Drum position encoder wheel 840 4 17 Fig 7 11 Marking the drum home flag sensor alignment 6 Rotate the X axis drive gear to move the printhead to its print position 7 Rotate the tilt gear to orient the gear s missing teeth to the drum position sensor assembly s rear mounting screw 8 With a small flatblade screwdriver slide the retaining spring out of the encoder wheel s groove toward the encoder disk 7 192 Phaser 840 850 860 8200 Color Printer Service Manual 9 Remove the three screws securing the drum position sensor assembly housing to the print engine Insert the gap tool to hold the encoder wheel in position Slide the assembly offthe drum shaft If necessary use the small flat blade screwdriver to push the encoder disk hub along the shaft as you remove the assembly Slide the retaining spring out of the groove Sets Dr
69. printhead and gap clip O tightly against drum Insert flatblade screwdriver in adjusting slot Use a twisting motion to move the printhead Tighten locking screws when both left and right adjustments are complete Repeat adjustment at this end of printhead if 0388 31 Fig 4 7 Drum adjustment 9 Perform the same adjustment at the left side of the printhead until the left gap clip is tight against the drum 10 Repeat both the right side and left side adjustments to ensure that both ends of the printhead are tight against the drum 11 Snug not tighten the four locking screws using an Z pattern starting with the rear screws Then tighten the four screws using the same Z pattern to 20 in Ibs 12 Remove the adjustment tension spring Warning Because the gap clips mount directly to the printhead they are very hot To avoid injury when removing them from the printer do not touch the metal areas on the clips 13 Tilt the printhead back and carefully remove the gap clips Tilt the printhead forward once the clips are removed 14 Reinstall the ink loader and metal heat cover 15 Select Adjustment Complete from the front panel to exit the Head to Drum Adjust sequence Reinstall the top cover 16 Print service test print 11 Head to Drum Check to check alignment This print indicates if the gap between the printhead and the drum is correct Refe
70. resuscitation is present Use care when servicing with power on 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 soldering 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 Power source This product is intended to operate from a power source that will not apply more than 250 volts rms between the supply conductors or between either supply conductor and ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Contents User Safety SUMMARY ain ni Seta ie dedi aep reads iii Service safety summary i List of Tables ISTITUTI i General Information 1 1 Phaser 840 Printer Overview 2 Phaser 850 Printer Overview 4 Phaser 860 Printer Overview 5 Solid Bn CEPR RR ep 1 6 Phaser 840 850 RAM and Printer Capabilities wel 7 Memory Considerations Phaser 840 850 sse 1 8 Phaser 860 RAM and Printer Capabilities eee 1 10 Memory Considerations Phaser 860 sess 1 11 Print Engine Assemblies 840 850 860 sess 1 12 Circuit Boards einn eiii d sis tesa e en ois eire ied 1 13
71. tall to fit inside a Phaser 840 printer Upon power up the image processor interrogates the 256 byte Serial Presence Detect EEPROM which describes the DIMM in great detail such as data width clock delay number of address columns and row refresh rate and more If the DIMM does not meet the required specifications it will be ignored no error message will be reported General Information 1 7 Memory Considerations Phaser 840 850 With more memory the printer dual frame buffers for printing one image while processing a second image which gives greater printing throughput The printer s capabilities can be increase as detailed in the following table For the Phaser 840 printer adding RAM memory and installing the SCSI daughter card enables the Plus and Extended configurations features For the Phaser 850 printer installing the DP Option code ROM module and adding RAM enables these features Table 1 1 Installed RAM and printer capabilities Feature 32 Mbytes 64 Mbytes 128 Mbytes 840N 840DP 840DX 850N 850DP 850DX Fast Color draft yes yes yes printing Standard Printing yes yes yes Enhanced Printing yes yes yes High Resolution no yes yes Photo Printing 2 sided printing no yes The printer yes The printer supports fast supports 2 sided standard and high resolution enhanced 2 sided 1200 x 600 dpi print prints Color PCL 5C yes yes yes Pipelining no yes yes Check Print no y
72. the right end of the duplex roller shaft Remove the duplex roller 14 Remove the tilt arm spring Note For Phaser 840 printers refer to Service Bulletin 409 regarding firmware version 8 24 and preventing stripper finger jams 7 188 Phaser 840 850 860 8200 Color Printer Service Manual Exit roller drive belt tensioner Wiring harness Exit roller drive belt Compound gear Remove drum transfix assembly screws C clip 840 4 19 Fig 7 9 Removing the drum transfix assembly left side Removal and Replacement Procedures 7 189 Right side 15 Remove the y axis belt drive assembly 16 Disconnect the wiring harnesses leading to the transfix solenoid bracket Remove the three screws securing the bracket in place and remove the bracket 17 Remove the left and right frame bridges Each is held in place with two screws 18 Remove the two screws securing the front of the drum transfix frame to the inside printer frame 19 Remove the five screws securing the left side of the drum transfix assembly to the print engine Note that one screw is removed with a 3 32 hex key 20 Remove the five screws securing the right side of the drum transfix assembly to the print engine Note that one screw is removed with a hex key 21 Carefully lift and remove the drum transfix assembly Protect the drum surface Wiring harnesses Transfix Right frame solenoid bracket Drum transfix V assembly 2 inside
73. to Troubleshooting then press Select Press and hold the Left Arrow button and press Select Energy Star Access NA Diagnostics 860 Only Hold Cancel or scroll Up and press the Back button You must be in printer setup mode Cool Down Mode The printer features a menu item that accelerates the cooling down of the printhead When the printer is turned off it automatically gives the option of performing a quick cool down 1 Turn off the printer 2 Scroll to the menu item Shutdown For Moving Printer and push Select The printer turns off all the engine heaters and runs the fans on high until the ink in the printhead has solidified Then the printer shuts itself off If you are shipping the printer remove the maintenance drawer The printhead will move to the parked position if a door is opened Fast Time to Ready FTTR Turn the printer on When the Tektronix logo appears on the display press and release the Left Arrow then press and release the Right Arrow The printer behaves the same as if it normally powered up and is in its Ready state except no ink is jetted Any prints requested print blank until the printer has actually warmed up Turn the printer on When the Xerox logo appears on the display press and release the Scroll Up then press and release the Scroll Down Bypass Power On NA Press and hold Back while turning Self Test POST on the power switch Do not release the but
74. to step 2 4 Visually check the C W P wiper gasket Is there any separation on the wiper blade or pitting of the C W P gasket YES NO Go to 5 YES replace C W P New C W P may take 6 purges before optimal performance Go to step 2 5 Check the Purge Performance BEFORE running the diagnostic test empty the Waste Bin Then enter diagnostics mode and select the Cap Vacuum test from the Check menu Enter the diagnostic results RO normally 20 200 RI normally 40 1600 R2 normally 3000 8000 Select Unlock DM Tray from the Function menu Remove the maintenance tray and note whether or not a normal volume of ink was purged from the printhead Note the Phaser 860 purge volume is about half as much as the Phaser 840 850 Purge Volume NORMAL LOW 5a Are either RO or R1 outside their normal ranges YES NO Go to 5b YES Something may be obstructing the printhead tilt mechanism RO is a measurement of the current needed to tilt the printhead R1 measures the amount of gear train slack in the tilt mechanism Continued on next page Appendix 263 C W P CHECKLIST continued 5b Was the purge volume low or is R2 less than 3000 YES NO Go to 5 YES there may be a leak in the vacuum system or inadequate peak vacuum is the measurement of the vacuum decay time This could be due to W Misaligned C W P due to improper belt alignment or C W P motion problem Damaged C W P gasket W Plugged or leaking tubing
75. to the end of the channels in the belt lock Position the right side timing belt lock so its pointer points at the index mark on the printer frame Holding the right belt so it does not move inspect the left side timing belt lock s pointer it should point between the index marks on the left side printer frame o A On If the left side pointer does not point between the index marks while the right side belt lock is at its mark loosen the right timing belt by removing the lower idler pulley and adjust the belt so that it aligns with the timing mark 7 Repeat until the right side timing lock s pointer points at the index mark on the right side frame as the left side timing belt lock s pointer points between its index marks on the left side frame 4 150 Phaser 840 850 860 8200 Color Printer Service Manual Belt lock Index mark on right frame Latch For new belt dl break off actuator on left side belt lock Left belt lock align pointer between two index marks Idler pulley Right cap wipe purge assembly belt Leave gap between latch and belt tensioner 0388 32 Fig 4 9 Aligning timing the cap wipe purge assembly drive belts Diagnostics and Adjustments 4 151 Drum position encoder gap This procedure ensures that the drum position sensor assembly s encoder wheel rotates freely inside the gap of the drum position sensor without the encoder wheel s disk touching the sens
76. vacuum module At the moment the solenoid valve opens you should hear a click as the valve opens the PEAK vacuum of about 50 cm Hg 20 in Hg 10 psi 10 is applied to the printhead faceplate and the vacuum gauge Immediately the vacuum should then drop to 25 cm Hg 10 in Hg 5 psi 10 The vacuum should then bleed off to 0 with a DECAY time of 4 to 6 seconds Low peak vacuum If the PEAK vacuum is less than 36 cm Hg 14 2 in Hg 7 psi check the vacuum at vacuum module without the T connector Disconnect the vacuum module s tubing and connect the vacuum gauge directly to the module If PEAK vacuum is less than 40 cm Hg 15 7 in Hg 7 7 psi replace the vacuum module No vacuum Determine if the vacuum module s pump is not running It should make a humming sound for 90 seconds as it creates a vacuum It s also possible for the vacuum module s solenoid valve to fail and not open in which case the accumulated vacuum will not be applied to the printhead Check the module s electrical connection it runs on 40 VDC Inspect the vacuum module s electrical connector in some cases the electrical connector can be partially seated allowing the pump to run but not the solenoid valve Vacuum decay too long If the DECAY time is much longer than 6 seconds there may be kinked tubing or ink in the tubing to the vacuum module or a clogged cap wipe purge assembly orifice Inspect the tubing for kinks or crimps To test the tubing for
77. wires from the printer frame Carefully plug the printhead s reservoir chamber holes with the silicone plugs The plugs keep liquid ink from spilling if you should inadvertently tip the printhead Disconnect yo ec Silicone plugs Fig 7 15 Plugging the reservoir holes 7 196 Phaser 840 850 860 8200 Color Printer Service Manual 9 If you use the removal tool rotate the removal tool s plastic leg into its up position Slide the removal tool s standoff locks inward 10 Place a sheet of transparency film or 10 sheets of paper between the printhead and the drum to protect the drum surface 11 If you use the printhead removal tool carefully lower it onto the printhead Rotate the process motor to tilt the printhead forward about 2 5 cm 1 inch 12 If you use the removal tool slide the standoff locks outward to secure the tool to the printhead Loosen the two mounting screws securing the printhead in place 13 Carefully lift on the plastic posts at each end of the printhead to remove the printhead and place it on a flat surface If you are using the removal tool lift and remove the printhead Lower the removal tool s leg to safely rest the printhead on a flat surface Lift printhead by the plastic posts at each end Mounting screw I gt epe pi gt EUN E 43 d 840 4 89 Fig 7 16 Removing the printhead Removal and Replacement Procedures 7 197 Installation If not alre
78. yellow reservoir IL_FAULT_Y_ Replace the printhead TWANGER 9 004 48 Malfunction of the ink level sensor in the black reservoir Replace IL_FAULT_K_ the printhead TWANGER 9 005 40 The cyan ink melt heater is on but ink does not seem to be IL_FAULT_C_JAM dripping Check that the ink stick is able to advance in the chute An ink stick jam will be reported three times before an ink melter fault is declared Replace the ink loader If the problem persists replace the power supply see SF157 9 006 41 and 9 069 41 IL FAULT M JAM The magenta ink melt heater is on but ink does not seem to be dripping Check that the ink stick is able to advance in the chute An ink stick jam will be reported three times before an ink melter fault is declared Replace the ink loader If the problem persists replace the power supply see SF157 9 007 42 and 9 037 42 IL FAULT Y JAM The yellow ink melt heater is on but ink does not seem to be dripping Check that the ink stick is able to advance in the chute An ink stick jam will be reported three times before an ink melter fault is declared Replace the ink loader If the problem persists replace the power supply see SF157 2 54 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 9 008 43 and The black ink melt heater is on but ink does not seem to be 9 101
79. 0 1 Rapid releas guide actuation spring refer to SB 541 FRU Parts List 213 Motor and Fan FRUs 0388 14 Fig 8 4 Motor and fan FRUs 8 214 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 4 Motor and fan FRUs Parts Partnumber Serial number Qty Name and description Effective Discont d 1 147 0086 00 X axis motor with gear 2 650 3621 00 X axis drive assembly Phaser 840 650 4147 00 X axis drive assembly Phaser 850 860 8200 3 119 5876 00 Drum fan 4 147 0180 02 Paper path motor 5 147 0082 00 Y axis motor Phaser 840 147 0113 01 Y axis motor Phaser 850 860 8200 6 147 0108 01 Process motor with encoder Phaser 840 147 0112 02 Process motor with encoder Phaser 850 147 0114 00 Process motor with encoder Phaser 860 8200 7 119 5781 00 Main fan FRU Parts List 8 215 Circuit Board FRUs Fig 8 5 Circuit Board FRUs Table 8 5 Circuit board FRUs Parts Part number Serial number Qty Name and description Effective Discont d 1 671 4194 50 1 board right Phaser 840 850 671 5258 50 1 board right Phaser 860 8200 2 671 4195 50 1 I O board left Phaser 840 671 5026 51 1 I O board left Phaser 850 860 8200 3 671 4542 50 1 IDE hard drive internal Phaser 840 650 4176 00 1 IDE hard drive internal programmed Phaser 850 650 4206 00 1 IDE hard drive internal programmed Phaser 860 650 4248 00 1 IDE hard drive internal Phaser 8200 386 6997 00
80. 1 2L 1S 11 8 not used 9 NVRAM This test does a walking 1s and a walking Os test for that Phaser 840 last 4 bytes in the VxWorks section of the NVRAM only 10 EEPROM This test reads in the first 24 bytes from the EEPROM then verifies that the Tektronix Ethernet address 0x08 0x00 and 0x11 has been copied into three locations 11 Mariner ASIC This test reads and verifies the version level of the Mariner ASIC on the main board 12 Medusa ASIC This tests reads and verifies the version level of the Medusa ASIC on the main board 13 Super Glue This tests reads and verifies the version level of the Super ASIC Glue ASIC on the main board 14 CL1284 IC This tests reads and verifies the version level of the parallel port controller CL1284 chip on the main board 17 Ethernet chip This test verifies the existence of the Ethernet chip on the main board 18 TEA error The error occurs during power up self tests when one of Phaser 850 the main devices previously enabled fails to respond only unexpectedly causing a TEA Normal TEAs cause the corresponding specific error This could be caused by either the Code ROM or Main Board none SCSI This test verifies the functionality of the SCSI I O Phaser 840 processor Any test failures with this component are only treated as non fatal errors with the error information written to the Startup Page If a failure is detected the message SCSI Option Card with one of the following messages will
81. 1 Blank cover plate no hard drive 4a 671 3994 51 1 100Base T Ethernet card Phaser 840 4b 671 4034 00 1 LocalTalk network card Phaser 840 4c 671 3932 51 1 Token Ring network card Phaser 840 850 4d 386 6998 00 1 Blank cover plate no network card 6 216 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 5 Circuit board FRUs Parts Part number Serial number Qty Name and description Effective Discont d 5 1 Phaser 840 Masked 671 4576 50 1 Code ROM DIMM English OS 1 36 PS 8 64 Eng 8 12 Net 10 50 671 4575 53 1 Code ROM DIMM English OS 1 38 PS 8 76 Eng 8 22 Net 10 62 671 4674 02 1 Code ROM DIMM Japanese Morisawa 671 4675 02 1 Code ROM DIMM Chinese Traditional 671 4676 02 1 Code ROM DIMM Chinese Simplified 671 4677 02 1 Code ROM DIMM Korean Hangul 671 4748 03 1 Code ROM DIMM Japanese Heisei Phaser 850 One Time Programmable 672 1594 00 1 Code ROM DIMM English Base 671 5299 00 1 Code ROM DIMM English Plus 674 5105 50 1 Code ROM DIMM Japan Heisei Base 674 5106 50 1 Code ROM DIMM Japan Heisei Plus Phaser 860 671 5284 01 1 Code ROM DIMM Base 671 5275 01 1 Code ROM DIMM Plus Phaser 8200 671 5309 00 1 Code Flash DIMM Base 671 5308 00 1 Code Flash DIMM Plus Japanese Morisawa and Heisei Chinese Traditional and Simplified Korean Hangul fonts on the internal hard drive 6 156 4800 10 1 32 Mbyte RAM DIMM Phaser 840 850 156 4759 00 1 32 Mbyte RAM DIMM Phaser 850 156 4811 10 1 64 Mbyte RAM
82. 11 Time out on pick flag of Lower Feeder 1 with media picked from Lower Feeder 2 Verify that the lower tray is properly loaded Use diagnostics to verify pick roller motion 1 The spring loaded media bias block in the lower tray is clamping the media in the tray usually there will be black marks on the media 2 60 a b Media loaded poorly Bad batch of media too wide a b Remove bad sheets and reload tray Get a different batch of media Phaser 840 850 860 8200 Color Printer Service Manual Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 2 Leading edge jam right a Media is low in tray a Add more media corner fold b Media has natural curvature b Flip over media or replace c Media is short grained media d Using lightweight media c Use long grain media e Paper path is obstructed d Use heavier weight media e Check paper path for obstructions and ensure all trays are fully seated 22 105 01 Unexpected standard tray sensor event with media in Lower Feeder 2 1 Pulled upper tray out during a Upper tray not present a Put upper tray back printing 2 None a Upper tray sensor a Verify that upper tray type damaged missing or plug is present replace mis installed sensors 22 106 13 Time out on pick flag of printer with media picked from Lower Feeder 2 Same as 22 104 11 22 200 06 Command stop event with media in lowe
83. 121 00 Exit cover open sensor Phaser 840GP 650 4143 00 Exit cover open sensor Phaser 850 650 4216 00 Exit cover open sensor Phaser 860 8200 16 119 5795 01 Drum temperature sensor assembly 17 119 5802 00 Transfix exit sensor 18 119 5802 00 Paper exit tray full sensor aj nc 19 Paper exit tray full flag part of Exit Cover FRU Parts List 8 223 High capacity Paper Tray Assembly 0388 65a Fig 8 9 High capacity Paper Tray 8 224 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 9 High capacity Paper Tray FRUs Parts Part number Serial number Qty Name and description Effective Discont d High capacity paper tray 436 0328 00 1 Phaser 840 850 A size 436 0329 00 1 Phaser 840 850 A4 size 436 0416 00 1 Phaser 860 8200 A size 436 0417 00 1 Phaser 860 8200 A4 size 2 116 0272 00 1 Paper pick roller 3 118 9588 01 1 Backstop for High Capacity paper tray assembly 4 High capacity paper tray assembly includes tray 437 0467 00 1 Phaser 840 850 A size 437 0468 00 1 Phaser 840 850 A4 size 437 0495 00 1 Phaser 860 8200 A size 437 0496 00 1 Phaser 860 8200 A4 size FRU Parts List 8 225 Service tools Table 8 10 Service tools Parts Part number Serial number Qty Name and description Effective Discont d 003 1489 00 1 Y axis encoder disk spacer tool 003 1500 00 1 Y axis belt tensioner Phaser 840 006 7997 00 1 Grease Rhe
84. 200 4 401 0778 01 1 Lower feed roller Phaser 840 401 0858 00 Lower feed roller Phaser 850 860 8200 5 401 0813 01 1 Paper pick roller Phaser 840 850 401 0882 00 1 Paper pick roller Phaser 860 8200 6 650 4155 01 1 Drum paper heater assembly Phaser 840 850 650 4228 00 1 Drum paper heater assembly Phaser 860 8200 7 351 1047 00 1 Upper feed assy top half with circuit bd Phaser 840 351 1048 00 1 Upper feed assy lower half Phaser 840 351 1079 00 1 Upper feed assy lower half Phaser 850 860 Upper feed assy top half with circuit bd 351 1106 00 1 Phaser 850 860 8200 351 1035 01 1 Duplex paper guide 401 0841 00 1 Duplex roller Phaser 840 401 0867 00 1 Duplex roller Phaser 850 401 0883 00 1 Duplex roller Phaser 860 8200 10 650 4026 01 1 Upper stripper finger assembly 11 650 4207 00 1 Rapid Release Guide Conversion Kit Phaser 840 see Service Bulletin 456 Rev 1 Stripper blade shaft 11a 384 1849 00 1 Rapid release guide blade assembly Phaser 11b 650 4153 00 1 840 850 Rapid release guide blade assembly Phaser 11b 650 4214 00 1 860 8200 12 401 0781 01 1 Exit roller Phaser 840 401 0857 01 1 Exit roller Phaser 850 401 0885 00 1 Exit roller Phaser 860 8200 13 351 1016 00 1 Guide lower exit pivoting 840 850 351 1095 00 1 Guide lower exit pivoting Phaser 860 8200 105 1064 00 1 Rapid release guide actuation lever refer to SB 541 401 0738 01 1 Rapid release guide cam follower arm refer to SB 541 214 4621 0
85. 214 4651 01 Drum maintenance actuators left and right Phaser 840 367 0515 00 Drum maintenance actuators left and right Phaser 850 860 8200 8 210 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 2 Imaging FRUs Parts Part number Serial number Qty Name and description Effective Discont d 3 351 1053 00 1 Maintenance drawer guide right 840 850 351 1099 00 1 Maintenance drawer guide right Phaser 860 8200 4 436 0383 00 1 Maintenance drawer with 10k roller Phaser 840 850 436 0414 00 1 Maintenance drawer with 10k roller Phaser 860 8200 5 351 1051 01 1 Maintenance drawer guide left 840 850 351 1097 00 1 Maintenance drawer guide left Phaser 860 8200 6 650 3617 00 1 Spring transfix actuation Part of 650 3617 00 Drum Transfix Assy Kit Phaser 840 214 4926 00 1 Spring transfix actuation Phaser 850 860 8200 7 650 3617 00 1 Drum transfix assembly kit Phaser 840 650 4140 03 1 Drum transfix assembly kit Phaser 850 650 4219 01 1 Drum transfix assembly kit Phaser 860 8200 8 441 2137 03 1 Cap wipe purge assembly Phaser 840 650 4179 01 1 Cap wipe purge assembly Phaser 850 860 8200 9 650 3623 00 1 Printhead kit Phaser 840 650 4112 00 1 Printhead kit Phaser 850 650 4208 00 1 Printhead kit Phaser 860 650 4245 00 1 Printhead kit Phaser 8200 10 174 3807 00 1 Cable printhead data 11 650 4025 00 1 Ink loader Phaser 840 650 4141 00 1 Ink loader Phaser
86. 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 707 00 Y axis declared media is too long Typically caused by a multipick or stuck A4 sensor 1 None a Verify that the lower tray is properly loaded b Try heavier media 2 More than one sheet found Multiple pick a Run again in paper path 3 One sheet hangs out at exit A or A4 flag not seated a Inspect and reinsert flag properly b Replace upper preheat b A4 flag is sticking to the entry assembly steel roller 22 721 05 Y axis print failure Media did not arrive at the preheat exit sensor soon enough to complete the print May also be due to an unexpected high capacity tray sensor event 1 None a Lower tray assembly sensor bouncing a Try lighter or smoother media less friction b Replace lower tray 22 722 06 Y axis timeout during transfix moving media to the stripper sensor 1 Media jammed on stripper fingers or rapid release guide excessive skew a b Last sheet in tray First sheet in tray c Failure of deskew system a Refill tray s b Make sure tray s is loaded properly and media is square in tray c Check deskew fingers on inside of front door If chronic check preheat entry assembly for deformation 2 Media jammed on stripper a Missing support foil clear a Replace Lower tray fingers or rapid release guide L shaped plastic media b R
87. 3 RF conducted Immunity EN61000 4 11 1994 06 Voltage Dips and Interruptions EN61000 3 3 1994 12 Flicker 73 23 EEC Low Voltage Directive 89 336 EEC Electromagnetic Compatibility Directive 89 392 EEC Machinery Directive Table 1 12 Environmental specifications Characteristic Specification Temperature Operating Storage and shipping 10 to 32 C 50 to 90 F 30 to 60 C 22 to 140 Humidity Operating Non operating 10 to 80 relative humidity non condensing 10 to 95 relative humidity non condensing Altitude Operating Non operating 0 to 2400 m 8 000 ft at 25 C 0 to 15000 m 50 000 ft Vibration shock Non Operating vibration Non operating shock Operating shock Will withstand 0 15 G excitation 5 to 200 Hz 3 axes for up to 7 minutes with no impairment or subsequent damage 0 5 g 25 minute sweep 5 200 5 Hz 100 200 sec sweep cycles The printer may have any corner raised and dropped 1 5 cm 0 6 in while printing is in progress without impairment of operation that cannot be recovered by a printhead purge cycle The printer may have any corner raised and dropped 6 cm 2 4 in while idle without subsequent impairment of operation 1 34 Phaser 840 850 860 8200 Color Printer Service Manual Regulatory Specifications The printers are in conformance with the following regulatory standards FCC Part 15 Class B for 115 VAC equipment EN55022 CISPR 22 Class B VCCI CI
88. 4 sensor event 1 Media stops just inside preheat entry rollers a A4 width media in A size tray a Check media and replace with good media verify tray type plug position 2 Media folded damaged or deformed in tray a Media gets out of the tray but hits the sensors at the wrong times a Remove media inspect and reload 22 512 14 Time out on preheat exit sensor 1 Damage on the right corner of A Size media a Probable preheater problem a Replace preheater 2 Tight wrinkles across media a Short grained media b Too much drag in preheater a Use long grained or heavier weight media b Replace preheater 3 Media found flat inside preheater Too much drag in drive train stalling media path motor a Use diagnostics to verify drive current requirements or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed 4 Media found flat right at deskew roller a Feed clutch problem a Replace feed clutch 22 514 05 Unexpected Exit Sensor event 1 Media in both duplex path and simplex path 2 64 a Media was pulled from exit into duplex path while printing b Short grained media c Label stock curling d Extreme environment a Make sure exit tray is not overfilled or messy empty tray Use long grain media Empty the exit tray often Donotleave media out of wrapper for extended periods of time in extrem
89. 40 cm Hg 15 7 in Hg 7 7 psi or more vacuum pump module is OK so troubleshoot the following for the source of the vacuum leak W Misaligned CWP due to improper belt alignment Improper Head to Drum Gap 340 350 360 380 840 only Interference with printhead tilt mechanism W Plugged or cracked tubing between CWP and air solenoid or vacuum module Go to Step 5c 5b If less than 40 cm Hg 15 7 in Hg 7 7 psi set vacuum voltage to 24V old 340s or replace the vacuum pump or module Go back to Step 5 5c Check the time it takes for the vacuum to decay to 0 cm Hg Decay time Decay time for 340 350 360 380 is 3 6 Sec decay time for Z840 Z850 is 4 6 Sec E Ifthe decay time is longer than the specified times check the metal and rubber lines for ink fouling If the lines are ok replace air solenoid for newer printers the entire vacuum module must be replaced as air solenoid is not accessible Ifthe decay time goes to zero suddenly check the rubber lines for cracks or holes and replace as necessary If lines are OK replace the air solenoid or the vacuum module 246 Phaser 840 850 860 8200 Color Printer Service Manual C W P CHECK LIST continued 6 Print Service Test 2 Weak and Missing Jets Are there weak or missing jet s YES NO W NO weak or missing jets and Non Xerox Tektronix ink is used go to Test for Non Xerox Tektronix Ink Failure Checklist on the next page W NO weak and missing jets and Xerox
90. 850 printer features the host interface connectors to the printer Standard parallel high density connector IEEE 1284C For the Phaser 850 printer it can also be used to connect a parallel interface scanner W Twisted Pair 10 100BaseT Ethernet connector A Universal Serial Bus port A special 5 pin connector accommodates a service RS 232 cable from a PC or Macintosh computer running PC based diagnostics The rear panel also includes two option slots One slot accommodates a Token Ring Card When the Token Ring card is installed the printer s built in 10 100BaseT Ethernet port is disabled The second slot accommodates an internal IDE hard drive for print job collation job accounting and font storage IDE hard drive di Optional Token Ring card Engine SEE S deg a eee m a light light pe oe Ethernet 10 100BaseT DIP Service Parallel B RS 232 URB Fig 1 18 Phaser 850 printer rear panel 1 26 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 860 printer connectors The rear panel of the Phaser 860 printer features the host interface connectors to the printer W Standard parallel high density connector IEEE 1284C For the Phaser 860 printer it can also be used to connect a parallel interface scanner Twisted Pair 10 100BaseT Ethernet connector A Universal Serial Bus USB port An optional hard drive can be installed on th
91. AC heaters within the printer they protect the power supply from most often a shorted triac If F2 or F3 blows replace the power supply rather than the fuse Otherwise with the fuse replaced but the triac shorted AC power may be applied to the heater without the printer even being turned on resulting in a thermal runaway condition Fuse F1 is for the DC power supply all DC outputs Fuse F2 is for the following heaters H3 Jet Stack Left H4 Paper PreHeat H10 Jet Stack Right H11 Reservoir 2 H12 Drum 2 H14 Reservoir 4 Fuse F3 is for the following heaters H1 Drum 1 H2 Reservoir 1 H5 Black Ink Melt H6 Magenta Ink Melt H7 Cyan Ink Melt H8 Yellow Ink Melt H9 Cap Wipe Heat H13 Reservoir 3 If the fuses are functional but the printer s power supply does not output DC voltages proceed to the topic Testing for shorted drivers on page 3 83 Also refer to SF157 3 82 Phaser 840 850 860 8200 Color Printer Service Manual Testing for shorted drivers 1 Turn off the printer 2 Disconnect the 40 DC loopback connector the 4 pin connector with the two loopback wires from J250 at the top of the power control board This isolates the Y axis motor process motor X axis motor paper feed motor vacuum pump solenoids and clutches 3 The 40 volt service load connector is not needed for the Phaser 860 printer go to step 4 For the Phaser 840 850 attach the service load connector to J250 on the top of the po
92. B test failure Reseat then replace main board Error Codes and Messages 2 41 Table 2 3 POST Power On Self Test Error Messages cont d PS PEand Front Description FrontPanel Panel LEDs Error Code Soft Error 14 xx Real Time Clock test failures These are soft errors and will allow the printer to continue printing though all time stamping activities will be incorrect Reseat then replace the main board Soft Error 15 01 RAM SODIMM in slot 1 failed Ensure supported RAM is being used Reseat then replace the RAM SODIMM Soft Error 15 02 RAM SODIMM in slot 2 failed Ensure supported RAM is being used Reseat then replace the RAM SODIMM Soft Error 15 03 RAM SODIMM in slot 1 incompatible Ensure supported RAM is being used Reseat then replace the RAM SODIMM Soft Error 15 04 RAM SODIMM in slot 2 incompatible Ensure supported RAM is being used Reseat then replace the RAM SODIMM Soft Error 16 01 Less than 64 MB of RAM is detected This is the minimum RAM required Add more RAM reseat the RAM SODIMM s then replace the RAM SODIMM s 17 17 xx An unrecognized option card is responding This failure should never occur the Phaser 860 does not support optional cards If this error occurs check the main board to power control board connector for damage Replace the main board and then the power control board Soft Error 18 xx Optional Token Ring card failures This failure should never o
93. DIMM Phaser 840 850 156 4831 00 1 64 Mbyte RAM SODIMM Phaser 860 8200 156 4780 10 1 128 Mbyte RAM DIMM Phaser 850 156 4832 00 1 128 Mbyte RAM SODIMM Phaser 860 8200 7 650 3991 00 1 Main board Phaser 840 650 4142 01 1 Main board Phaser 850 650 4210 05 1 Main board Phaser 860 7a 650 4250 00 1 Main board Phaser 8200 367 0506 00 1 Board pull out handle Phaser 840 850 367 0528 00 1 Board pull out handle Phaser 860 8 650 3886 01 1 Dallas Real Time Clock NVRAM Module Phaser 840 9 650 4024 01 1 Power supply 10 671 4053 50 1 SCSI riser board assembly Phaser 840 386 7074 00 1 Blank cover plate no SCSI riser board Phaser 840 11 163 1217 00 1 Boot ROM Printer ID Phaser 840 850 860B 8200B 163 1471 00 1 Boot ROM Printer ID Phaser 860DP 8200DP 12 131 6411 00 1 Jumper 40 volt isolation 13 650 4029 01 1 Power control board Phaser 840 650 4157 00 1 Power control board Phaser 850 650 4211 00 1 Power control board Phaser 860 650 4251 00 1 Power control board Phaser 8200 FRU Parts List 8 217 Solenoid and Clutch FRUs N lt Wig KAP o N he S d el S a PNG yoy Pd ew Qo Fig 8 6 Solenoid and Clutch FRUs 0388 23 8 218 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 6 Solenoid and clutch FRUs Parts Part number Serial number Qty Name and description Effective Discont d 1 401 0792 00 El
94. DOWN UP use only Recovery mode engineering use DOWN UP DOWN UP only Recommended DIP switch postion If DIP switch 4 is left in the down position the printer will not turn off 1 28 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 840 850 and 860 Printer Differences Note There are additional part differences not detailed in this table Please refer to FRU Parts List on page 8 207 for a complete listing of parts and part numbers Table 1 7 Summary of differences between Phaser 840 850 860 Phaser 840 Part 840 to 850 Difference 850 to 860 Difference Description Main board The main board is based on a 603E The 8240 processor at 250 MHz processor at 200 MHz It features a Internal Hard drive now mounted new rear panel with built in on the main board 10 100BaseT and no SCSI port or riser card The large Dallas NVRAM caras are supported chip is no longer used Also the Code ROM is usually soldered RAM connectors are angled A down battery on the main board will Easier insertion support the real time clock 10 year integrated ASICs life The printer supports up to 256 Mbytes of RAM Only a Token Ring Card and an IDE Internal Hard Drive are available RAM DIMMs Phaser 850 printer is not as Uses the smaller 144 pin restricted on the height of the RAM DIMMs the main board will accept since it uses angled RAM DIMM connectors PC66 compliant SODIMMs PC100 compl
95. Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly Test Prints 5 169 19 Yellow Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 20 OHP Color Bands T
96. Hz PowerPC processor oversees print engine operations and PostScript image processing All configurations except the Phaser 860B feature a 10 100BaseT Ethernet port with support for EtherTalk Novell NetWare NDS TCP IP DHCP and Windows Peer to Peer A USB high speed serial port is also provided LocalTalk Tolken Ring and 10Base2 are not supported by the Phaser 860 printer An internal IDE hard drive can be installed on the main board for font storage and job accounting if the printer has DP features the hard drive will support collation proof print saved print and secure print An integral bi directional parallel port IEEE 1284C with ECP mode supports printing and also allows connecting a parallel interface scanner for optical copying support General Information 1 5 The printer supports Job Accounting which maintains from 50 to 5000 records of processed print jobs depending on memory and hard drive options The record contains information such as time duration of the print and the percentage of color coverage on the print The log of reconds can be retrieved using CentreWare software Proof Print Jobs A proof job is a specific case of a multiple copy job With a proof job the customer assigns a password and copy account at the client workstation before printing The first set of prints are printed immediately The original number of requested sets are printed after the customer enters the matching password on the printer s control pane
97. Information 1 11 Print Engine Assemblies 840 850 860 Cap wipe purge Ink load assembly Printhead assembly Drum Transfix roller Process motor Paper drum heater Y axis X axis drive motor and motor Paper feed motor 0388 0 Fig 1 3 Internal features of the print engine 1 12 Phaser 840 850 860 8200 Color Printer Service Manual Circuit Boards Seven circuit boards support the printer s electronics Two boards called I O boards left and right support the front panel solenoids and sensors The main board contains the printer s CPU processor RAM and ROM The power control board distributes power supply voltages to the other printer boards and many of the printer motors The power supply converts the AC line voltage into internal AC and DC voltages The front panel provides a user interface to the printer The printhead drive board a part of the printhead manages the signals and voltages of the printhead s printing elements and sensors The optional network card Phaser 840 and 850 only and internal hard drive could be considered eight and ninth circuit boards Front panel IP PK board right 0388 03 Fig 1 4 Circuit boards of the print engine right front view of the Phaser 850 General Information 1 13 Printhead drive board Internal hard drive Drum Maintenance counter Network EEPROM card A4 Power board Power supply board Main board left 0388 04 Fig 1 5
98. O boards and their solenoid drivers If the rear panel LEDs illuminate isolate which I O board is shorting or which I O board ribbon cable is defective T If the power supply still does not work replace the power supply Troubleshooting 3 83 Testing for a shorted motor 1 Reinstall the power supply if removed in the previous procedure 2 Disconnect the process motor the Y axis motor X axis motor and the cap wipe purge assembly motor wiring harness 3 Turn on the printer again to see if it does not overload now that the motors are disconnected from the power supply If the power supply is functional move to the following procedure Testing motor and solenoid resistances If the motors and solenoids are not shorted but the power supply still does not function replace the power control board Testing motor and solenoid resistances 1 Turn off the printer and disconnect the power cord 2 With a DMM set for measuring resistance test each motor s windings for correct resistance disconnected from the printer Rotate the motor s drive shaft slightly while taking the measurement Table 3 5 Motor and solenoid resistances Motor or solenoid Phaser 840 printer Resistance approximately Phaser 850 860 Printer Resistance approximately Process motor 2 9 ohms 15 Difficult to measure due to variability at the brush commutator interface 4 3 ohms 15 Difficult to measure due to variabili
99. Oil Chase When this menu item is turned enabled the printer will process a blank sheet of paper through the printer when ever the printer is switched from printing envelopes to printing on paper or transparency film This removes ink artifacts from the drum that might otherwise appear on a print 1 Access the Hidden Service Menu 2 Scroll and highlight the menu item Envelope Oil Chase 3 Press Select Phaser 840 850 or OK Phaser 860 to turn the menu item on 4 Exit the Hidden Service Menu Center Image This menu item allows you to alter the left right position of an image on a page Access the Hidden Service Menu Scroll and highlight the menu item Center Image Press Select Phaser 840 850 or OK Phaser 860 to access the menu item Up the up and down arrow keys to enter a value to move the image to the left or right Exit the Hidden Service Menu o1 N Diagnostics and Adjustments 4 137 Locking the printhead During normal power down the printer tilts the printhead back and energizes the x axis drive to move the printhead to the far right This allows the printhead s tilt arm which moves as the printhead moves to engage a pin protruding from the left side printer frame This effectively automatically locks the printhead in place for moving and shipping The printer will not lock the printhead if any printer door is open Caution Afier servicing the printer with power off never leave the printhead i
100. Paper Path Drive ID 5 R Definition Duplex feed clutch to width A4 flag Results gt 220 lt 180 Interpretation Actions Media was not deskewed successfully Ensure proper tray loading and verify front door deskew fingers are not damaged This may also be due to a bad feed clutch slippery feed roller or misaligned sensor Duplex width A4 flag to preheat exit flag gt 180 lt 160 Media was not deskewed successfully Ensure proper tray loading and verify front door deskew fingers are not damaged This may also be due to a bad feed clutch slippery feed roller or misaligned sensor Preheat exit flag to strip exit flag gt 730 The media was delayed in reaching the strip sense flag Light weight or coated media may tend to stick to the transfix roller This may also occur if the transfix roller is dirty or not properly oiled The rapid release guide may also be bound or damaged 12 Strip exit flag to paper exit flag gt 150 Something may be obstructing the exit path Paper Path Drive Test ID 5 This test runs successive pieces of paper through the media path at low current levels to determine the minimum drive current Due to the nature of the test the last sheet results in a paper jam and in some cases causes engine firmware to halt By counting the number of sheets that were tried including the sheet that jammed you can interpret the test results
101. R1 outside their range If yes something may be obstructing the printhead tilt mechanism RO is a measurement of the current needed to tilt the printhead R1 measures the amount of gear train slack in the tilt mechanism Was the purge volume low or is R2 less than 3000 If yes there may be a leak in the vacuum system or inadequate peak vacuum This could be due to m Misaligned CWP due to improper belt alignment or CWP motion problem m Damaged CWP gasket m Plugged or leaking tubing holes cracks in tubing m Defective vacuum module Inspect and replace the CWP or tubing as needed Note that it may take up to 6 purges before a new CWP runs at optimal performance If no problem is seen replace the vacuum module e Note Is R2 greater than 8000 If yes there may be a problem with the air solenoid or clogged tubing If the tubing is okay replace the vacuum module After exiting diagnostics there may be some color mixing as the Cap Vacuum test does not do a complete series of faceplate wipes Printing Service Print 8 Solid Fills and or performing an Eliminate Light Stripes should resolve this Troubleshooting 3 109 6 Perform the front panel Clean cycle Eliminate Light Stripes and check the PEAK vacuum and DECAY time to determine if there is a problem with the vacuum system pump solenoid valve or tubing or cap wipe purge assembly gasket 3 110 Normal operation In normal operation the vacuum builds up a inside the
102. Resolution Photo mode will almost always be counted in the 25 100 coverage category A front panel message indicates when the maintenance roller is low Printing is still possible when the maintenance roller fluid is low When a front panel message indicates that the maintenance roller is empty the maintenance roller and its counter must be replaced before continued printing is possible Refer to the instructions included with the kit to replace the maintenance roller kit Phaser 840 and Phaser 850 maintenance cartridges are interchangeable Note The drum gir an oil poses no known adverse health effects Refer to the Material Safety Data Sheet for amino oil in printer s Advanced Features and Troubleshooting Manual for more information Waste tray The maintenance drawer contains a waste tray that collects ink that has been purged from the printer s ink jets The waste tray should be emptied each time the maintenance drawer is removed from the printer Refer to the printer s user guide for instructions on removing and emptying the waste tray Be sure to insert the waste tray into the maintenance drawer before reinstalling the maintenance drawer in the printer Never reuse waste ink in the printer 6 176 Phaser 840 850 860 8200 Color Printer Service Manual Lubrication Tools and supplies required m Light oil mGrease 006 7997 00 In general all of the printer s bearings and motors are lifetime factory lubricated Howev
103. SPR 22 Class B EN61000 3 2 Flicker on AC Mains Susceptibility The packaged product meets National Safe Transit Committee Test Procedures Listed UL 1950 Information Technology Equipment Certified to CSA C22 2 No 950 Safety of Information Technology Equipment Including Electrical Business Equipment GS licensed IEC 950 1991 Second Edition EN60950 Information Technology Equipment General Information 1 35 1 36 Phaser 840 850 860 8200 Color Printer Service Manual Error Codes and Messages Phaser 840 850 Rear Panel PS and PE LED Codes The rear panel LEDs are located on each side of rear panel DIP switches The left LED represents the operation of the PostScript firmware The right LED represents operation of the main board 5 print engine firmware During the POST tests the two LEDs toggle back and forth for each successful pass through each SDRAM test A failure in the power on self tests is indicated by the left LED the PS LED flashing in a specific pattern of long and or short flashes and repeated indefinitely A long flash represents a 5 while a short flash is a 1 For example a long flash followed by 4 short flashes is 5 4 9 If the left LED repeatedly flashes in the same sequence then the PostScript processor has encountered an error and is looping For the Phaser 850 printer when a fatal error occurs the front panel Error LED flashes the same pattern as the PS LED The possible LED encoded error c
104. SYMPTOMS BUT NO EVIDENCE OF NXTI CAN BE FOUND Provide the customer with the Customer Alert 6 March 2002 letter If there are weak or missing jets replace the printhead per normal procedures Check the Non Xerox Tektronix Ink Box on Greentag Enclose all sample prints and this checklist with the printhead and return it to Wilsonville for evaluation Enclose a sample of waste ink with the printhead return if possible Xerox Personnel please provide full documentation in TekLink Appendix 265 On site Electronics Troubleshooting Checklist Phaser 860 8200 Phaser 860 8200 Version 1 1 NAME OUT REQUEST ID DATE TPM ASP COMPANY if no OUT REQUEST ID PHONE IMPORTANT This checklist outlines proper electronics troubleshooting procedures and should be performed by all Xerox employees Authorized Service Providers ASPs Self Service Providers SSPs and Third Party Maintenance TPM personnel on any job involving replacement of any of the three main electronics components Main Board Power Supply and Power Control Board The completed checklist is to be included with any failed circuit board returned to the factory Also include print samples if applicable to the problem and a Usage Profile Report printed after the problem has been resolved Before troubleshooting any printer hardware failure be sure to disconnect the printer from the network or host computer The hardware ports on the main board are very reliable a
105. Service Manual Rear Panel Connections Phaser 840 printer connectors The rear panel of the Phaser 840 printer features the host interface connectors to the printer W Standard parallel high density connector IEEE 1284C Twisted Pair 10BaseT Ethernet connector W AUniversal Serial Bus port E Optional SCSI high density connector hard disk drive or Tektronix approved scanner W A special 5 pin connector accommodates a service RS 232 cable from a PC or Macintosh computer running PC based diagnostics The rear panel also includes two option slots With the addition of a PhaserShare network card in one slot the printer can feature either of these connector combinations LocalTalk connector W ThinNet 10Base2 and Twisted Pair 100BaseT Ethernet or Token Ring connectors Note When an Ethernet or Token Ring PhaserShare card is installed the printer 5 built in 10BaseT Ethernet port is disabled The second slot accommodates an internal IDE hard drive for print job collation job accounting font storage and PDF direct printing IDE hard drive Network card PostScript light health light 36 eries Ethemet Card Ome xO Or 1 1 mmm O em eA SCSI Ethernet TN 058867 Parallel USB RS 232 DIP switches 0388 1 Fig 1 17 Phaser 840 printer rear panel General Information 1 25 Phaser 850 printer connectors The rear panel of the Phaser
106. THE DOCUMENT COMPANY XEROX Phaser 840 850 860 Color Printer Manual With Phaser 8200 Color Printer Addendum Tektronix 7 COLOR PRINTERS BY NENNEN PHASER 840 850 860 NETWORK COLOR PRINTER Service Manual with the Phaser 8200 Color Printer Addendum 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 This printing April 2002 071 0723 00 Tektronix 7 COLOR PRINTERS BY XEROX Copyright O 2002 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 stylized x CentreWare ColorStix DocuPrint Made For Each Other Phaser PhaserShare and the TekColor icon are registered trademarks of Xerox Corporation infoSMART PhaserLink PhaserPort PhaserPr
107. Tektronix ink is used repair is complete W YES and Non Xerox Tektronix ink is used go to Test for Non Xerox Tektronix Ink Failure Checklist W YES and Xerox Tektronix ink is used go to Step 7 7 Install a new printhead Make sure the printhead voltage is set to 128 Test performance Comments Xerox US personnel please add all comments in TechLink Appendix 247 NON XEROX TEKTRONIX INK FAILURE CHECKLIST PERFORM THIS CHECKLIST ONLY IF NON XEROX TEKTRONIX INK IS IN USE 1 Print Test Print 2 Weak Missing Jets CAREFULLY examine it and proceed with the questions below 1 Does Test Print 2 show at least one color with 8 or more weak missing jets YES NO Goto 2 Goto 1b 1b Print up to 10 solid fills of the suspected color s After these solid fills did the printhead develop at least one color with 8 or more weak missing jets YES NO Goto 2 Gotolc 1c Does the customer symptom involve intermittent failure that cannot be reproduced where virtually all jets for a color fail YES NO Goto 2 Goto B 2 Does the faceplate of the printhead show obvious head to drum contact damage this is typically seen S as an obvious horizontal scratch running from one end of the printhead faceplate YE NO Goto B Go to 3 3 Does the printhead reservoir of the affected color have ink visible in it YES NO Goto 4 GotoB 4 Do ALL 4 COLORS have the same or nearly the same jets missing not weak in a ba
108. The printers 2 1 15 Printhead Maintenance System essere 1 16 Sensor Maps sioe He ettet ii ao DP 1 17 Combination sensors and their meanings sse 1 20 Media tray type sensing nnne 1 20 The M in Board eee tote 1 21 Front Panel Phaser 840 850 Printers ccccsccsscescesseeseseeeeceececececeseeaeeseeaeenes 1 23 Front Panel Phaser 860 1 24 Rear Panel Connections 1 25 Rear Panel Status 5 2 1 28 DIP Switches 2 1 28 Phaser 840 850 and 860 Printer Differences esse 1 29 Specifications E EERE 1 31 Regulatory Specifications sese 1 35 Error Codes and Messages 2 37 Phaser 840 850 Rear Panel PS and PE LED 2 37 Phaser 860 Power Up Error Messages and LED 2 40 The BIST Built In Self Test 2 40 POST Power On Self Test irnar siat 2 41 Fault Codes sie eo onte euim ER 2 44 Contents i Troubleshooting 3 73 Network Event A bea 3 75 Electronics Troubleshooting 3 76 System power up sequence 3 76 Inoperative printer problems
109. a revolution from their original position Any adjustment beyond this point results in ink adhesion problems 9 If wrinkling continues to occur replace the drum transfix assembly Original registration mark 3 8 turn 3 8 turn maximum maximum Tension spring set screws 0388 38 Fig 4 11 Adjusting the transfix roller pressure springs 4 154 Phaser 840 850 860 8200 Color Printer Service Manual Vacuum check Phaser 840 850 Only Tools required m Magnetic screwdriver m Vacuum gauge m T 20 TORX tip m T 15 TORX tip m PC diagnostics Use this check to verify the actions of the vacuum pump and the solenoid valve In addition you can determine if the cap wipe purge assembly is sealing properly against the printhead faceplate Note Phaser 860 vacuum performance can be verified with the built in diagnostics Cap Vacuum test Refer to step 5 of Evaluating the printhead and cap wipe purge system on page 3 106 Turn off the printer Remove the top and right side covers Turn on the printer The cap wipe purge seal must be checked while the printhead is hot With a T connector connect the vacuum gauge to the between the vacuum pump module and the cap wipe purge unit A Vacuum guage T connector Vacuum assembly Cap wipe purge vacuum hose 0388 35 Fig 4 12 Connecting the vacuum gauge to the printer 5 Turn on the printer and enable the diagnostics as explained in the topic PC based
110. action Many of the tests rely on mechanical positions and slight changes can effect the results Ensure that the printer is not out of paper ink or maintenance kit life The diagnostics routines are not designed to address all of these conditions consistently 4 126 Phaser 840 850 860 8200 Color Printer Service Manual Table 4 4 Check Menu Value Key Paper Path Status Test ID 3 This test looks at the paper path sensor to identify if anything would prevent a prage from printing The front panel will display messages indicating if anything unexpected is found The diagnostics history reports a single result RO which is a string of 0 s and 1 s one digit for each sensor state 24 total 1 the sensor state was normal 0 the presence of paper an open door or missing tray if the printer has no lower trays those sensors report 0 s Not used always 0 No media at duplex sensor These are the typical results for a printer with no lower trays No media at exit sensor No media at transfix strip sensor No media at preheat exit sensor No media at preheat entry sensor No media at A or A4 width sensor No media at A4 width sensor No media at A width sensor Exit cover closed Front cover closed Maintenance kit present No media at handfeed sensor No media at pick sensor Upper tray not empty Upper tray present Tray Ajar 2 Tray Ajar 1
111. ady in place install the printhead s data ribbon cable to the printhead 1 Using the printhead removal tool reverse the removal steps to reinstall the printhead 2 Rotate the printhead to its print position and attach the head tilt spring 3 Torque the mounting screws to 20 in Ibs Caution careful not to spill ink out of the hot printhead For the Phaser 840 only refer to Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 4 Plug the printhead s data ribbon cable and power wiring harness into the power control board Inspect both ends of the data ribbon cable to ensure they are properly seated Reconnect the two printhead ground wires to the printer frame 5 Install the ink loader 6 Plug in the printer and turn on 7 198 Phaser 840 850 860 8200 Color Printer Service Manual X axis motor and drive assembly Remove the right cover Remove the left cover Disconnect the head tilt spring Disconnect the X axis motor wiring harness at the x axis motor Remove the screws securing the X axis motor and bracket in place Rotate the black plastic retainer counterclockwise Lift up the bottom portion of the X axis drive yoke Lift up the yoke and remove the upper portion of the yoke Rotate the X axis cone gear counterclockwise to remove it from the X axis shaft Retainer gear X axis drive yoke tsp remove bottom first phaser 840 o
112. agement Tools CD ROM all languages 063 3178 00 Network Setup Guide English 063 3178 10 Network Setup Guide French 063 3178 20 Network Setup Guide Italian 063 3178 30 Network Setup Guide German 063 3178 40 Network Setup Guide Spanish Phaser 8200 061 4473 00 World Kit Standard 061 4474 00 World Kit Metric 063 3424 00 Phaser 8200 Drivers and Utilities with Advanced Network Management Tools CD ROM all languages 063 3425 00 Phaser 8200 Advanced Network Management Tools CD S W 8 232 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d Cords 161 0066 00 Power cord Standard U S 115V 161 0066 09 Power cord Euro 220V 161 0066 10 Power cord United Kingdom 240V 161 0066 11 Power cord Australian 250V 161 0154 00 Power cord Swiss 220V 161 0240 00 Power cord Danish 065 0619 00 Shipping carton kit FRU Parts List 8 233 8 234 Phaser 840 850 860 8200 Color Printer Service Manual Wiring Diagrams Phaser 840 only Ink Low load Empt board CE High capacity Size A A4 Main Board papertray2 Empty Tray present Printer ID Drum heater Paper preheater High capacity Size A A4 paper tray 1 Empty Tray present Cap wipe purge unit Drum maintenance counter EEPROM X axis
113. ailure none Token Ring This test verifies the functionality of the processor chip Option Card Any test failures with this component are treated as Phaser non fatal errors with the error information written to the 840 850 Only Start Page If a failure is detected the message Token Ring Option Card with one of the following messages will Token Ring is be sent to the Startup Page not supported General error in the Phaser m Problem with EEPROM 860 printer m Error trying to Bring Up Diags m Error initializing device m Command completion error m Interrupt error Wrong vendor ID m Wrong microcode version m Wrong version ID none LocalTalk This test verifies the functionality of the LocalTalk option Option Card card Any test failures with this component are treated as Phaser 840 non fatal errors with the error information written to the printer only Startup Page If a failure is detected the message LocalTalk Option Card General Error will be sent to the Startup Page Error Codes and Messages 2 39 Phaser 860 Power Up Error Messages and LED Codes The Phaser 860 has two sets of tests that are run when the printer is first powered on Built In Self Tests BIST and Power On Self Tests POST BIST verifies basic main board CPU operation and reports failures with rear panel LED blink codes refer back to the 840 850 Rear Panel LED Codes for greater detail on blink codes POST checks communication paths from the main bo
114. anel to the right I O board passing beside the Y axis belt drive assembly 3 Remove the drum fan Note the fan orientation it blows into the drum Caution Never loosen or remove the three screws securing the assembly parts together Also improperly removing the tension spring can cause the tension bracket to flip off forcefully causing injury 4 Insert a flat blade screwdriver through the tension bracket as a holder Anchor the screwdriver tip against the Y axis belt drive assembly 5 Remove the tension bracket s mounting screw Using the screwdriver as a lever slowly tilt the bracket up and away from the frame 6 Remove the three mounting screws securing the Y axis belt drive assembly to the engine frame Remove the assembly with its two belts S X Y axis belt C X assembly Tension bracket Y Mounting screws 840 4 79 a Fig 7 19 Removing the Y axis belt drive assembly Phaser 850 860 printer 7 Reverse these steps to reinstall the Y axis drive assembly 8 Tension the belts using the Y axis belts tension adjustment Phaser 850 860 printer on page 4 144 Removal and Replacement Procedures 7 201 Cap wipe purge assembly Phaser 840 printer Warning Even when the printer is turned off AC line voltages may be present at the printer heaters while the printer is plugged into AC power Turn off the printer and remove the power cord Remove the right cover Remove the left cover
115. anese 063 3322 70 Phaser 850 Drivers and Utilities CD ROM Simplified Chinese Traditional Chinese Korean 061 4229 00 Phaser 860 Manual pack English 061 4343 00 Phaser 860 Manual pack French 061 Phaser 860 Manual pack Pacific MNLCK 061 4344 00 Phaser 860 Manual pack Italian FRU Parts List 231 Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 061 4345 00 Phaser 860 Manual pack German 061 4346 00 Phaser 860 Manual pack Spanish 061 4347 00 Phaser 860 Manual pack Brazilian Portuguese 061 4357 00 Phaser 860 Manual pack Simplified Chines 061 4358 00 Phaser 860 Manual pack Traditional Chinese 061 4362 00 Phaser 860 Manual pack Korean 061 4348 00 Phaser 860 Manual pack Dutch 061 4349 00 Phaser 860 Manual pack Swedish 061 4350 00 Phaser 860 Manual pack Russian 061 4351 00 Phaser 860 Manual pack Norwegian 061 4352 00 Phaser 860 Manual pack Danish 061 4353 00 Phaser 860 Manual pack Finnish 061 4354 00 Phaser 860 Manual pack Czechoslovakian 061 4355 00 Phaser 860 Manual pack Polish 061 4356 00 Phaser 860 Manual pack Hungarian 061 4357 00 Phaser 860 Manual pack Japanese 063 3402 00 Phaser 860 Drivers and Utilities with Advanced Network Management Tools CD ROM English 063 3403 00 Phaser 860 Drivers and Utilities with Advanced Network Man
116. ar panel knobs securing the main board Slide out the main board If you are replacing the main board transfer the printer ID chip to the new board so that the printer s settings and Ethernet address are retained Also swap the code ROM DIMM and the RAM SODIMM s and the upgrade Code ROM DIMM and internal IDE hard drive if applicable OND Factory Code ROM RAM EEPROM SODIMM Printer ID Upgrade Code ROM a J 02 p a oO E P860 006 P860 007 Fig 7 3 Removing the Main Board Phaser 860 7 182 Phaser 840 850 860 8200 Color Printer Service Manual Power supply Warning Even when the printer is off AC line voltages may be present at the printer heaters while the printer is plugged into AC power Turn off the printer and remove the power cord Remove the right cover Remove the left cover Remove the rear cover Remove the top cover At the right side of the printer disconnect the two wiring harnesses leading to the power supply Remove the four screws securing the power supply in place Remove the power supply Wiring harnesses Power supply o 840 4 32 Fig 7 4 Removing the power supply Removal and Replacement Procedures 7 183 Power control board Turn off the printer and remove the power cord Remov
117. ard CPU to other parts of the main board and other systems of the printer POST testing initializes the front panel and if an error occurs a POST error message will be displayed on the front panel LCD POST errors are also displayed using rear panel LED patterns in case the communication path to the front panel has failed Some POST errors are soft errors which do not prevent the printer from powering up completely These errors are displayed on the front panel for 5 seconds and then the printer continues through the remainder of POST Because soft errors do not stop the printer from powering up there are no rear panel LED codes associated with them in normal mode Most soft errors will also cause the printer to print a Startup Page with the error message on it BIST and POST errors are not stored in the fault history logs The BIST Built In Self Test These tests occur immediately at power up before the front panel is initialized Table 2 2 BIST Rear Panel LED Codes PS LED PE LED Description 1 Blink 1 Blink and then andthen off off The power supply could not remain regulated when the DC power was applied so it was shut down Follow the troubleshooting procedures for electrical shorts and check the power supply fuses On Solid On Solid The printer is held in reset mode Make sure the DIP switches are all in the up position This can be caused by a faulty or missing MIG chip In early printers this chip is sockete
118. ards Use current PANTONE Color Reference Manuals for accurate colors PANTONE Color simulations are only obtainable on this product when driven by qualified Pantone licensed software packages Contact Pantone Inc for a current list of qualified licensees TE MP ck mp User safety summary Terms in manual CAUTION Conditions that can result in damage to the product WARNING Conditions that can result in personal injury or loss of life Power source For 110 VAC printers do not apply more than 130 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector For 220 VAC printers do not apply more than 250 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector Refer to a qualified service technician for changes to the cord or connector Operation of product Avoid electric shock by contacting a qualified service technician to replace fuses inside the product Do not operate without the covers and panels properly installed Do not operate in an atmosphere of explosive gases WARNING Turning the power off using the On Off switch does not de energize the printer You must remove the power cord to disconnect the printer from the mains Keep the power cord accessible for removal in case of an emergency Safety instructions Read all installation instructions carefully before you plug the
119. ave a small amount of cyan ink added to them which tints them green to make them more visible Look for No interlacing is used in this print expect light dark variation between jets Look for much lighter colored vertical bands in the horizontal bars Weak jets in the yellow band are distinguished by a cyan tint Causes A jet may be partially clogged perform printhead clean purge cycles on the printhead to remove contaminants from the poor performing jet Test the vacuum system of the cap wipe purge system Turn the printer off for 4 to 6 hours or overnight if practical Then perform a clean purge cycle again As last resort replace the printhead 3 Color Bands RGBK Dither The large secondary colored areas in this print reveal banding and weak jets Look for Vertical bars or bands of much lighter color or a different hue running in line in one or more of the solid fills Causes Banding is caused by color to color misregistration Ensure the printhead to drum spacing is correct Then use the PC diagnostics to ensure that the printhead and drum thermals are correct A weak jet can also cause banding refer to the Weak missing Jets test print Make sure that the drum temperature sensor is correctly mounted and in proper even contact with the drum If necessary remove the sensor and check it for an accumulation of debris at its contact point As a last resort replace the printhead 9923 114
120. be shorted Replace the paper preheater 16 003 45 TCP_THERMISTOR_ HOT The preheater heater is running away Unplug the printer NOW Check the preheater cabling Replace the preheater 16 004 46 TCP_THERMISTOR_ SLOW The preheater is not heating at all or is not heating as quickly as it should Check for an open connection Replace the paper preheater Replace the power supply 16 005 47 TCP_THERMISTOR_ADC _BAD An inalid reading is being reported by the preheater thermistor Verify the connections to the paper preheater replace the paper preheater replace the main board and then replace the power control board 19 000 PRINTHEAD CALIBRATION PROGRAM FAULT CODES 19 001 4X HC_DEV_FAULT 0x01 Occurs during the scales and offset calibration Any part in the chain could be responsible for the incorrect reading including the printhead electronics the A D electronics the waveform generation electronics power supply wave amplifier on the power control board printhead interconnect cable 19 002 4X HC_DEV_FAULT 0x02 Occurs when the printer is attempting to determine how many data taps the printhead uses Any part in the chain may be responsible for the reading including the printhead electronics the A D electronics the waveform generation electronics power supply wave amplifier on the power control board and printhead interconnect cable 19 008 63 HC_PROG_FAULT 8 Incorrect Printh
121. ble 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 8 002 67 CAP PROG FAULT 22 Generic Cap Task Program Fault This error indicates that the main CAP state sequencer cap main has entered the program fault state There are multiple reasons that this can happen Genereally they involve unexpected conditions while performing CAP movements home goto etc 08 003 46 The cap home sensor was activated too soon This can occur if the cap wipe purge assembly was obstructed while moving up and therefore retruned to the home position too soon Ensure that the head tilt mechanism is working properly Run diagnostics to verify cap drive motion and alignment 08 009 65 An unexpected message was received while homing the Cap Wipe Purge assembly usually during system initialization This fault is due to a failure of the Y Axis Encoder 8 022 60 CAP PROG FAULT 22 Unexpected CAP Command in Idle State An invalid CAP command or unknown ITC message was received by the CAP task while it was in the idle state 9 000 INK LOADER INK MELTERS AND PRINTHEAD INK LEVEL SENSORS 9 001 45 Malfunction of the ink level sensor in the cyan reservoir Replace IL FAULT C the printhead TWANGER 9 002 46 Malfunction of the ink level sensor in the magenta reservoir IL FAULT M Replace the printhead TWANGER 9 003 47 Malfunction of the ink level sensor in the
122. ble missing weak or contaminated jet Print the service test print Weak Missing Jet to determine if a jet is not performing 2 Verify the drum temperature using diagnostics Ensure the drum temperature sensor is cleaned and properly positioned 3 Head to drum gap is too small Verify the gap with the adjustment explained in the topic Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 4 Verify the operation of the Y axis encoder using diagnostics Replace the encoder if needed 5 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation 6 If the problem persists replace the printhead 3 96 Phaser 840 850 860 8200 Color Printer Service Manual Ghosting Drum is too warm ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 71 Table 3 15 Ghosting Step Question and Actions 1 Occasionally if the prints have been sitting atop one another the pressure of the stack and the heat of the printer can cause blocking This has the appearance of ghosting Try printing the image s again without the prints stacking on each other in the output tray Run multiple prints the first 2 sided print will have the worst ghosting Some transfix roller ghosting is inherent to the printer however the prints should
123. board fault Refer to Appendix Electronics Troubleshooting Checklist A few rare conditions were specifically not included in the checklist W The power switch is turned off and the printer remains on Check the DIP switches then pull the plug and reseat the main board If LEDs blink and then hang either both off on unknown combination the issue is unknown Reseat everything then replace the main board Also refer to Error Codes and Messages on page 2 37 and System power up sequence on page 3 76 3 80 Phaser 840 850 860 8200 Color Printer Service Manual Verifying print engine operation by printing a built in page 1 If not already on turn on the printer If the printer does not begin initializing go to the topic Measuring power supply voltages 2 Once the Power light is on not blinking and the front panel displays Ready to Print itis now possible to print any built in pages 3 If the printer prints the Page the print engine is working correctly If the printer does not print the Page then a problem exists with the print engine Verifying power supply operation Required tools m TORX T 20 screwdriver Digital multi meter DMM The power supply is divided into two sections the AC section used for heaters and the DC section for control logic printhead drivers and motors Verifying the power supply involves three steps W Checking for proper AC voltage W Inspecting the power supply fuses W Tes
124. cale press inward on the tension idler of the process belt with a pressure of 0 7 kgs 1 5 Ibs and then tighten the tensioner in place Do not over tension the belt Press here to set belt deflection Process belt tensioner 0388 28 Fig 4 1 Setting process belt tension 3 Reinstall the left side panel Diagnostics and Adjustments 4 139 Exit roller drive belt tension adjustment 1 Turn off the printer and remove the left side cabinet panel 2 To adjust the belt tension loosen the exit roller drive belt tensioner With a spring scale press downward on the idler tensioner of the exit roller drive belt with a pressure of 0 5 kg 1 Ib then tighten the tensioner in place Do not over tension the belt 3 Reinstall the left side panel Press here to set belt deflection Exit roller drive belt tensioner NL 2 0388 29 Fig 4 2 Setting exit roller drive belt tension Diagnostics and Adjustments 4 141 Y axis belt tension adjustment Phaser 840 printer Perform this procedure after replacing loosening or removing the Y axis belt drive assembly Follow the complete tensioning procedure Pay special attention to the following m Never loosen or remove the screws holding the assembly together The assembly is put together in a precision fixture and loosening these screws affects the alignment of the assembly m Always use the Position for Belt Tightening diagnostic test to align the pulleys for
125. ccur the Phaser 860 does not support optional cards If this error occurs check the main board to power control board connector for damage Replace the main board and then the power control board 20 20 01 l O Left not detected Verify the IIC cable connetion Replace the Left 20 20 02 I O Left partially responding Verify the IIC cable connection Replace the I O Left 21 21 01 Printhead not responding Verify printhead cable is properly attaced Reseat main board then replace printhead 21 21 02 Printhead NVRAM is not responding Verify printhead cable is properly attached Reseat main board then replace printhead Soft Error 21 03 Printhead ink level sensed below range Ensure the ink level connector on the printhead is plugged in Reseat main board then replace the printhead Soft Error 21 04 One color is sensed out of range for the printhead ink level Ensure the ink level connector on the printhead is plugged in Reseat main board then replace the printhead 21 21 05 Printhead reservoir thermistor is above range Ensure the thermistor cable is plugged in Reseat main board then replace the printhead 2 42 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 3 POST Power On Self Test Error Messages cont d PS PEand Front Description FrontPanel Panel LEDs Error Code 21 21 06 Left printhead jetstack thermistor is out of range Replace the printhead 21 21 07 Right printhead jetsta
126. cedures Check the Non Xerox Tektronix Ink Box on Greentag Enclose all sample prints ink samples and this checklist with the printhead and return it to Wilsonville for evaluation Enclose a sample of waste ink with the printhead return if possible Inform the customer that although the Field NXTI Failure Test criteria were not satisfied engineering will further evaluate the printhead upon its return to Wilsonville It will be subjected to complete analysis at that time and if found to be NXTI damaged the customer will be billed Xerox Personnel please provide full documentation in TekLink Appendix 249 On site Electronics Troubleshooting Checklist Phaser 840 850 NAME OUT REQUEST ID DATE COMPANY if no OUT REQUEST ID PHONE Use the checklist below along with the provided electronics troubleshooting guide when repairing a Phaser 840 or 850 printer that has experienced a failure related to electronic circuit boards For each step fill in all blanks that apply and return the filled out checklist with any circuit board that is returned to the factory such as the main board or the power supply Before troubleshooting any printer hardware failure be sure to disconnect the printer from the network or host computer The hardware ports on the main board are very reliable and almost never fail If the printer works fine when completely isolated it is most likely a customer setup problem To obtain copies of th
127. ck thermistor is out of range Replace the printhead 21 21 08 Printhead reservoir thermistor is out of range Replace the printhead Soft Error 22 01 Maintenance Kit counter is not responding Check for bent pins on the counter Reseat then replace the maintenance kit Soft Error 22 02 Intermittent response from the maintenance kit counter Reseat the maintenance kit cycle power then replace the maintenance kit Error Codes and Messages 2 43 Fault Codes Error codes indicate the following The failing system XX yyy zz The failing subsystem xx YYY zz The type of problem xx yyy ZZ The print engine copy count xx yyy zz 123 when the error occurred Program faults indicated by a 6 in the tenths place of the fault code 62 Unfortunately there are too many program faults to enumerate them all and most program faults will not mean anything unless you are intimately familiar with the code base Some of the more common program faults are documented in this section In customer mode program faults cause the printer to automatically reboot and no message is displayed on the Front Panel The fault codes are saved into non volatile memory and can be retrieved from the fault history CPU exceptions are indicated by a 7 in the tenths place of the fault code xx yyy 7x The error code indicates both the PowerPC exception number and the region of firmware that was executing when the exception occurred Engine PostScri
128. cover jam access Phaser 850 200 4638 00 1 Front cover jam access Phaser 860 8200 3 214 4814 00 1 Hinge Front cover pivot 840 850 214 4982 00 1 Hinge Front cover pivot Phaser 860 8200 4 650 4028 00 1 Front cover control panel Phaser 840 650 4121 00 1 Front cover control panel 840GP Designer Edition 650 4143 00 1 Front cover control panel Phaser 850 650 4216 00 1 Front cover control panel Phaser 860 650 4253 00 1 Front cover control panel Phaser 8200 5 200 4365 00 1 Left cover 840 850 200 4589 00 1 Left cover 840GP Designer Edition 200 4634 00 1 Left cover Phaser 860 8200 6 200 4375 00 1 Exit cover Phaser 840 200 4599 00 1 Exit cover 840GP Designer Edition 200 4604 00 1 Exit cover Phaser 850 200 4642 00 1 Exit cover Phaser 860 8200 7 200 4367 01 1 Top cover with inkload door 840 850 200 4600 00 1 Top cover with inkload door 840GP Designer Edition 200 4635 00 1 Top cover with inkload door Phaser 860 200 4690 00 1 Top cover with inkload door Phaser 8200 8 200 4377 00 1 Rear cover 840 850 200 4592 00 1 Rear cover 840GP Designer Edition 200 4644 00 1 Rear cover Phaser 860 8200 9 650 4104 00 4 Printer feet FRU Parts List 8 209 Imaging FRU s Fig 8 2 Imaging FRUs Table 8 2 Imaging FRUs 0388 79 Parts Part number Serial number Qty Name and description Effective Discont d 1 650 4027 00 Y axis pulley assembly Phaser 840 650 4227 00 Y axis pulley assembly Phaser 850 860 8200 2
129. ctuates the vacuum solenoid repeatedly until a button is pressed Upper Aux Pick Motor Actuates the upper high capacity paper tray pick motor repeatedly until a button is pressed Upper Aux Feed Motor Actuates the upper high capacity paper tray feed motor repeatedly until a button is pressed Lower Aux Pick Motor Actuates the lower high capacity paper tray pick motor repeatedly until a button is pressed Lower Aux Feed Motor Actuates the lower high capacity paper tray feed motor repeatedly until a button is pressed Heaters Verifies heater operation all heaters are turned off when this test is entered All Heaters On Turns all heaters on to be regulated at normal printing set points All Heaters Off Turns all heaters off Toggle Cap printhead Heaters Turns on off cap wipe purge and printhead heaters Toggle Preheat Heater Turns on off preheat heater Toggle Drum Heater Turns on off drum heater Monitor Heaters Displays current heater state on off and of power being applied Monitor Temps Displays current heater temperature and the setpoint Temps Displays current heater temperature and the setpoint Cycle Menu Verifies standard cycle motion X Axis Moves the X axis through its full range of motion Transfix Axis Performs a transfix cycle DM Cam Axis Performs a drum maintenence cycle Check Menu Check Menu Items display numer
130. d Replacement Procedures 7 203 Cap wipe purge assembly Phaser 850 860 printer Warning Even when the printer is turned off AC line voltages may be present at the printer heaters while the printer is plugged into AC power Turn off the printer and remove the power cord Remove the right cover Remove the left cover Disconnect the head tilt spring Remove the top cover Remove the ink loader Remove the metal heat duct over the printhead Tilt back the printhead and center it Remove the maintenance drawer Remove the right maintenance drawer guide ODNDIRON Right maintenance s drawer guide 840 4 80 Fig 7 24 Removing the lower cap wipe purge retainer clip 10 Disconnect the wiring harness leading from the cap wipe purge assembly to the power supply wiring harness Clip the tie wraps securing the cap wipe purge wiring harness Disconnect the green ground wire from the printer frame 11 From within the maintenance drawer cavity remove the lower white retainer clip at the lower right end of the cap wipe purge assembly 7 204 Phaser 840 850 860 8200 Color Printer Service Manual 5 Plastic Cap wipe purge P M al i assembly EN 840 4 81 Fig 7 22 Removing the lower cap wipe purge retainer clip 12 Rotate the cap wipe drive gear to position the cap wipe purge assembly at the top of its travel 13 Place a few sheets of paper between the drum and the cap wipe purge assembly
131. d rather than soldered down Make sure it wasn t accidentally removed instead of the Printer ID chip Try reseating the main board and all it s components and remove any unnecessary components extra RAM Hard drive ROM upgrade Replace the main board if required 1 Rapid CPU Bridge and or PCI bus is not communicating reseat and then blinking replace the main board 2 Rapid ROM not responding Try reseating the main board and all of its blinking components replace the Code ROM if it is socketed and not soldered down and then replacing the main board 3 Rapid System hangs during code initialization Reseat the main board blinking of its components Replace the main board 2 40 Phaser 840 850 860 8200 Color Printer Service Manual POST Power On Self Test When these tests begin the front panel has been initialized In most cases if an error occurs a text message is displayed on the front panel along with an LED blink code flashing on all three LEDs front panel LED PS LED and PE LED The LED blink codes are setup similarily to the 840 and 850 Short Blink 1 Long Blink 5 Both rear panel LED s and the front panel LED all blink together for the 860 POST messages Table 2 3 POST Power On Self Test Error Messages PS PEand Front Description FrontPanel Panel LEDs Error Code Rear panel RAM Neither RAM socket has a supported RAM SODIMM installed LEDs cycl
132. dden Service Menu 4 121 Built in Diagnostics Phaser 860 Only sss 4 122 Check Menu Value Keys and Descriptions Phaser 860 only 4 126 Check Value Menu Parameters 4 135 4 136 Printing service test prints esee eere 4 136 Printing the Configuration Page sese 4 136 Selecting Duplex 2 sided Oil Chase essere 4 137 Selecting Envelope Oil Chase sess 4 137 Center Image sete 4 137 Locking the printhead 4 138 Process belt tension adjustment 4 139 Exit roller drive belt tension adjustment see 4 140 Y axis belt tension adjustment Phaser 840 4 142 Y axis belts tension adjustment Phaser 850 860 4 144 Printhead to drum spacing adjustment Phaser 840 Printer Only 4 146 X axis scale adjustment essere Cap wipe purge assembly belt adjustments Drum position encoder Transfix roller pressure spring adjustment sse Vacuum check Phaser 840 850 Only sss Resetting NVRAM Test Prints Oc But Weak missing jet Colo
133. drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance drawer to correct streaking Check the drum temperature sensor for debris build up on the sensor Check to see if the sensor is in improper contact with the drum Refer to the Reverse Text test print The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 5 164 NI TT TH VEELEEEEEEEEETELEETEEEEREETEEE E EET ET ERE T A A TEEPE TTT D TTT 9923 118 9923 119 Phaser 840 850 860 8200 Color Printer Service Manual 9 Drum Seal These five prints are used to treat a newly installed drum To seal a newly installed drum 1 Power up the printer in Bypass Mode to skip any pages at power up refer to Front Panel Shortcuts on page 4 119 2 Select the test print Manuf paper path to verify the paper path and that all ink jets operate 3 Printthe test print Drum Seal to seal the new drum 9923 154 10 Manuf paper path These two prints verify that the paper path works correctly by processing a blank sheet of paper through the
134. e ERROR Ensure that supported RAM is being used Reseat and then back and replace the RAM SODIMM forth 2 2 01 Failure to read the chip ID s Reseat and then replace the main board 2 2 02 Failure testing timer values Reseat and then replace the main board 4 4 01 Neither I O Right or the front panel are detected Verify the IIC cable connections then replace the I O Right NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR 5 5 01 The front panel is not detected Verify the IIC cable connections and the state of the front panel sensor Replace the front panel NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR 6 6 01 The duplex sensor is detected but the front panel is not responding Verify the IIC cable connections Replace the front panel NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR 7 7 01 Front panel is detected but the I O Right is not responding Replace I O Right 10 10 01 EEPROM read failure Reseat then replace the Printer ID chip 10 10 02 EEPROM write failure Reseat then replace the Printe ID chip 10 10 03 EEPROM re read failure Reseat then replace the Printer ID chip 10 10 04 EEPROM write read mismatch Reseat then replace the main board 11 11 01 Ethernet port chip failure Reseat then replace the main board 11 11 02 Ethernet port ID error Reseat then replace the main board 12 12 xx CPU Interrupt test failure or unexpected interrupt request Reseat then replace the main board 13 13 01 US
135. e completion 4 122 Phaser 840 850 860 8200 Color Printer Service Manual 0 Initializing 1 OK 2 Interupted by front panel button press 3 Abort encountered a status condition which prevented it from continuing 4 Failed test completed but did not produce the expected results 5 Fault the print engine declared a fault during the test 6 Pass PC xx The current page count R0 xx Rn xx These are the results from the test s If a test was unsuccessful the Rn infromtaion may be substituted for a Sn message string Mn a message ID number or an Fn a fault number Refer to infoSMART for additional information on these conditions Diagnostics for call center menu and diagnostics for service technicians Table 4 3 Diagnostic Menu Map Menu Item Description Menu Help Information on how to navigate the menu items Return to Customer Mode Returns to Customer Mode Field Service Menu The most common tests are grouped in this menu Chase Runs a chase sheet through the paper path Sensors Reports changes in sensor states interactively Activators Verifies activation of clutches and solenoids Exercise All Activators Energizes each device 4 times Pick Clutch Actuates the standard tray pick clutch repeatedly until a button is pressed Cap Clutch Actuates the cap wipe purge clutch repeatedly until a button is pressed DM Clutch Actuates the drum maintenance cl
136. e environments Phaser 840 850 860 8200 Color Printer Service Manual Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 522 04 Media not exiting completely 1 None a Media slipping on exit a Try different media clean rollers the exit rollers or replace the exit cover b Clean the exit rollers c Replace the exit cover 22 538 13 Time out on preheat exit sensor duplex with media in the front door area a Verify that the lower tray is properly loaded 1 Skew a Last sheet in tray a Refill tray s b First sheet in tray b Make sure tray s is c Failure of deskew system loaded properly and media is square in tray c Check deskew fingers If chronic check preheat entry assembly for deformation 2 More than one sheet in a Media was pulled from exit Empty exit tray duplex path into duplex while printing b Retry b Multiple pick 3 Media is from lower feeder Lower feeder bias problem b Make sure media is flush and has small left margin with the left side of the tray 4 Stiff media a Can tturn cornerform paper b Run lighter media tray to drum lt 32 22 541 05 Unexpected A A4 sensor event Same as 22 511 02 22 542 17 Time out on preheat exit sensor duplex Unexpected duplex sensor event Same as 22 512 14 22 548 03 Duplex long declaration determined from duplex sensor 1 More than one sheet i
137. e for the Phaser 860 only High Capacity Paper Tray Assembly Reliability improvements These improvements are also being made on the Phaser 840 and 850 Front Panel Display Improved design for ease of navigation Service diagnostics are accessible through the Front Panel for more information refer to Front Panel Shortcuts on page 4 119 Reduced ESD susceptibility 1 30 Phaser 840 850 860 8200 Color Printer Service Manual Specifications Table 1 8 Physical dimensions Dimensions Value Height 38 7 cm 15 25 ins 51 4 cm 20 25 ins with one High Capacity Paper Tray Assembly 64 1 cm 25 25 ins with two High Capacity Paper Tray Assemblies Width 40 cm 17 25 ins Depth 57 8 cm 22 75 ins Weight Approximately 36 kgs 79 Ibs Print engine weight only add 9 kgs 20 Ibs for each optional High Capacity Paper Tray Assembly Table 1 9 Printer installation clearances Clearances Value Top 45 7 cm 18 ins Left 10 2 cm 4 ins Right 10 2 cm 4 ins Front Unrestricted to replace trays and clear paper jams Rear 10 2 cm 4 ins Bottom No obstruction under printer that could block its cooling vents Mounting surface flatness Within 3 degrees of horizontal with all four feet in contact with the surface General Information 1 31 Table 1 10 Functional specifications Characteristic Specification Printing process Sol
138. e main board Optional Network cards are not supported for the Phaser 860 Ethernet TP lt eee gt RCV XMT Parallel 11 a P860 005 Fig 1 19 Phaser 860 printer rear panel General Information 1 27 Rear Panel Status LEDs Two LEDs on the rear panel indicate the status of the printer s CPU functions PostScript processing and print engine control or diagnostics PostScript health light LED normally blinks once per second Engine health light PE LED normally blinks twice every 2 5 seconds During the first minute of power up the LEDs are used to indicate diagnostic progress refer to System power up sequence on page 3 76 If the LEDs stop blinking for more than a minute refer to the topic Error Codes and Messages on page 2 37 If the LEDs are blinking in a repeating pattern other than normal operating health status as described refer to the topic Error Codes and Messages on page 2 37 DIP Switches Four DIP switches allow you to reset the printer or place the printer in different operating modes You must set the switches before power is turned on to enter the selected mode CN Table 1 6 Rear panel DIP switch settings Function Switch 1 Switch 2 Switch 3 Switch 4 Normal operating mode UP UP UP UP Service mode DOWN UP UP UP Reset printer UP UP UP DOWN then UP Manufacturing mode Bypass UP DOWN UP UP mode Development mode engineering DOWN DOWN
139. e power supply Process Motor Test ID 14 This test measures the ability to track the process motor Report Current Temps Test ID 16 This is n the current operation temperatures as values for results This test is intended primarily for monitoring the temperatures as they warm up rather than ch Test ID R amp Definition Results Interpretation Actions Encoder wheel gt 58 Process Motor duty cycle 242 IDs 14 Quadriture phase 73 Replace the Process Motor 4 angle 252 Transfix Load Test ID 15 This test measures the variation the transfix load Test ID R Definition Results Interpretation Actions Transfix load is too high Perform gt 99 transfix roller pressure spring Transfix Load 0 Peak PM following adjustment ID 15 error Transfix load is too low Perform lt 74 transfix roller pressure spring adjustment ot part of the Check Test suite but does report ecking the final temperature Test ID R Definition Results Interpretation Actions 0 Jetstack left 139 2 Ensure the printer was fully 1 Jetstack right 139 2 warmed up and the temperatures are stable before taking the measurement pud Current 2 Reservoir 131 5 4 3 emps This temperature is not directly IDE 3 Cap Wipe Purge 110 measured but estimated based on other temperatures Do not use for troubleshooting Ensure the printer was fully 4 Preheat 6042 wa
140. e printer power supply has auto ranged to the 220 VAC setting Remove the power cord wait 30 seconds then reinstall the power cord The printer should power up at its 110 VAC setting within two seconds refer to SF156 Phaser 840 only If the fans twitch and the LEDs flash There may be a short in the power supply system Refer to the later procedure Testing for shorted drivers on page 3 83 If the fans do not move and the LEDs do not flash There is either no AC power to the printer or the power supply has failed Check the AC voltage If replacing the power supply does not correct the problem refer to the later procedure Testing for shorted drivers on page 3 83 There are no lights and no sound upon power up Phaser 850 A manufacturing process error resulted in some power control board brackets getting bent The serial number range for this potential problem is M0A7600 to MOD3800 These bent brackets prevent the 40v loopback connector from fully seating and in some cases can result in it disconnecting due to shipping vibrations When the power switch is turned on with a disconnected 40v loopback connector the front and rear panel LED s will blink briefly and go out and the printer will appear to have no power See SF169 Main Board CPU operation The main board has sophisticated self test capabilities The main board is usually not the cause of the fault unless an error code specifically indicates a potential main
141. e sensor 3 Verify the drum temperature using diagnostics Ensure the drum temperature sensor is properly positioned 4 Ensure that the X axis drive system is correctly assembled and lubricated 5 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation 6 If the problem persists replace the printhead 3 96 Phaser 840 850 860 8200 Color Printer Service Manual Vertical line appear wavy Straight vertical lines appear to be wavy and ill formed ABCDEFGHI NOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 0388 50 Table 3 17 Vertical line appears wavy Step Question and Actions 1 Too much oil on the drum Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer 2 Are the drum maintenance cam roller and electric clutch operating correctly Test them using diagnostics 3 Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller Troubleshooting 3 99 Oil streaks on print Oil stains the edge of the print ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 51 Table 3 18 Oil streaks on print Step Question and Actions 1 Ar
142. e state of the printer The printer monitors the positions of some of the movable assemblies such as the drum as well as the temperature of many other assemblies such as the printhead paper preheater and the drum Note Unlike the Phaser 840 printer the Phaser 850 860 printer does not have a separate drum home position sensor Ink load Ink stick cover sensor out sensor Exit tray full Ink stick sensor low sensor Top cover switch Front cover SEN switch A4 size media sensor A size media sensor Cap wipe home sensor Preheater P d entry left 4 gage sensor C sg a2 H Maintenance 2 gt blade position EAS sensor Hand feed Paper empty sensor Paper pick Tray type sensor sensor sensors 0388 07 Fig 1 9 Sensors and switches on the right side of the print engine General Information 1 17 Transfix exit sensor Drum temperature sensor Duplex paper sensor ee e Drum home position sensor Phaser 840 onl y Et NN Drum encoder Preheater sensor NV exit sensor Process gear position sensor Transfix roller Preheater exit sensor located on inside Preheater wall of drum transfix frame me 0388 34 Fig 1 10 Switches and Sensors on the left side of the print engine 1 18 Phaser 840 850 860 8200 Color Printer Service Manual Caution The actual position of some printer assemblies such as the printhead or the cap wipe purge assembly cannot be asc
143. e the drum maintenance cam roller and electric clutch operating correctly Test them using diagnostics 2 Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer 3 Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller 4 Replace Maintenance Drawer 3 100 Phaser 840 850 860 8200 Color Printer Service Manual Inc omplete image transfer to paper All of the image does not transfer to the paper Part of the image remains on the drum to be picked up by a chase page or the next print usually caused by insufficient or non uniform drum oiling ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 72 Table 3 19 Incomplete image transfer to paper Step Question and Actions 1 Media that is not smooth or too light can cause this problem use higher quality or heavier media 2 Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer 3 Inspect the drum maintenance system Does the drum maintenance roller contain sufficient oil Replace the drum maintenance roller if necessary 4 Are the drum maintenance cam roller and electric clutch operating correctly Test them using diagnostics 5 Ensure the left and right drum maintenance actuators operate correctly wh
144. e the right cover Remove the left cover Remove the top cover Remove the ink loader Remove the main board Remove the power supply Remove the network card or its cover plate whichever is in place Remove the internal hard drive or cover plate which ever is in place Disconnect the wiring harnesses leading to the power control board 10 Remove the four screws securing the power control board cover plate Remove the plate 11 Remove the four screws securing the power control board in place Lift and remove the board 550v Power control board Fig 7 5 Removing the power control board 7 164 Phaser 840 850 860 8200 Color Printer Service Manual Upper feed roller assembly Remove the right cover Remove the left cover Disconnect the head tilt spring Left side Remove the upper feed roller electric clutch from the end of the upper feed roller shaft Remove the feed roller drive belt and compound gear from the left end of the upper feed roller Note the small slot in the compound gear to ease removal gt Disconnect head tilt spring UI Upper feed roller shaft Upper feed roller electric clutch 840 4 13 Fig 7 6 Remove the upper feed roller assembly left side 6 Front Open the front door and remove the drum maintenance drawer Also remove the bright metal duplex paper guide from the front of the printer It is held
145. e x axis scale adjustment 6 Select the menu item Print X axis calibration pattern to verify the adjustment Repeat the adjustment if necessary Diagnostics and Adjustments 4 149 Cap wipe purge assembly belt adjustments The tension of the cap wipe purge assembly belts is factory set Do not adjust the belts tension unless you remove or replace one or both belts The belts are Kevlar reinforced they will not stretch over their lifetime The belts are also factory adjusted for parallel tracking alignment As long as the belts cap wipe purge assembly motor or the belt clips which hold the cap wipe purge assembly are not disturbed no adjustment is needed However if you replace one or both of the belts or the cap wipe purge drive motor you must ensure that the belts are in alignment timing with each other this ensures that the cap wipe purge assembly is perfectly aligned to the faceplate of the printhead If the belts are not aligned the printhead purging is ineffective due to poor sealing between the printhead faceplate and the cap wipe purge assembly Ensure that the cap wipe purge assembly is properly installed Tilt the printhead back to its locked position Rotate the large drive gear to pull the cap wipe purge assembly to about the middle of its travel in the chassis frame slot Ensure each timing belt lock is tightened to its fourth tooth as illustrated and that the belts are installed completely all the way
146. ead Installed The printhead installed on the printer is not the correct type the software was compiled for 22 024 01 The indicates that the printhead was not parked when powered off In the 840 850 this error code may be reported in conjuction with other faults that cause the printer to reset This code is not related to media jams 2 58 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 5 22 LSS TC Error Codes Media Jams 22 LSS TC Media jams L indicates the location of SS indicates sensor location the jam 00 Usually because of an opened door 1 Bottom Hi capacity 01 Bottom High Capacity tray sensors Paper Feeder 02 Bottom High Capacity pick sensors 2 Middle Hi capacity Middle High Capacity tray sensors Paper Feeder 04 Middle High Capacity pick sensors 3 Top standard tray 05 Standard tray sensors E Erit 06 Standard tray pick sensors 6 Top cover 07 Handfeed sensors 7 Y axis jams 08 Preheat entry sensor see following error codes p PUR not activated 8 Door opened jams wi following iror codes 11 A and A4 width sensor 12 Preheat exit sensor 18 Stripper exit sensor 14 Duplex entry sensor 15 Media Exit Sensor 16 VE DM CYCLE DONE out of order 17 VE TF ROLLER LIFTED out of order 18 Duplex length measured to be too long 19 Timing delay affected transfix staging 20 Media not visible in top cover not used 21 High Capacity media length too long not used 22 Unkn
147. ead thermostat open check for open from common leads to all other heater leads YES NO No go to 3c Phaser 340 350 360 Phaser 840 850 QOC QQQ V V 3c If one of the specified error codes below is present follow the steps indicated otherwisxe replace the prinhead and perform the C W P Checklist with the new printhead If error 13 004 43 or 13 020 41 readjust HTD left and right applies only to 340 350 360 380 840 If the error reoccurs replace printhead Perform C W P Checklist with new printhead If error 13 001 40 13 002 41 13017 47 or 13018 48 reseat or replace printhead ribbon cable before replacing the printhead Perform C W P Checklist with new printhead If error 4002 41 or 4 006 45 check printhead ribbon cable before replacing the power control board If the problem persists replace the printhead Perform C W P Checklist with new printhead 4 Print Service Test 2 Weak and Missing Jets Are there weak or missing jets YES NO If YES do the following No go to C W P Checklist m Clean the maintenance drawer wiper blade to prevent contamination of the printhead m Check the exit area of the paper path for debris that could be scraping ink off the durm and may mimic a weak or missing jet m Select Clean Eliminate Light Stripes from the pri
148. ect all components of the y axis for damage or binding Y axis Belt Slip Test ID 12 This test prints a special banded image and measures the effect on y axis motion as the print is transfixed Test ID R Definition Results Interpretation Actions Ensure that the media is not gt 4 0 heavier than 24 Ib Retension y axis belt then replace y axis pulley assembly Media may be too light 16 Ib or 0 Slip index 1 8 the test image may not be a good Y Axis Belt Slip solid fill The front to back ID 12 alignment of the test image may also be off Re run the test 1 Peak Y axis gt 72 following error 40 Re run the test Verify that 2 Average Y axis gt D5 Pda weight media is being following error 17 Diagnostics and Adjustments 4 133 Table 4 4 Check Menu Value Key Voltages Test ID 13 This test mesures key power supply voltages Test ID R Definition Results Interpretation Actions 0 AC volts Varies Local line voltage 40 volt ADC gt 30739 1 reading lt 27039 voltage gt 32235 Verify adequate line voltage then Voltages 2 reading 30662 replace power supply els 3 3 volt ADC gt 33838 reading lt 30615 May be caused by a bad 4 Ground sense gt 405 connection between the main ADC reading 201 board and the power control B board Reseat the main board Verify adequate line voltage then replace th
149. ectric clutch upper feed roller exit roller Phaser 840 401 0855 00 Electric clutch upper feed roller exit roller Phaser 850 860 8200 2 401 0808 02 Electric clutch pick roller Phaser 840 850 401 0855 00 Electric clutch pick roller Phaser 860 8200 3 401 0807 02 Electric clutch drum maintenance Phaser 840 401 0871 00 Electric clutch drum maintenance Phaser 850 860 8200 4 401 0792 00 Electric clutch cap wipe purge drive Phaser 840 401 0855 00 Electric clutch cap wipe purge drive Phaser 850 860 8200 5 148 0301 01 Solenoid transfix assembly 105 1057 00 Transfix solenoid latch cam refer to SB 541 FRU Parts List 219 Gear and Belt FRUs Fig 8 7 Gear and belt FRUs 8 220 Phaser 840 850 860 8200 Color Printer Service Manual The Phaser 840 850 860 printer gears and belts are all part of kits When referencing a specific part its associated kit will be listed in the Kit column with a description of the particular part listed in the Name and description column The kits are as follows W Phaser 840 850 Gear Kit Part 650 3619 00 W Phaser 860 8200 Gear Kit Part 650 4221 00 W Phaser 840 850 860 8200 Belt Kit Part 650 3615 00 Table 8 7 Gear and belt FRUs Parts Part number Serial number Qty Name and description Effective Discont d 1 Gear Kit 5 Pulley lower paper transport 2 Belt Kit 2 Paper feed roller drive belt 3 Belt Kit 5 Tens
150. electronics troubleshooting guide Failures Occurring During Power On Sequence Record the following Step 1 Il Clue 1 2 Root Cause A B Action a b __4C Refer to the following section in the electronics troubleshooting guide Failures Occurring After Power On Sequence Is Complete Record the following Step I Il Clue 1 2 Root Cause A B Action a b Go to Action 5 Appendix 251 ACTION LOOK FOR WHAT NEXT Record Reason for Check the one that applies to Action 6 Returning This board has failed and p eae cause o i ilure the factory you This board has failed but are returning check the was damaged by another box that applies in the failing part next column __ Printer had an intermittent failure and this board was identified as the most probable cause __ Board is an FRU part and being returned because __Never installed in printer return to inventory __Used for troubleshooting definitely not damaged should be okay eUsed for troubleshooting could be damaged questionable if okay __Used for troubleshooting damaged by other failed part not okay Record Other Parts 4 Other parts replaced on Record any additional com Replaced this job ments in the space pro vided below 6 List all other parts that were replaced on this job in addition to this board in the next column
151. emble the printer and make a test print a A N 4 152 Phaser 840 850 860 8200 Color Printer Service Manual Gap tool Groove Phaser 840 Retaining spring Phaser 840 c 5 SN A 0388 33 Fig 4 10 Setting the drum position encoder gap S Diagnostics and Adjustments 4 153 Transfix roller pressure spring adjustment 1 Print the service test print YMCKRGB in duplex mode Duplex mode can be set using the front panel menu Printer Default Settings If any of the prints are wrinkled on both the left and right sides of the print the drum transfix assembly must be replaced No adjustment will solve the problem If wrinkling is only present on the left or right side of any print note which side Remove the front cover to access the drum transfix assembly Draw a reference mark on the both the left and right spring set screws On the side of the printer corresponding to the wrinkling tighten the set screw clockwise 1 8 of a revolution using a 4 mm hex driver On the side that does not wrinkle loosen its set screw 1 8 of a revolution occ N Note Whatever adjustment is added to one side must be taken away from the other side to maintain roller balance 7 Reassemble the printer and again print the service test print YMCKRGB in duplex mode 8 If wrinkling still occurs on the same side repeat Steps 6 and 7 Do not adjust the set screws more than 3 8 of
152. emove media inspect folded corner guide on the front left side and reload of the lower tray b Folded in tray 3 Media jammed on stripper a Damaged or deformed a Replace media fingers or rapid release guide media bad media 4 Media jammed on stripper a Excess plastic on end of a Replace stripper fingers fingers or rapid release guide stripper fingers part defect or rapid release guide margin good stripper down on b Deformed stripper fingers b Replace stripper fingers eccentric cam location good c Damaged from jam earlier or rapid release guide c Replace stripper fingers or rapid release guide 5 Media jammed on stripper a Transfix eccentric shaft a Replace drum transfix fingers or rapid release guide key way problem assembly margin good stripper down on eccentric cam location repeatedly fails 6 Media jammed on stripper a Process motor problem a Replace process motor fingers or rapid release guide margin good stripper down on eccentric cam location Error Codes and Messages 2 69 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 7 Stripper fingers or rapid release guide do not move freely a Bushing out of place b E ring missing c Parts bound up a Reassemble stripper fingers or rapid release guide b Reassemble stripper fingers or rapid release guide c Reassemble stripper fingers or release guide 8 Media jammed on or co
153. en lifted by the cams of the drum maintenance cam roller 6 The drum may be too warm verify the drum temperature using diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 7 Verify the paper preheater temperature using diagnostics 8 If the problem persists replace the printhead Troubleshooting 3 101 Ink smears on first side of duplex print Preheater temperature is too high See SB439 ABCDEFGHIJKLMNOPQRSTUV abcdefghijklinnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklinnopqrstuvwxyzab 0388 73 Table 3 20 Ink smears on first side of duplex printt Step Question and Actions 1 Verify the paper preheater temperature using diagnostics 2 Replace the paper preheater if necessary 3 102 Phaser 840 850 860 8200 Color Printer Service Manual Repeating print defects on print The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 54 Table 3 21 Repeating print defects on the print Step Question and Actions 1 Repeating defect 13 6 cm 5 34 in are caused by the transfix roller Clean the transfix roller 2 If the problem persists replace the transfix assembly 3 A single repeating defect on the page is probably due to a defect
154. er over time and under certain extreme operating conditions oil and grease may dry out causing squeaks and rumbling noises in the printer Look for fine metal particles a clear sign of an old or worn bearing Replace the bearing or the assembly it is a part of A drop of grease on a noisy bushing will quiet a noisy printer Too much lubrication can get into the paper path and attract dust so apply lubrication sparingly Lubricate the following only when needed Bushings Apply a drop of light oil to a bushing if it is noisy or running dry Plastic gear train This gear train from the process motor to the paper feed module requires only a small amount of white grease for noise reduction purposes Apply grease sparingly so that it does not fling off of the gears when they turn You need only to apply a dab of grease to a single gear and the grease will migrate throughout the entire gear train Do not apply oil to gears only use approved grease Caution Do not apply lubricant to the head tilt gear or the head tilt gear guide or any gear where grease could migrate to these parts X axis drive Apply a small amount of grease on the tip of the nose cone Apply a small amount 3 dabs on the threads of the X axis shaft White nylon plastic bearings No lubrication required Transfix cam If lubrication is needed apply a very small dab of grease to the two contact points between the cam and the latch and the cam and the cam advanced spri
155. er up the firmware reports a fault Sending a file to the printer or pressing one of the front panel buttons will wake the printer up normally There is no sevice action to correct this programming bug Cycle the power to restart the printer 6 033 66 PROGFAULT X6 XA Unexpected Message The XA task received an unexpected ITC message while in the idle state 7 000 PROCESS MOTOR TASK PROGRAM FAULT CODES 07 001 43 There is a problem with the lower tray assembly or it s installation INSURE THE INK HAS SOLIDIFIED PRIOR TO THE REMOVAL OF THE PRINTER FROM THE LTA Remove the printer and inspect the LTA connection If there is any damage to the connector replace the lower tray assembly or connector If there is not any damage remove and inspect the connnection to the printer This connection is on the left side of the printer next to the left rear foot it is mounted with two e rings and plugs into the power control board 07 001 65 There have been instances where a bad I O Right circuit board can cause this fault code 07 002 44 PM FAULT PROCESS MOTOR STALL Verify process motor operation with the Process Motor diagnostic test Also exercise processes run with the process motor transfix drum maintenance and head tilt This can be caused by the power control board The process motor may have more than one task initiated Reset all solenoids and the pressure roller prior to cycling power 07 003 45
156. ers connected to that fuse If the fuse in the new power supply also opens the problem is likely a shorted heater Appendix 267 NORMAL OPERATION CHECKLIST 1 Does the printer intermittently stop responding or hang YES NO Go to Nla Does the front panel respond opening a cover or pressing the 1 button but the printer appears to be stuck in the current operation warming up canceling etc YES NO Go to YES some operations such as changing thermal states can take several minutes For example it can take up to 20 minutes for the printer to cool down enough to print a duplex image after initial warm up or an interrupted Clean for Ink Smears cycle Canceling a print job may also take longer than expected if the job is still being sent to the printer by the network or host computer N1b Does the problem occur when a file is sent or while the printer is in Standby mode overnight YES NO Go to NIc YES disconnect the printer from the network or host computer Use the front panel Shutdown menu to verify that the printer can enter and exit Standby mode without crashing This type of failure is usually caused by corrupt data from the network or host computer causing the printer to crash rear panel LEDs stop blinking Refer to the Communications Checklist to verify printer port hardware Nic Does the problem occur even when the printer is disconnected from the network or host computer YES YES reseat the
157. ertained at all times The printer records in NVRAM where it last positioned such assemblies each time it moves them 1 after power down or a power interruption the assemblies are manually repositioned the printer erroneously assumes that the assemblies are in the position it last left them This assumption can result in damage to the printer when it tries to position the assemblies For example the printhead could be tilted forward and crash into the raised cap wipe purge assembly Before turning on the printer ensure the printhead is tilted forward centered in front of the drum and the cap wipe purge assembly is in the retracted home position The tilt cam gear should be disengaged from the gear drive train Electric clutches and solenoids are used by the printer to engage rollers as needed to move paper through the printer as well as start some print processes Drum maintenance Cap wipe purge cam clutch clutch Upper feed roller clutch 2 K Air valve solenoid Pick clutch Transfix solenoid 0388 08 Fig 1 11 Solenoids and clutches on the print engine General Information 1 19 Combination sensors and their meanings Combinations of sensors are used by the printer to determine the type of standard or upper media tray installed in the printer Media tray type sensing The combinations ofthe three tray sensors inform the print engine what type of media tray is installed The print engine does not detect
158. es yes Collation requires no yes yes hard drive Job accounting 50 records 500 records 5000 5000 records with records with optional hard drive included hard drive Frame buffer lower print resolutions can provide additional frame buffer space 1 Letter size image 1 Letter size image 2 Letter size images 1 6 Phaser 840 850 860 8200 Color Printer Service Manual Print the Configuration Page and check the item Installed RAM to see what type of RAM is installed For example Installed RAM 64 Mbytes Mem slot 1 SDRAM parity 64 MB KMM3668823BTL GO Mem slot 2 Empty This is a list of SDRAM DIMMs that are branded for use by Xerox in this printer at the time this guide was published Table 1 2 Acceptible SDRAM DIMMs Size Maker Part Number Printer 32 Mbytes Samsung KMM366S403CTL GO 840 850 32 Mbytes Micron MT16LSDT464AG 662XX 840 850 64 Mbytes Samsung KMM366S823BTL GO 840 850 64 Mbytes Micron Crucial CT8M64S4D10 MBTBGLP 840 850 32 Mbyte Samsung KMM366S424DTS GL 850 see note 64 Mbyte Samsung KMM366S823DTS GL 850 64 Mbyte Samsung KMM366S924BTS GL 850 128 Mbytes Samsung KMM36681623DT GL 850 128 Mbytes Samsung KMM366S1724BT GL 850 32 Mbytes Micron MT4LSDT464AG 662xx 850 see note 32 Mbytes Micron MT4LSDT464AG 10Exx 850 see note 64 Mbytes Micron MT8LSDT864AG 662xx 850 64 Mbytes Micron MT8LSDT864AG 10Exx 850 64 Mbytes Micron MT4LSDT864AG
159. ets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly Test Prints 5 167 15 Green Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 16 Blue Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of t
160. ettes French 063 2627 20 Phaser 840 Drivers and Utilities Diskettes Italian 8 230 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 063 2627 30 Phaser 840 Drivers and Utilities Diskettes German 063 2627 40 Phaser 840 Drivers and Utilities Diskettes Spanish 063 2627 70 Phaser 840 Drivers and Utilities Diskettes Simplified Chinese 063 2627 80 Phaser 840 Drivers and Utilities Diskettes Traditional Chinese 063 2627 90 Phaser 840 Drivers and Utilities Diskettes Korean 063 2627 05 Phaser 840 Drivers and Utilities Diskettes Russian 061 4208 00 Phaser 850 Manual pack English 061 4208 10 Phaser 850 Manual pack French 061 4208 15 Phaser 850 Manual pack Pacific MNL C K 061 4208 20 Phaser 850 Manual pack Italian 061 4208 30 Phaser 850 Manual pack German 061 4208 40 Phaser 850 Manual pack Spanish 061 4208 60 Phaser 850 Manual pack Brazilian Portuguese 061 4208 70 Phaser 850 Manual pack Simplified Chines 061 4208 80 Phaser 850 Manual pack Traditional chinese 061 4208 90 Phaser 850 Manual pack Korean 063 3322 00 Phaser 850 Drivers and Utilities CD ROM English 063 3322 10 Phaser 850 Drivers and Utilities CD ROM French Italian German Spanish 063 3322 35 Phaser 850 Drivers and Utilities CD ROM Jap
161. f the windings are opened shorted or far out of tolerance replace the motor If the motor s winding resistances are within specification inspect the wiring harness for nicks crimps opens or other problems If the harness is functional then replace the power control board Inspect the gear train on the left side of the printer frame look for stripped gears loose or damaged belts unseated bushings or broken teeth Be sure to inspect the inner teeth on the process motor gear 3 86 Phaser 840 850 860 8200 Color Printer Service Manual Media skews passing through the paper path 1 Check to see if the media is excessively curled Curled media can get mistracked in the paper path 2 Examine the paper path ensure it is clear of obstructions 3 Ensure that the pick roller is not visibly dirty so that it picks up a sheet of media smoothly and evenly Check the upper and lower feed rollers Also make sure that the front door is properly closed Check the flexible white paper deskew springs on the inside of the front cover Ensure that none are bent damaged or missing The printer should be installed on a flat level surface Ensure the pick guide assembly is properly snapped into the front of the printer frame Troubleshooting 3 87 Print Image Quality Problems Not printing The printer processes a sheet of paper but no image is printed on it Table 3 6 Not Printing Ste
162. flag a Remove and replace top exit trapped cover without capturing b Exit flag bound up exit flag b Replace exit cover 3 Media 1 inch out of exit flat Exit flag warped and not a Exit flag warped and not and undamaged functioning functioning b Bad paper exit sensor b Bad paper exit sensor 4 Media not able to exit a Problem with idler rollers Ensure all idler roller cleanly exit cover springs are present and b Top cover installed too high not damaged c Problem with exit roller b Reassemble top cover c Ensure that all bushings and e clips are properly installed 5 Printing transparencies a Printer running at fast color a Reboot printer and rerun speed prints 22 706 08 Y axis declared page short Uses the A4 sensor or preheat exit sensor for smaller size media 1 Skew a Last sheet in tray a Refill tray s b First sheet in tray b Make sure tray s is c Media was hand fed and loaded properly and was loaded skewed media is square in tray d Failure of deskew system c Reload media more carefully d Check deskew fingers on inside of front door If chronic check preheat entry assembly for deformation 2 Media deformed or a Right trailing edge bent a Remove media inspect damaged in media tray b Hole or tear in media and reload b Remove media inspect and reload 3 Media perfectly straight a Unknown static a Try again 2 68 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 6
163. front panel Other Pattern Note the LED Pattern Refer to the Service Quick Reference Guide for other LED patterns P3 Is the display blank with the rear panel LEDs on solid YES NO Go to P4 YES ensure that all DIP switches are up and then reseat the main board and the Printer ID Chip In early main boards the MIG chip is socketed and not soldered down this chip looks very similar to the Printer ID Chip Ensure that these chips did not get swapped If the problem continues replace the main board P4 Does the electronics fan twitch and or the rear LEDs blink before the printer goes silent YES NO Go to P5 YES check for shorted motor drivers Removing the 40V jumper from the power control board will disconnect all motor drivers When turned on without the 40V jumper the printer will get through POST testing and crash with the Xerox logo on the display If the printer still does not respond with the 40V jumper removed go to P5 To isolate a shorted driver reconnect the 40V jumper and systematically try disconnecting each cable from the power control board If this does not isolate the problem replace the power control board P5 Is there no response to turning on the power switch YES NO YES verify that the power source is good Then check for open fuses measure from fuse to line If open replace the power supply Also note which fuse was open and refer to the Service Quick Reference Guide to identify any heat
164. g 7 13 Marking the shaft for drum home alignment 6 Rotate the tilt gear to orient the gear s missing teeth to the drum position sensor assembly s rear mounting screw 7 194 Phaser 840 850 860 8200 Color Printer Service Manual 7 Remove the three screws securing the drum position sensor assembly housing to the print engine Insert the gap tool to hold the encoder wheel in position Slide the assembly offthe drum shaft If necessary use the small flat blade screwdriver to push the encoder disk hub along the shaft as you remove the assembly z Drum position sensor assembly Y Screws 840 4 78 Fig 7 14 Removing the drum position sensor assembly Phaser 850 printer Reverse these steps to reinstall the drum position sensor assembly Use the encoder wheel gap tool to space the encoder wheel to the drum position sensor Removal and Replacement Procedures 7 195 Printhead Warning Even when the printer is turned off AC line voltages may be present at the printer heaters while the printer is plugged into AC power Warning 77e printhead is hot Turn off the printer and remove the power cord Remove the right cover and the left cover Disconnect the head tilt spring Remove the top cover Remove the ink loader Remove the metal heat duct from over the printhead Disconnect the power wiring and data harnesses leading from the printhead to the power control board Also disconnect the two ground
165. gnostic tests Refer to the Diagnostic Menu Map items with an are not available in this mode but must be accessed through the hidden service diagnostic mode detailed below Service Diagnostics Mode This mode can be entered from either the hidden service menu or by powering up the printer with DIP switch 1 in the down position AII diagnostics are available in this mode Diagnostic tests will not run in normal printing mode it is necessary to reboot the printer after entering or exiting all diagnostic modes The printer will keep the printer thermals hot during diagnostics to avoid unnecessary cleaning cycles If a diagnostic test runs into a problem while initializing the heaters a message will display Test Fault can t warm up press any key you can still continue to run diagnostics under this condition Diagnostic Results Results from diagnostic tests are displayed on screen Results from the last six Check Menu diagnostics can be viewed in the Diagnostic History available from the front panel or from lines 401 406 using the CentreWare IS interface The results will be displayed in the follwing format ID xx TS x PC xx Date of Test Time of Test RO xx R1 xx R2 xx Rn xx ID xx The ID number from the test refer to the Check Menu test results for the ID s associated with the tests TS x The Termination Satus the status the test was in when it ended in case the test failed or was interupted befor
166. guration Page Phaser 840 850 Turn on the printer Allow the printer to complete its power up self tests The front panel displays Ready to Print Scroll to the Menu and press the Select button Scroll to the menu item Printer Configuration and press the Select button Scroll to the menu item Print Configuration Page and press the Select button N Phaser 860 1 Turn on the printer 2 When the display reads Ready to Print Scroll to Menu and press OK 3 Scroll to Printer Setup Menu press OK 4 Scroll to Print Configuration Pages and press OK 4 136 Phaser 840 850 860 8200 Color Printer Service Manual Selecting Duplex 2 sided Oil Chase This item is turned on to correct a print artifact called blistering Blistering when it occurs affects the duplexed side of a solid fill and appears similar to the texture of an orange peel For blistering to occur it appears on the second side of the second of two or more solid fill duplex prints Before enabling Duplex Oil Chase try different heavier paper With Duplex Oil Chase enabled a blank page will print on simplex to duplex printing transitions and after every 50 duplex prints 1 Access the Hidden Service Menu 2 Scroll to the menu item Phaser 840 Duplex Oil Chase Phaser 850 860 2 sided Printing Oil Chase 3 Press Select Phaser 840 850 or OK Phaser 860 to turn the menu item on 4 Exit the Hidden Service Menu Selecting Envelope
167. h memory DIMM C NVRAM corrupt D Code DIMM corrupt or connection problem E Boot ROM corrupt or connection problem 1A Confirm good power is supplied to printer and not plugged into power strip 2B Reseat memory DIMM 2C Reset NVRAM Replace NVRAM 840 only 2D Reseat or replace code ROM DIMM 2E Reseat or replace Boot ROM Appendix 257 Failures occurring after power on sequence is complete VII Front Panel is Frozen ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order A Front panel needs reset likely due to static B Connection problem with code DIMM C Connection problem with memory DIMM B Connection problem with main board 1A Open and close printer s front Cover 1B Reseat the code ROM DIMM 1C Reseat the memory DIMM 1D Reseat the main board Vill Fault Info Hang Device Fault any Most device faults are mechanically related to the printer engine not its electronics XX XXX 4x Refer to service manual for error code descriptions and recommended actions ADDITIONAL CLUES PROBABLE ROOT CAUSEACTIONS follow in order 1 5 001 41 A Mechanical failure or 1A See the Service Quick failed power control Reference Guide for mechanical board recommendations first Replace the power control board 2 7 002 44 A Mechanical failure or 2A See the Service Quick failed power control Reference Guide for mechanical board recommendations first
168. he paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 5 168 Phaser 840 850 860 8200 Color Printer Service Manual 17 Cyan Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance tray to correct streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 4 154 As a last resort replace the drum transfix assembly 18 Magenta Solid Fill This prints shows uniformity of fill Look for
169. he version of your LaserWriter driver to ensure that it is version 8 0 x or higher Earlier versions of the driver do not support color PostScript The application may require special instructions to print such as those contained in a PPD file check in the Phaser 840 Printer CD ROM or Phaser 850 Printer CD ROM Troubleshooting 3 115 Printer isn t in the Chooser 1 Ensure that the printer is turned on and the rear panel health light is flashing at a regular rate Check the Network or AppleTalk control panel to ensure the proper network or zone Is selected Power cycle the printer 4 Check to see if the printer has not been renamed or placed in another zone You can print a Configuration Page which lists this EtherTalk information as well as other information about the printer Verify the EtherTalk settings on the printer s Configuration Page 6 Verify that the printer is correctly cabled to the network and that the Ethernet cable 8 9 functions properly Locate and remove and Windows NT shared printers that have captured the AppleTalk queue for the printer Verify the driver version for the built in Ethernet port on a Macintosh G3 Reset the printer s NVRAM settings 10 Disable QuickDraw GX 32 116 Phaser 840 850 860 8200 Color Printer Service Manual Windows printing problems Image never prints The printer s front panel Receiving data message is displayed as if receiving data but
170. head tilt mechanism but the motor stalled The X axis was then displaced to the right 3 8 mm 0 15 in and the disengage was repeated but the motor stalled again This fault is then declared 4 013 43 Printhead unable to tilt Tilt Visually inspect the arm motion process motor drive obstructed train left side of printer Remove obstruction printhead heater cable C W P assembly poorly installed ink loader Ti arm parked on its locking pin Replace damaged gears or reset belt tension Measure the resistance of the x axis motor Resistance approximately 12 5 Ohms Replace the x axis motor Replace the power control board 0388 82 2 46 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 4 014 44 PC DEV FAULT 6x6DPI CAL Calibration Failure Defined but not used 4 015 45 PC DEV FAULT HEAD A DJUST TIMEOUT The engine spent over 20 minutes in the printhead adjust state The engine declares a device fault and shuts down rather than leave a hot heater against a cold drum for an indefinite period Remove the adjustment tools and cycle power 4 016 46 PC DEV FAULT HEAD NV FORMAT The printhead format number stored in printhead NVRAM is not understood by this version of engine firmware Verify the correct
171. hind the vacuum pump module Vacuum pump Paper path motor X axis motor Drum fan Right board Wire dressing above the x axis drive Wiring Fold 9 237 Tie wraps on the vacuum hose should be trimmed closely and each tie wrap s knot should be oriented inward so that it does not rub against the printer cabinet panel Do not pinch shut the vacuum hose Tie wrap cap wipe purge wiring harness to Orient knots in ties inward both ends of metal vacuum hose bois cap wipe purge wiring with hose Vacuum hose dressing 9 238 Phaser 840 850 860 8200 Color Printer Service Manual Tie wrap to frame Main fan Process motor encoder Tie wrap to Process bracket motor Y axis motor High capacity paper tray Left board Wrap drum position sensor wiring harness around drum temperature sensor wiring harness Routing wiring on the left side of the printer Wiring Fold 9 239 Wire dressing behind the printhead 9 240 Phaser 840 850 860 8200 Color Printer Service Manual Printhead ground lugs built into frame Maintenance tray counter sensor wiring harness restraint Phaser 8200 Color Printer Addendum The Phaser 8200 Color Printer is the latest generation of solid ink printing technology This section provides the differences between the Phaser 860 model and the new Phaser 8200 model as outlined below Note Unless otherwise specified al
172. his print consists of sequential bands of primary and secondary colors followed by a blue tint This print is used for manufacturing and engineering evaluation of printhead performance 0388 37 5 170 Phaser 840 850 860 8200 Color Printer Service Manual 21 Primary Solid Fills 10x Phaser 850 860 printer only This item prints 10 cyan solid fill prints then 10 magenta solid fill prints then 10 yellow solid fill prints and then 10 black solid fill prints 22 Manuf Skew Margins Phaser 850 860 printer only This print consists of an image used by manufacturing to gauge skew on 2 sided prints 23 Manuf Banding Phaser 850 860 printer only This print consists of an imaged used by manufacturing to gauge banding Test Prints 5 171 Cleaning and Maintenance The printer requires periodic cleaning to keep it in peak operating condition Some cleaning procedures such as purging the ink jets are done automatically when necessary Other procedures such as scrubbing the paper feed rollers with an alcohol soaked cloth must be done by customers but only if the rollers are visibly dirty The printer should be cleaned when any of the following symptoms occur Light stripes or missing colors appear in prints Ink smears or random streaks appear on the front or back of prints Oily spots appear along the tops of prints Mispicks or multiple picks occur at the media tray Persistent paper jams ins
173. his printer at the time this guide was published Table 1 3 Acceptible SODIMMs Size Maker Part Number 64 Mbytes Samsung 156 4831 00 64 Mbytes Micron MT8LSDT864HG 10E 128 Mbytes Samsung 156 4832 00 128 Mbytes Micron MT8LSDT1664HG 10E 1 10 Phaser 840 850 860 8200 Color Printer Service Manual Memory Considerations Phaser 860 With more memory the printer dual frame buffers for printing one image while processing a second image which gives greater printing throughput The printer s capabilities can be increase as detailed in the following table For the Phaser 860 printer installing the DP Option code ROM module and adding RAM enables these features Table 1 4 Installed RAM and printer capabilities Feature 64 Mbytes 128 Mbytes 860B 860DP 860N 860DPF 860DX Fast Color draft yes yes printing Standard Printing yes yes Enhanced Printing yes yes High Resolution no yes Photo Printing 2 sided printing no yes The printer supports 2 sided high resolution 1200 x 600 dpi print Color PCL 5c yes yes Pipelining no yes Collation requires hard yes drive Job accounting 500 records 500 records 5000 records with included hard drive Frame buffer lower print resolutions can provide additional frame buffer space 1 Letter size image 2 Letter size images Proof Print Secure Print Saved Print Requires Hard Drive no yes General
174. iant Power control board Improved fusing Resettable fuses by disconnecting AC power on 5v and 40v High Capacity Paper Tray leads No x axis fuse 40V service load connector no longer needed Printhead The Phaser 850 printhead mount has been factory calibrated so no head to drum adjustment is required when installing the printhead as long as the printhead s four mounting screws have not been loosened nor the printhead tilt setting altered on the left side of the frame Internal changes to support new ColorStix II ink Y axis pulley assembly The Y axis pulley assembly now features a built in spring tension A Y axis belt tension tool is not required New Y Axis pulley assembly made of aluminum to imporve print quality and reduce noise Cap wipe purge assembly This is a new assembly It also uses a new mounting system that does not require the disassembling of the timing belts in order to remove the cap wipe purge assembly Preheater entry flags New sensor flags less prone to snagging paper when jammed paper is pulled from the printer are mounted on the upper feed roller assembly General Information 1 29 Table 1 7 Summary of differences between Phaser 840 850 860 Phaser 840 Part 840 to 850 Difference Description 850 to 860 Difference Left I O board A new left I O board Right I O board New board to support the new front panel Y axis drum A new
175. ic values Refer to the Check Menu Value Key Table on page 4 126 Items in this group test the indicated system and report the data collected Check All Runs all check tests in sequence to verify all applicable subsystems Paper Path Status Reports the status of all paper path sensors Paper Path Timing Runs a sheet through the paper path and reports timing between sensors Paper Path Drive Measures the minimum drive current needed to move paper through the path DM Axis Performance Measures the motion of the drum maintenance system Cap Vacuum Measures the vacuum generated by the printhead maintenance system Cap Axis Geometry Mesures the alignment of the cap wipe purge assembly 4 124 Phaser 840 850 860 8200 Color Printer Service Manual Table 4 3 Diagnostic Menu Map Cap Axis Drive Measures the minimum drive current needed for cap wipe purge motion Y Axis Encoder Measures the fastest rate at which the encoder home pulse can be detected Y Axis Geometry Measures the frequency and magnitude of Y axis velocity variations Y Axis Belt Slip Measures the amount of belt slip during transfix Voltages Measures several printer voltages Process Motor Measures the process motor encoder accuracy Transfix Axis Loading Measures the transfix load pressure Monitor Menu I
176. id ink onto plain paper Color medium Cyan magenta yellow and black ink sticks each shape coded The printer uses the subtractive color system to produce the colors red green and blue Addressability Phaser 840 printer Selectable 273 x 300 409 x 409 491 x 982 or 600 x 1200 dots per inch horizontal and vertical Phaser 850 printer Selectable 177 x 409 355 x 464 450 x 818 or 600 x 1200 dots per inch horizontal and vertical Phaser 860 printer Selectable 205 x 409 355 x 464 464 x 927 or 600 x 1200 dots per inch horizontal and vertical Engine printing speed single sided Phaser 840 Phaser 850 Phaser 860 Fast Color 10 0 14 0 15 9 ppm Standard 5 7 7 8 10 0 ppm Enhanced 3 3 4 4 6 4 ppm Photo 2 2 2 2 3 6 ppm Fast Tranperancy 5 0 6 3 7 0 ppm Standard Transperancy 2 7 3 5 3 5 ppm Print times do not include image processing time which varies due to image complexity 25 mm 1 in margins assumed with 35 ink coverage Minimum printing margins All sides 5 mm 0 2 in Legal size 1 inch Top and Bottom 5mm right and left sides Envelope margins vary see user guide for specifications Maximum print area A size 8 1x 10 6 in A4 size 200 x 283 mm Legal size 8 1 x 12 in Phaser 860 only Usable paper sizes Tray fed A size and A4 size legal size 860 only auto duplex Manual fed A size and A4 size legal size 860 only auto duplex Phaser 850 860 only single sided printing on
177. ide the printer or at the media tray if the rollers are visibly dirty Wiggly vertical stripes caused by too much oil created by a dirty maintenance drawer blade Most print quality and can be cured by initiating cleaning procedures available through the printer s front panel menu Cleaning and Maintenance 6 173 Cleaning Supplies required 90 pure isopropyl alcohol m Alcohol moistened wipes m Foam swabs Clear packaging tape Caution Do not use rubbing alcohol because it can contain water and oils that leave undesirable residue on the printer parts Never use water to clean the printer s internal components Appropriate cleaning procedures as listed in the following tables should be performed when specific print quality or paper transport problems occur All cleaning procedures are detailed in the printer s User documentation Light stripes or missing colors Problem type Solution Missing or light colored Select the automated procedure Eliminate Light Stripes stripes on prints from the front panel Ink smears oil spots or random ink streaks Problem type Solution Ink smears on the front Select the automated procedure Remove Ink Smears or back or edges of a page Print Smears from the front panel Check the drum maintenance tray for ink and paper dust build up on the wiper blade Oil drum fluid on top edge Select the automated procedure Remove Ink smears of print Print Smears from the fron
178. imes in a row the fault message will be displayed N3 Refer to the Service Quick Reference Guide for other symptoms related to electronics failures 268 Phaser 840 850 860 8200 Color Printer Service Manual COMMUNICATIONS CHECKLIST Use the following tools to verify that the printer hardware ports are good If these operations are successful the printer communications hardware is good and no components should be replaced C1 The printer is connected by the Ethernet port This connection can be verified by Ifthe problem is isolated to some users while others can communicate with the printer the hardware is good E InaTCP IP environment open a web browser a computer connected to the same network as the printer and enter the IP address If the printer s CentreWare IS web page comes up the hardware is good W Usea laptop computer with a cross over cable to connect directly to the printer over TCP IP If you can open the printer s CentreWare IS web page the hardware is good C2 The printer is connected by the parallel port This connection can be verified by FromaDOS prompt enter echo showpage gt LPT1 substitute LPT2 etc if the printer is connected to a different port If the printer prints a blank page the hardware is good Tryreseating the parallel cable or swap it with a known good cable If the parallel cable is connected to any other devices remove them and connect the cable directly to the prin
179. includes a 6 3 ppm Fast Transparency Mode and a 3 4 ppm Standard Transparency Mode Standard Phaser 850N The Standard Phaser 850 printer features 136 built in fonts and is equipped with 32 Mbytes of RAM It can be upgraded to configurations of 64 128 192 and 256 Mbytes of RAM using combinations of two 32 and 64 and 128 Mbyte RAM DIMMs The Phaser 850DP The Phaser 850DP printer option upgrades the printer to 64 Mbytes of RAM and includes additional features like 2 sided printing job pipelining and First Page Preview mode The Phaser 850DPF This is a freecolorprinters com program printer which includes a High Capacity paper tray and 3 years of on site service The Phaser 850DX The extended features DX option has all the features of the Phaser 850DP printer but includes additional RAM to bring the printer to 128 Mbytes of RAM It also includes a High Capacity Paper Tray and an internal IDE hard drive Like the Phaser 840 printer all printers support four available paper trays They also support the optional 500 sheet High Capacity Paper Tray Assembly The printer can also print seven sizes of hand fed envelopes A 200 MHz PowerPC processor oversees print engine operations and PostScript image processing The printer features a 10 100BaseT Ethernet port with support for EtherTalk Novell NetWare NDS TCP IP DHCP and Windows Peer to Peer A USB high speed serial port is also provided A rear panel slot allows customers to install a
180. ing the printhead Perform a cap wipe purge with the new printhead 13 003 33 and 13 035 47 errors A heater is running away Ifthe gray data cable is not making a good connection the incorrect data will be sent to the main board Reseat or replace the printhead ribbon cable If the problem continues replace the power supply and then the printhead 13 004 43 or 13 020 41 errors The printhead jet stack is not heating as quickly as it should Readjust the left or right head to drum adjustment the printhead is too close to the drum which prevents it from warming up 840 only If the error reoccurs after the adjustment replace the printhead 13 001 40 and 13 017 47 errors An open left and right jet stack thermistor Reseat or replace the gray data cable If the error reoccurs replace printhead If the new printhead gives the same error replace the power control board 13 002 41 and 13 018 48 errors A jet stack thermistor appears to be shorted Reseat or replace the gray data cable If the error reoccurs replace the printhead If the new printhead gives same error replace the power control board 13 035 47 Replace the power supply Troubleshooting 3 113 m 13 033 45 error the thermistor in the reservoir appears to be open If the 4 pin connector on the top of the driver board is disconnected this error will occur Turn off the printer and reseat the cable I Yt e Quin uM 2 piama
181. int PhaserSMART PhaserSym PhaserTools and the TekColor name are trademarks of Xerox Corporation Total Satisfaction Services M formerly TekColor Care and RealSuppport is a service mark of Xerox Corporation Adobe Acrobat Reader and PostScript are registered trademarks of Adobe Systems Incorporated Apple LaserWriter LocalTalk Macintosh Mac OS and AppleTalk are registered trademarks of Apple Computer Incorporated PCL and HP GL are registered trademarks of Hewlett Packard Corporation MS DOS and Windows are registered trademarks of Microsoft Corporation Novell and NetWare are registered trademarks of Novell Incorporated Sun and Sun Microsystems are registered trademarks of Sun Microsystems Incorporated SPARC is a registered trademark of SPARC International Incorporated SPARCstation is a trademark of SPARC International Incorporated licensed exclusively to Sun Microsystems Incorporated UNIX is a registered trademark in the US and other countries licensed exclusively through X Open Company Limited This product includes an implementation of LZW licensed under U S Patent 4 558 302 Other marks are trademarks or registered trademarks of the companies with which they are associated PANTONE Colors generated by the Phaser 840 850 860 8200 Color Printers are four and or three color process simulations and may not match PANTONE identified solid color stand
182. ioner process belt 4 Gear Kit 1 Lower process gear pulley 5 Belt Kit 1 Process drive belt 6 Gear Kit 5 Roller flat head maintenance 7 Gear Kit 5 Head tilt cam gear 8 351 1015 00 1 Guide head tilt 9 Belt Kit 1 Head maintenance timing belt and ratchet clip 10 Gear Kit 5 Pulley drive head maintenance 11 Belt Kit 1 Exit roller drive belt 12 Gear Kit 5 Pulley exit drive 13 Belt Kit 1 Tensioner exit drive belt 14 Gear Kit 5 Transfix gear eccentric 15 Gear Kit 5 Gear compound eccentric flagged 16 Gear Kit 5 Duplex roller gear pulley 17 Gear Kit 5 Paper path idler 1 18 Gear Kit 5 Paper path idler 2 19 Gear Kit 5 Gear pulley upper feed roller preheat entry Gear Kit 1 Drum maintenance cam FRU Parts List 221 Sensor and Flag FRUs 0388 15 Fig 8 8 Sensor and flag FRUs All sensor flags are provided in Flag Kit 650 3618 00 Phaser 840 printer or Flag Kit650 4156 00 Phaser 850 860 printer Phaser 840 850 860 8200 Color Printer Service Manual 6 222 Table 8 8 Sensor and flag FRUs Parts Partnumber Serial number Qty Name and description Effective Discont d 1 650 3618 00 1 Cap wipe purge home flag Phaser 840 650 4156 00 1 Cap wipe purge home flag Phaser 850 860 8200 2 650 3618 00 1 Drum maint cam home flag Phaser 840 650 4156 00 1 Drum maint cam home flag Phaser 850 860 8200 3 386 6902 00 1 Media tray sense flag assy 4 650 3618 00 1 Paper out sen
183. is checklist and troubleshooting guide refer to Service Bulletin 437 Warning When removing the power supply always unplug the power cord first Note Always use static electricity precautions when handling the printer s circuit boards ACTION LOOK FOR WHAT NEXT Verify Failure 1 Power cycle printer 3 times and verify failure Briefly describe the failure In addition please check one of the below Hang Reset Reboot __ Print Quality Other Check all of the below 1A Status of front panel and rear LED s as on off blinking If the PS LED left is blinking and the PE LED right is not then it is flashing a POST error Interpret the repeating pat tern of long and short pulses long 5 and short 1 Add them together and refer to the Service Quick Reference Guide SQRG for details If flashing POST error record here POST error 1B Status of front panel 1C Status of cooling fan rear left corner of printer Record all of the below 1A Record status of all LED s Front panel Error LED ON OFF Front panel Ready LEDON OFF Rear PS LED ON OFF Rear PE LED ON OFF Blinking Blinking 1B Record status of front panel blank Tek logo error etc 1C Record status of cooling fan OFF AHigh Speed Low Speed Go to Action 2 250 Phaser 840 850 860 8200 Color Printer Service Manual ACTION LOOK FOR WHAT NEXT Verify
184. k flag motion a Replace the Lower Feeder 22 102 18 Time out on pick flag of Lower Feeder 2 with media picked from Lower Feeder 2 Verify that the lower tray is properly loaded Use diagnostics to verify pick roller motion 1 Leading edge jam right a Media is low in tray a Add more media corner is folded b Media has natural curvature b Flip over media or replace c Media is short grained media d Using light weight media c Use long grain media d Use heavier weight media 2 The spring loaded media a Media loaded poorly a Remove bad sheets and bias block in the lower tray is b Problem with bias block reload tray more carefully clamping the media in the tray Bad batch of media too b Flip media over or replace usually there will be black wide animis marks on the media d Use heavier weight media Media is found above the pick a A sheet of paper from the a Remove jammed sheets arm bottom of the stack is lining and reload tray more the ramp at the front of the carefully tray b Flip over media or replace b Media has natural curvature media c Media is short grained Use long grained media d Using light weight media d Use heavier weight media 22 103 08 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 2 Same as 22 101 06 22 104 00 Sticky pick flag in Lower Feeder 1 with media picked from Lower Feeder 2 Same as 22 102 07 22 104
185. l The customer has the option of printing the original number of requested sets or deleting the job Using the same password will cause any previous job s to be deleted A proof job that has not been printed is retained on hard disk through power cycles Proof jobs sent to a printer without the hard disk option are not printed and are discarded Secure Print Jobs Secure printing allows the customer to defer printing ofa job until a matching password is entered from the control panel The customer assigns the password at the client workstation before printing The job is stored and printing is delayed until the password is entered on the printer s control panel Using the same password will cause any previous jobs s to be deleted A secure job that has not been printed or released is retained on disk through power cycles This function requires the internal hard drive Saved Print Jobs Saved print allows the user to save print jobs to the internal hard drive of the printer The print job is not deleted after printing it is stored on the hard drive for print on demand This function requires the internal hard drive Solid inks Solid inks sometimes called phase change inks are solid at room temperature and are liquid at the higher temperature used during printing The inks solidify almost instantly after being jetted onto the printer s drum Because Xerox proprietary solid inks bleed much less than ordinary liquid inks they allow the printe
186. l board 0388 83 07 005 47 The Drum Maintenance home sensor actuated but not at the PM FAULT DM CAM expected time Inspect the maintenance drawer lift pins for wear POSITION ERROR Run diagnostics to verify clutch and sensor operation Also verify that the drum maintenance shaft is properly assembled 07 006 48 The Drum Maintenance home sensor actuated when no motion PM FAULT DM CAM should have occurred Run diagnostics to verify clutch and UNEXPECTED MOTION _ sensor operation Also verify that the shaft is properly assembled Error Codes and Messages 2 51 Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 7 035 63 Negative delay in pm sleep for A negative delay argument PM PROG FAULT was passed to pm sleep for FUNCS 3 7 036 64 Unexpected message in pm sleep for An unexpected ITC PM PROG FAULT message was received by pm get message during processing FUNCS 4 of pm sleep for 7 052 62 Bad message ID in pm update dmc status The ITC message PM PROG FAULT received and passed to pm update dmc status did not match FUNCS 20 any DMC status message that the Process Motor task was expecting 2 52 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 8 000 CAP TASK PROGRAM FAULT CODES 08 001 44 The cap home sensor did not see the
187. l characteristics of the Phaser 860 Color Printer apply to the Phaser 8200 Color Printer Printer Features and Configurations Hardware Updates Internal Pages Inks Memory Phaser 8200 Printer Configurations The Phaser 8200 series Color Printer features and configurations are the sames as the Phaser 860 with the following exceptions W The printer now contains a faster 300Hz Power PC Processor Colorstix 8200 ink system with unique shapes W The Free Black Ink program has been eliminated for the Phaser 8200 Color Printer Hardware Updates All parts for the Phaser 8200 Color Printer are listed in the section FRU Parts List on page 8 207 Internal Pages and Menu Items Some modifications have been made to the Phaser 8200 internal printable pages When performing service or maintenance on a Phaser 8200 use the internal pages from the printer you are servicing The Service Tools Menu has reorganized Use the menu maps from the printer s front panel Addendum PA 241 Inks These inks are of a unique shape size and formulation which are supported only by the Phaser 8200 Color Printer The inks provide better brand ID and better ink loading reliability W Print Quality The same as the Phaser 860 except the color tables are optimized for the new ink sticks and Darker Fast Text will be the default setting Wee P8200 001 Fig 10 10 New ink sticks Memory The Phaser 8200DX model will include 192 Mbyte
188. le in the Printer Setup Menu and resets all parameters within that menu to factory defaults Reset Job Defaults This option is available in the Job Defaults Menu and resets all parameters within that menu to factory defaults Reset NVRAM This option is available in the Service Tools Menu and resets all customer editable printer parameters to factory defaults Clear PS NVRAM This option is available in the Service Diagnostics function menu and clears all PostScript NVRAM settings Clear PE NVRAM This option is available in the Service Diagnostics function menu and clears all Print Engine NVRAM settings Set PE NVRAM to Defaults This option is available in the Service Diagnostics function menu and sets all Print Engine NVRAM settings to factory default 4 156 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 840 850 Running Reset PE NVRAM to Default or Clear PS NVRAM downloads a file to the printer that performs the indicated reset function there is no confirmation or cancel function 4 MS DOS Prompt DIAGS_UI rape wf T Sel IB NVRAM PE ROM 0 Reset NVRAM to Defaults Say Fig 4 13 Resetting print engine NVRAM menu item 2 MS DOS Prompt DIAGS Ul uhe a efe NVRAM PE ROM 0 Clear PS NVRAM Fig 4 14 Clearing PostScript NVRAM menu item Diagnostics and Adjustments 4 157 4 158 Phaser 840 850 860 8200 Color Printer Service Manual lest Prin
189. lide out the main board If you are replacing the main board transfer the socketed realtime clock NVRAM chip and the printer ID chip to the new board so that the printer s settings and Ethernet address are retained Also swap the SCSI riser board code ROM DIMM and the SDRAM DIMMs AON RAM Realtime clock NVRAM Code ROM DIMMS ur m y board v Printer ID S M lt n when installing 840 4 36 Fig 7 1 Removing the Phaser 840 printer main board 7 180 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 850 printer 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges Remove the interface cables 2 Loosen the two rear panel securing screws 3 Slide out the main board 4 If you are replacing the main board transfer the printer ID chip to the new board so that the printer s settings and Ethernet address are retained Also swap the code ROM DIMM and the SDRAM DIMMs RAM DIMMS Code ROM n Module D Boot ROM Printer ID When installing press on indents to seat board 840 4 85 Fig 7 2 Removing the Phaser 850 printer main board Removal and Replacement Procedures 7 181 Phaser 860 printer 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges Remove the interface cables Loosen the two re
190. line are normally present in the print 2 Uniform density Look for uniform fill from the left to the right edge of the print Lack of uniformity could be caused by printhead to drum misalignment Lack of uniformity on the edge of the print may be caused by incorrect transfix roller pressure A defective printhead can also cause uniformity problems particularly if the density difference is about 1 3 of an A size page wide Narrower density problems may be caused by a paper preheater Print Service Print 6 3 Wrinkling See Service Print 8 Causes Gaps could either be caused by a defective X axis drive or by something else such as a wiring harness interfering with the horizontal movement of the printhead The ink loader without the top cover installed to secure itin place may rest too low and interfere with the printhead s motion In this case the ink loader should rest on extrusions on the printer s side frames Also ensure that the spring under the printhead is intact and free of ink In the second print the jagged black bars in the four purple columns should align horizontally if they do not adjust the x axis scale using the procedure X axis scale adjustment on page 4 149 0388 40 5 160 Phaser 840 850 860 8200 Color Printer Service Manual 2 Weak missing jet This print shows which jets are not outputting enough if any ink compared to its neighboring jets Note that the yellow jets bands h
191. llers Run 2 or 3 sheets of blank paper through the printer to clean the rollers or manually clean the rollers 6 Replace the Power Control Board 7 Replace the Main Board 8 Replacd the Printhead 3 94 Phaser 840 850 860 8200 Color Printer Service Manual Fuzzy Text Text appears indistinct and difficult to read GHIJKLMNOPQRSTUV of hijklmnopqrstuvwxyzab DEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 70 Table 3 13 Fuzzy Text Step Question and Actions 1 Head to drum gap is too great Verify the gap with the adjustment as explained in the topic Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 2 Verify the drum temperature using diagnostics Ensure the drum temperature sensor is clean and properly positioned 3 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation 4 Verify the operation of the Y axis encoder using diagnostics Replace the encoder if needed 5 If the problem persists replace the printhead Troubleshooting 3 95 Poor primary color fills Primary fills appear banded and inconsistent 1 ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnoporstuvwxyzab ABCDEFGHIJKLMNOPQRSTL 4 abcdefghijkImnoparstuvwxyz 0388 47 Table 3 14 Poor primary color fills Step Question and Actions 1 Possi
192. lt of 128 Often the printhead adjust is raised to extend the life of older printheads Adjusting it above 128 causes the jets to fail on multi page jobs and increases customer ink usage DO NOT ADJUST THE PRINTHEAD ON THE PHASER 850 OR 860 REPLACE THE PRINTHEAD 2 Print Service Test Print 2 Weak and Missing Jets Use this test print to evaluate the cap wipe purge assembly and printhead performance 3 106 If you see color mixing from one row to the next for example magenta jet 46 to cyan jet 46 the cap wipe purge assembly blade may be damaged Visually inspect the wiper as described in Step 4 below If you see weak or missing jets the problem may be caused by the cap wipe purge assembly vacuum system tubing air valve or pump or the printhead To isolate the problem begin by checking the performance of the cap wipe purge assembly and vacuum system as described in the following steps If you see white spaced 0 1 inches 0 25 cm apart across the page but not present on the test page the problem is not with the cap wipe purge assembly or printhead Check for something binding the x axis such as a cable rubbing the printhead Phaser 840 850 860 8200 Color Printer Service Manual 3 Visually check printhead faceplate Closely examine the printhead s faceplate to help evaluate whether the cap wipe purge assembly s wiper blade and gasket are damaged Fig 3 2 Faceplate showing blade wipe with
193. ly Executive 7 25 x 10 5 in Ab 148 x 210 mm Usable paper weights Tray fed 16 32 Ib Bond 60 120 g m Phaser 840 16 40 Ib Bond 60 150 g m Phaser 850 860 up to 65 Ib 176 g m Cover stock main tray only single sided 20 28 Ib Bond Legal size Phaser 860 only Manual fed 16 40 Ib Bond 60 150 g m up to 80 Ib Cover 135 220 g m single sided up to 110 Ib 216 g m Index stock 20 28 Ib Bond Legal size 860 only Note media up to 150 g m can be auto duplexed Tektronix Xerox brand cover paper and glossy paper exceed this specification but are supported Phaser 840 850 860 8200 Color Printer Service Manual Table 1 10 Functional specifications Characteristic Specification Usable envelopes 10 U S DL Metric 6 3 4 U S Choukei 3 Gou C5 Metric Choukei 4 Gou US Monarch Phaser 850 860 printer only Note Do not use envelopes with endflaps except Choukei 3 amp 4 Gou plastic windows or metal clasps they can damage the printer Specialty Media Labels A A4 laser quality sheet stock only Recommended Avery white laser labels Phaser 840 850 860 use Tek branded labels The Phaser 840 also supports U S 5160 5960 and Metric L7162 The Phaser 840 850 860 also support Glossy Photo Cover stock and Transparencies Table 1 11 Electrical specifications Characteristic Specification Primary line voltages 87 to 132 VAC
194. mmand stop event while transfixing Typically becuase of a positioning error at the start of drum maintenance or imaging a Verify that the lower tray is properly loaded b Try heavier media 1 More than one sheet of a Multiple pick a Try again media in the path 2 Media perfect in media path Check for drum rotation a Check for Y axis motion exit door area b Y axis encoder defective or blockage not seated properly b Reseat or replace c Drum maintenance clutch encoder d PostScript fault c Replace the drum e Front panel error maintenance clutch f Power supply problem d Try again cycle power or Error Codes and Messages NVRAM reset Replace front panel assembly Replace power supply 2 67 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 703 05 Y axis stall Typically during transfix May result from belt slippage a Verify that the lower tray is properly loaded b Try heavier media 2 More than one sheet of a Multiple pick a Try again paper in duplex path 3 Media all wrinkled up a Short grained media a Run stiffer long grained media 22 705 07 Y axis time out during transfix while moving media to the exit sensor 1 Exit tray nearly full a Media was pulled from exit a Empty exit tray into duplex while printing exit flag can t move properly 2 Media unable to get out of a Top cover has exit
195. mpletely under stripper fingers or rapid release guide margin too large or too small a Preheat sensor not seated properly b Preheat sensor not properly assembled to bracket c Preheat sensor is bad a Confirm bracket is properly screwed down onto load frame Reseat sensor Replace preheat exit sensor oo 9 Media over stripper fingers or rapid release guide not damaged and stopped at strip sensor a Problem with strip flag b Bad transfix exit sensor a Replace pivoting blue lower exit guide b Replace sensor assembly 10 Media under transfix roller right at stripper fingers Eccentric solenoid problem Transfix cam problem Cam spring problem a Replace eccentric solenoid b Replace cam c Replace drum transfix assembly 11 Media doesn t make it to the transfix roller a Too much drag in drive train or preheater a Short grained media a Use PC based diagnostics to run verify drive current requirements from the paper path group to check for stall or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed Check electronics if needed b Use long grained media 22 900 04 Unexpected front door event 1 Media perfect in media path or tray a Unknown static b Someone opened a door a Run again b Close door 22 901 05 Unexpected exit cover event 1 Media perfect in media path or tray a Unkn
196. n a The heaters in the printhead and cap wipe purge assembly are activated as a precaution to melt the ink which may have cooled and solidified thus gluing the cap wipe purge and printhead together 10 minutes pass while the cap wipe purge assembly heats up b The printhead is tilted back The ink is allowed to drain from the cap wipe purge assembly Thecap wipe purge assembly is lowered to its home position 3 76 Phaser 840 850 860 8200 Color Printer Service Manual 5 The process motor is activated to rotate the head tilt gear into its home position If the printhead is in the locked position it will not tilt forward The process motor also rotates all the rollers to their ready positions disengage the transfix roller and lower the maintenance drawer blade and wiper 6 The x axis motor activates to move printhead off its locking post The x axis motor activates for three short bursts to ensure the printhead is in its far left travel printhead home position Then the x axis motor is reversed to move the printhead to the center the of the x axis travel 7 The process motor is again activated to tilt the printhead forward into the print position The drum is rotated to sense it home position The Phaser 850 printer uses a slower rotation to find its home position 8 A short cap wipe purge assembly motion is performed and the assembly is returned to its home position 9 After the print engine is in a known
197. n a Media was pulled from exit a Empty exit bin duplex path into duplex while printing b Retry b Multiple pick 22 600 01 Command stop event with media in exit cover area See SF144 1 Media perfect in media path Drum maintenance clutch a Inspect maintenance exit door area b PostScript fault drawer for worn lift pins c Front panel error and replace if needed d Power supply problem b Replace the DM Clutch this is a solution for the Phaser 840 only c Try again cycle power or NVRAM reset d Replace front panel assembly e Replace power supply 22 601 02 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in the exit door area Same as 22 101 06 22 603 04 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in the exit door area Same as 22 101 06 Error Codes and Messages 2 65 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 605 05 Unexpected standard tray sensor event with media in exit door area Same as 22 105 01 22 613 05 Unexpected stripper exit sensor event 1 Paper started backing up before a jam a Paper didn t fully exit in time a Ensure media is the correct size try a different media clean the exit rollers or replace the exit cover 2 Paper was still exiting a Stripper exit sensor bounced a Tryincreasing the stripper sens
198. n site Electronics Troubleshooting Checklist Phaser 860 8200 on page A 266 Phaser 840 850 Customer Mode Power Up Sequence Power switch is turned on 1 Power supply senses AC line voltage conditions 110 VAC or 220 VAC and enables DC voltages If an overload occurs the printer turns off the DC supplies giving a blink effect to the front panel LEDs 2 Low level power on self test POST diagnostics are performed The two status LEDs at the rear panel should toggle and the front panel LEDs are turned on The front panel display is blank This test takes from 4 to 15 seconds depending on installed RAM 3 If POST diagnostics pass the front panel Error LED is turned off and the front panel displays the Tektronix logo while the mechanical initialization checks are performed If an error is detected the Phaser 850 printer flashes the front panel Error LED with a repeating error code pattern as well as the rear panel PS LED On the Phaser 840 printer the pattern is displayed only on the rear panel PS LED left side of the DIP switches 4 The mechanical initialization is conditional on the initial position of the printhead and cap wipe purge assembly Two NVRAM parameters are checked for the last known position If the printhead is in either the Locked or Print position a The cap wipe purge motor is run to ensure that the cap wipe purge assembly activates its home position sensor If the printhead is in the cap wipe purge positio
199. n the tilted forward far right position Upon power up the printhead will be tilted backward and the head tilt arm will crash into the head lock pin This can damage process gears and belts driving the tilt arm After servicing the printer When you service the printhead x axis drive cap wipe purge assembly or other relevant printer components leave the printhead in its print position centered in front of the drum Upon power up the printer can safely move the printhead Manually locking the printhead If you must manually lock the printhead 1 With the printer powered off carefully tilt the printhead back about two thirds of the way by rotating the compound gear Do not allow the spring loaded printhead to fall forward or it may damage the drum 2 Manually rotate the X axis drive gear to move the printhead to the extreme right of its travel Ensure the lock pin on the left side of the printer frame properly engages the slot in the head tilt arm 3 Rotate the x axis gear in the opposite direction about 1 rotation This prevents the x axis drive from binding so tightly that the motor cannot free it upon power up 4 Reverse these steps to unlock the printhead 4 138 Phaser 840 850 860 8200 Color Printer Service Manual Process belt tension adjustment Required tool m Spring Scale 1 Turn off the printer and remove the left side cabinet panel 2 To adjust the belt tension loosen the process belt tensioner With a spring s
200. ncludes a High capacity Paper Tray and an internal IDE hard drive The Phaser 840GP This Designer Edition printer includes all the features of the Phaser 840DP but includes 128 Mbytes of RAM a 10 100BaseT network card and translucent blue cabinet panels The Phaser 840DPF This freecolorprinters com program printer is a Phaser 840DP printer but it also includes a High Capacity paper Tray and 3 years of onsite service All printers support four available paper trays Two A and A4 trays are intended for paper and low volumes of transparencies two other A and A4 trays are meant for label stock and high volume transparencies The optional 500 sheet High capacity Paper Tray Assembly gives the printer a two tray capability With the addition of a second High capacity Paper Tray the printer has a three tray capability The High capacity Paper Tray Assembly is sometimes referred to as a lower feeder it only supports paper printing The printer can also print six sizes of handfed envelopes 1 2 Phaser 840 850 860 8200 Color Printer Service Manual A 133 MHz PowerPC processor oversees print engine operations and PostScript image processing The printer features an integral bi directional parallel port IEEE 1284C with ECP mode and a 10BaseT Ethernet port with support for EtherTalk Novell NetWare NDS TCP IP DHCP and Windows Peer to Peer A USB high speed serial port is also provided A rear panel slot allows customers to install one smart ca
201. ncomplete image transfer to paper page 101 Ink smears on first side of duplex print page 102 Repeating print defects on print page 103 Wrinkling page 104 Image is offset or cut off page 105 Poor ink adhesion poor image durability page 105 Macintosh Printing Problems Table 3 4 Macintosh Printing Problems RAP Table Problem on Page Image Never Prints page 115 Image is rotated 90 degrees page 115 Image prints in black and white page 115 Printer isn t the Chooser page 116 3 74 Phaser 840 850 860 8200 Color Printer Service Manual Network Event Logs Phaser 850 The Phaser 850 printer maintains three logs in memory detailing network functions The logs contain TCP IP and Netware initialization landmarks and limited print time processes The log also shows the state of the networking hardware The logs are useful for troubleshooting network setup problems and isolate network problems from printer problems The log indicates that network hardware is properly functioning with messages like NETWORK HARDWARE PROVEN GOOD USING The logs can be accessed through the front panel menu 1 Navigate to Menu Printer Configuration Network Setting Network Logs 2 Scroll to Hardware Startup Log or TCP IP Startup Log or NetWare Startup Log and press Select The log can also be accessed remotely via PhaserLink 2 0 The logs lists events chronologically The log is limited in length logging stops when the log is f
202. nd 6 to 8 jets wide this will create a white stripe about 1 2 inch 1 cm wide on the page YES NO Goto B Go to 5 5 If the printer is a Phaser 340 or 350 is the 2nd letter of the printhead serial number A B C or D OR is it E and the next two digits are in the range 01 40 YES NO Goto B Goto A A WHAT TO DO WHEN A PRINTHEAD FAILS DUE TO NXTI Inform the customer that service will only be provided with a credit card or purchase order outside North America where credit cards are not commonly available Xerox Warranty Service Agreement DOES NOT cover repair cost of the printhead when it has been damaged by Non Xerox Tektronix ink and the repair cost is the responsibility of the customer m Replace the printhead per normal procedures W Provide the customer with the Diagnosis Form and Onsite Failure Notification letters B Check Non Xerox Tektronix Ink Box on Greentag Enclose all sample prints ink samples and this checklist with the printhead and return it to Wilsonville for evaluation W Enclose a sample of waste ink with the printhead return if possible Xerox Personnel please provide full documentation in TekLink 248 Phaser 840 850 860 8200 Color Printer Service Manual WHAT TO DO WHEN PRINTHEAD DOES NOT MEET THE NXTI FAILURE CRITERION Provide the customer with the Customer Alert 6 March 2002 letter If there are weak or missing jets replace the printhead per normal pro
203. nd almost never fail If the printers works when completely isolated the problem is most likely related to the network or host computer configuration or hardware Warning WARNING When removing the power supply always unplug the power cord first Note NOTE Always use static electricity precautions when handling the printer s circuit boards Initial Checklist Turn the power off and back on to verify that the failure can be recreated Then answer the questions below A Does the failure occur during power up before the Xerox logo is displayed YES NO Yes Go to Power up Checklist B Does the printer Reset or Reboot after initial power up YES NO YES use the Service Quick Reference Guide to troubleshoot the codes in the fault history fault history can be accessed in diagnostics if you are unable to get to that menu in normal mode If this does not isolate the failure refer to the Normal Operation Checklist C Is the printer displaying a fault code YES NO YES Note the fault code Use the Service Quick Reference Guide to troubleshoot the fault If this does not isolate the failure refer to the Normal Operation Checklist D Is the failure a communication problem with the network or host computer YES NO Yes Go to Communication Checklist For all other Electronics problems including intermittent failures refer to the Normal Operation Checklist Once the problem is resolved answer the following Xerox US perso
204. ng CAUTION Excess grease can fall onto the drum belts causing them to slip replace the belts and clean the drum gear with alcohol Never clean belts with alcohol it will damage them Add small dab AL 1 grease if needed 0388 75 Fig 6 1 Lubricating the transfix cam Cleaning and Maintenance 6 177 Inspection Rollers Replace the rollers when you see any of the following defects Flat spots Out of roundness Cracked rubber Loss of traction tackiness causing pick or feed failures Gears Replace gears that show any signs of wear or breakage Look for these problems Thinned gear teeth Bent or missing gear teeth check especially where a metal gear drives a plastic gear Fractured or cracked gears Oil or incorrect grease on a plastic gear can cause the gear to crack Belts Inspect the belts for wear There are eight rubber belts in the printer A belt from the process motor to the compound gear Two belts from the y axis motor drive A belt from the lower paper feed roller to the upper paper feed roller Two belts on the cap wipe purge drive An exit roller drive belt A small belt for driving the cap wipe purge assembly from the cap wipe purge clutch Look for these problems Loose rubber particles below the belts indicate a worn belt Missing teeth in the belts Cracking or moderate fraying a small amount of fraying is inevitable so look for other signs of wear before replacing the belt Clutche
205. nly 840 4 22 Fig 7 17 Removing the x axis motor and drive assembly For reassembly apply a small amount of grease on the tip of the nose cone Apply a small amount 3 dabs on the threads of the X axis shaft Be sure to rotate the black plastic retainer so its end locks the yoke in position Perform the X axis scale adjustment on page 4 149 Removal and Replacement Procedures 7 199 Y axis belt drive assembly Phaser 840 printer 1 Remove the right cover 2 Disconnect the wiring harness leading from the front panel to the right I O board passing beside the Y axis belt drive assembly 3 Remove the drum fan Note the fan orientation it blows into the drum Caution Never loosen or remove the three screws securing the assembly parts together 4 Remove the three tension set screws securing the Y axis belt drive assembly to the engine frame Remove the assembly with its two belts 5 Reverse these steps to reinstall the Y axis drive assembly 6 Tension the belts using the Y axis belt tension adjustment Phaser 840 printer on page 4 142 Y axis belt assembly Never remove these screws Mounting screws 840 4 12 Fig 7 18 Removing the Y axis belt drive assembly Phaser 840 printer 7 200 Phaser 840 850 860 8200 Color Printer Service Manual Y axis belt drive assembly Phaser 850 860 printer 1 Remove the right cover 2 Disconnect the wiring harness leading from the front p
206. nnel please document in TechLink 1 Which Checklist Item Number addressed the issue 2 What was the corrective action 3 Record the SERIAL NUMBER of any main electronics components replaced 4 Note any additional comments 266 Phaser 840 850 860 8200 Color Printer Service Manual POWER UP CHECKLIST P1 Is there a failure message on the front panel YES NO Go to P2 YES the message is RAM ERROR Neither RAM socket has a supported RAM DIMM installed Ensure that supported RAM is being used Reseat and then replace the RAM DIMM POST Error XX XX Note the POST Error code Refer to the Service Quick Reference Guide for specific actions to take for each message Other Message The above messages are the only ones that occur during power up Refer to the Operating Failure Checklist P2 Is the display blank with the rear panel LEDs flashing a pattern YES NO Go to P3 YES The flashing pattern is __ BIST Error 1 2 or 3 PE LED flashing rapidly and PS LED flashing 1 2 or 3 Reseat all main board components Next replace the ID Chip then Code ROM and if necessary the Main Board __ POST Error 4 both LEDs flashing 4 Neither I O Right or the front panel are detected verify that the IIC cable is connected then replace I O Right POST Error 5 both LEDs flashing 5 one long flash The front panel is not detected verify that the IIC cable is connected then replace the
207. no drops smudges or streaks If you see spattered ink on the edges of the printhead the cap wipe purge assembly s gasket may be leaking during the purge cycle A misaligned printhead or a defective gasket may cause this To verify the printhead alignment move the cap wipe purge assembly to its purge position and tilt the printhead forward until the upper edge of the gasket touches the faceplate If the left and right sides touch at the same time the printhead side to side alignment is correct and the problem is probably due to the gasket If not you need to readjust the printhead to drum gap If you see streaks or smudges of wax in the jet area of the printhead s faceplate after a purge cycle the cap wipe purge assembly wiper blade is damaged and the cap wipe purge assembly needs to be replaced In this example the blade has several defects in most cases there is only one smudge or streak Fig 3 3 Faceplate showing streaks and smudges from a poor wipe 4 Visually check cap wipe purge assembly wiper and gasket a Open the front cover and remove the drum maintenance drawer b Ifnotin its standby position lower the cap wipe purge assembly to its standby position under the drum Troubleshooting 3 107 With a flashlight closely examine the cap wipe purge assembly Inspect the gasket for defects and signs of separation Tilt the printhead all the way back and raise the cap wipe purge assembly to its purge position Inspect the r
208. nopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefahiiklmnoparstuvwxvzab 0388 68 Table 3 10 Scratches parallel to the long axis of printing Step Question and Actions 1 Inspect the exit area for anything that may be touching the drum 2 Run a transparency through the manual feed to see if the scratch appears on the print If it does not the scratch occurred in the paper pick and early transport of the transparency film Try changing the paper pick guide front door or maintenance drawer 3 A scratch or smear can be caused by debris built up on the paper preheater heating surfaces Run the front panel cleaning procedure Remove Ink smears Force a sheet of thick 65 to 80 Ib paper through the paper preheater to buff the paper preheater heating surfaces With the leading and trailing ends of the sheet of paper extending from the entry and exit of the paper preheater gently pull the sheet of paper back and forth several times and then remove the sheet of paper Be careful of the paper sensor flags 4 Clean the stripper fingers or the rapid release guide 3 92 Phaser 840 850 860 8200 Color Printer Service Manual Printing too light or too dark Table 3 11 Printing too light or too dark Step Question or Action 1 Make sure the printer is correctly reading the type of tray installed and that the tray is correctly set for the media loaded in it Printing on paper in transparency mode significantly darkens a
209. nothing comes out of printer or the printer goes back to Ready to Print mode without printing an image 1 From the printer driver under the printer s set up options set TRANSMISSION RETRY 850 2 Use the error handler 3 In the print dialog box make sure print to file is not checked 4 Does the same error occur on all PC s If not verify the PC settings Printer settings and drivers 5 Is it a network printer Troubleshoot possible network connection problems Troubleshooting 3 117 3 118 Phaser 840 850 860 8200 Color Printer Service Manual Diagnostics Adjustments and NVRAM Front Panel Shortcuts Table 4 1 Front Panel Shortcuts Phaser 840 850 Phaser 860 Access Fault History When a jam message is displayed Hold down the Cancel or Scroll Up button and then press OK This displays the Fault History Menu with the most recent code at the top 1 Pull the paper tray out about 1 1 inch 2 5 cms This activates all three tray sensors 2 Hold down the Left Arrow and press the Help button This displays the Fault History Menu with the most recent code at the top Set Front Panel Language Press and hold the Right Arrow and then the Select Button Press and hold Scroll Up then press the i button Service Tools Menu and Diagnostic Menu Press and hold the Cancel or Scroll Up button then press the OK button Scroll to and enter the Troubleshooting men
210. nter front panel run up to 3 times as needed to recover a weak or missing jet If the problem persists continue to the C W P Checklist Appendix 245 CAP WIPE PURGE C W P CHECK LIST 1 Verify C W P belt alignment Is the C W P out of alignment YES NO Go to 2 YES Perform C W P belt alignment procedures Go to step 2 2 Print Service Test Print 2 Weak and Missing Jets Is there color mixing from one row to the next row for the same jet YES NO Go to 3 YES Replace C W P New C W P may take 6 purges before optimal performance Repeat Step 2 3 Visually check the printhead faceplate Are there streaks or smudges of wax in the jet area of the printhead YES NO Go to 4 YES replace C W P New C W P may take 6 purges before optimal performance Go to Step 2 4 Visually check the C W P wiper gasket Is there any separation on the wiper blade or pitting of the C W P gasket YES NO Go to 5 YES replace C W P New C W P may take 6 purges before optimal performance Go to Step 2 5 Check the Purge Performance 5a Check the vacuum and decay time at the metal pipe using vacuum T during front panel CLEAN cycle The peak vacuum at the metal pipe is If more than 38 cm Hg 15 in Hg 7 4 psi Go to Step 5c If less than 38 cm Hg 15 in Hg 7 4 psi check the vacuum at the pump side of the air valve or outlet of vacuum module without T during front panel CLEAN cycle Measured vacuum pump reading If measured vacuum is
211. nthead Perform C W P Checklist with new printhead Iferror 4002 41 or 4 006 45 check printhead ribbon cable before replacing the power control board If the problem persists replace the printhead Perform C W P Checklist with new printhead 4 Print Service Test 2 Weak and Missing Jets Are there weak or missing jets YES NO If YES do the following No Go toC W P Checklist Clean the maintenance drawer wiper blade to prevent contamination of the printhead Check the exit area of the paper path for debris that could be scraping ink off the drum and may mimic a weak or missing jet Select Eliminate Light Stripes from the printer front panel run up to 3 times as needed to recover a weak or missing jet If the problem persists continue to the C W P Checklist 262 Phaser 840 850 860 8200 Color Printer Service Manual CAP WIPE PURGE C W P CHECK LIST 1 Verify C W P belt alignment Is the C W P out of alignment YES NO Go to 2 YES Perform C W P belt alignment procedures Go to step 2 2 Print Service Test Print 2 Weak and Missing Jets Is there color mixing from one row to the next row for the same jet YES NO Go to 3 YES Replace C W P New C W P may take 6 purges before optimal performance Repeat step 2 3 Visually check the printhead faceplate Are there streaks or smudges of wax in the jet area of the printhead YES NO Go to 4 YES replace C W P New C W P may take 6 purges before optimal performance Go
212. o be shorted Check the TCH RESERVOIR SHORT printhead cabling Replace the printhead 13 035 47 TCH RESERVOIR HOT The reservoir heater is running away Unplug the printer NOW Check the printhead cabling Then replace the power supply If the problem continues replace the printhead 13 036 48 TCH RESERVOIR SLOW The reservoir heater is not heating at all or is not heating as quickly as it should Check the printhead cabling Replace the printhead 13 037 61 TCH RESERVOIR ADC IS BAD The analog to digital converter appears to be bad Try reseating the printhead data cable Then reseat the main board If the problem continues try replacing the main board and then the printhead 15 000 DRUM THERMALS Drum thermal faults are determined by a thermistor in contact with the drum surface Ensure that there is adequate clearance for airflow at least 4 inches 10 cms on all sides and that the room temperature is between 90 F 35 C and 50 F 10 C User diagnostics to verify the thermals are changing 15 000 40 The drum temperature is incorrect as sensed by the drum TCD THERMISTOR thermistor Ensure that there is adequate clearance for airflow at FAULT least 4 inches 10 cms on all sides and that the room temperature is within specification 15 001 42 The drum thermistor appears to be open Replace the TCD THERMISTOR drum temperature sensor OPEN 15 002 43 The drum thermisto
213. o check the printhead and drum for correct thermal regulation Also check the printhead to drum gap Phaser 840 only Ensure the drum fan is running properly A vertical band 1 5 of a page wide running the length of the page is caused by a stuck heating plate in the paper preheater Run the front panel cleaning procedure Clean Ink Smears which raises the temperature of the paper preheater and may free the stuck heating plate Additionally you may manually force a thick sheet of paper 65 to 80 Ibs through the paper preheater to jar the plate free Light spots are caused by a defective transfix roller with a weak soft spot that is not pushing the ink into the paper as the rest of the roller does In this case replace the drum transfix unit Replace the drum maintenance cartridge roller particularly if you observe variations in the glossiness of the print 9923 88 5 163 Test Prints 7 Manuf Dot position scanner Printhead diagnostic This print is used for manufacturing and engineering evaluation of printhead performance 8 YMCKRGB Solid Fills These seven prints show uniformity of fill Look for Even uniform fills throughout each print Wrinkles or deformity of the paper itself caused by the print process show up in duplexed solid fill prints at Standard or Enhanced resolutions To test for wrinkling print the YMCKRGB prints in duplex mode at the Standard resolution Causes Weak jets or uneven
214. o clean the transport rollers if they are visibly dirty See SB402 Check that the pick roller is being rotated Diagnostics can be used to verify Use diagnostic s to run Verify Drive Current Requirement Test Phaser 840 850 or Paper Path Drive test Phaser 860 to check the operation of the paper pick system Inspect the wiring harness leading to the paper transport clutch for nicks cuts or crimped wiring Ensure the connector is seated 10 Inspect the rollers bushings and gears of the paper path Troubleshooting 3 85 Print transfer jams 1 If a piece of paper is trapped in the paper preheater try pushing out the paper by inserting a stiff piece of cardstock into the paper preheater Using diagnostics test the paper preheater sensors If the test fails replace the paper drum heater assembly Check to see if the upper feed roller drive belt is broken or slipped off of its pulleys In such a case the upper feed roller does not rotate when the lower feed roller rotates Check that the feed rollers rotate smoothly and that the front cover is fully closed and seated Check the paper eject path for obstructions Ensure no small pieces of paper are trapped around the stripper fingers or rapid release guide Ensure that the transfix roller rotates during the transfix process See SF168 and SB467 Test the sensors in the paper path Look for damaged or non operating sensor flags
215. odes are listed in the following table Other failures are indicated by the failure being printed on the Startup Page After successful power up the left LED flashes at a regular heartbeat rate The front panel Power light turns on the Error light flashes and the LCD is cleared When troubleshooting Rear Panel LED Codes try reseating the affected components first If the problem continues then replace the affected components Table 2 1 Main board power up self test error codes PS LED Meaning Details flashes Long flash 5 Short flash 1 21 15 11 1 2 SDRAM SIMM This test verifies the presence of both SDRAM SIMMs If Presence both SDRAM SIMMs are missing the resultant error indication is 2 short flashes from the left LED 3 SDRAM bankO This test verifies DRAM bank 0 in the DRAM DIMM located in Position 1 closest to the rear panel 4 SDRAM bank 1 This test verifies DRAM bank 1 in the DRAM DIMM located in Position 1 closest to the rear panel 5 SDRAM bank 2 This test verifies DRAM bank 0 in the DRAM DIMM located in Position 2 farthest from the rear panel 6 SDRAM bank 3 This test verifies DRAM bank 1 the DRAM DIMM located in Position 2 farthest from the rear panel 7 not used Error Codes and Messages 2 37 Table 2 1 Main board power up self test error codes cont d PS LED Meaning Details flashes Long flash 5 Short flash
216. of 64 and 128 Mbytes RAM SODIMMs The Phaser 860B does not support networking or High resolution Photo mode The Phaser 860N The Phaser 860N printer adds a 10 100 BaseT Ethernet port and has all the same features as the Phaser 860B model The Phaser 860DP The Phaser 860DP printer option upgrades the printer to 128 Mbytes of RAM and includes additional features like 2 sided printing job pipelining and High Resolution Photo mode The Phaser 860DPF This is a freecolorprinters com program printer The Phaser 860DPF has all the features of the Phaser 860DP printer but adds a High capacity paper tray and 3 years of on site service The Phaser 860DX The extended features DX option has all the features of the Phaser 860DP printer but includes a High capacity Paper Tray and an internal IDE hard drive All printers support five available paper trays Two A and A4 trays are meant for paper and low volumes of transparencies two other A and A4 trays are meant for label stock and high volume transparencies and a legal size paper tray which comes with an output bail There is an optional 500 sheet High capacity Paper Tray Assembly gives the printer a two tray capability With the addition of a second High Capacity Paper Tray the printer has a three tray capability The High Capacity Paper Tray Assembly is sometimes referred to as a lower feeder it only supports paper printing The printer can also print six sizes of hand fed envelopes A 250 M
217. olube 768 012 1535 00 1 Cable Diagnostics PC DB 9F to DB25M 012 1543 00 1 Cable adapter diagnostics Phaser 840 850 only 003 1707 00 1 40 volt service plug and jumper Phaser 840 850 only 650 4197 00 1 Head to Drum Gap Clip Phaser 840 063 3009 00 1 Service diagnostics diskette SW Phaser 840 063 3346 00 1 Service diagnostics diskette SW Phaser 850 650 3973 01 Phaser 840 Tool kit Encoder Alignment Tool Head to Drum Gap Tool Assy Y Axis Belt Tensioner tool Serial Adapter Cable 40 v Service Plug PC DB 9F to DB25M Cable Vacuum gauge assembly Torque screwdriver Hot head resevoir plugs Hot head removal tool Torx bits assorted 650 4103 00 Phaser 850 Tool kit Encoder Alignment Tool Serial Adapter Cable 40V Service Plug PC DB 9F to DB25M Cable Vacuum gauge assembly 003 1623 00 1 Spring removal tool 650 4222 00 Hardware kit Note Some items are not used in all products 650 3616 00 Cable kit printer wiring harnesses Phaser 840 650 4139 00 Cable kit printer wiring harnesses Phaser 850 650 4218 00 Cable kit printer wiring harnesses Phaser 860 8200 650 4051 00 1 Vacuum Gauge assembly Phaser 840 850 only 8 226 Phaser 840 850 860 8200 Color Printer Service Manual Table 8 10 Service tools Parts Part number Serial number Effective Discont d Qty Name and description 071 0723 00 Phaser 840 850 860 Printer Service Manual with Phaser 8200 Addendum Supplies and accesso
218. on the drum 4 Replace Drum transfix assembly Troubleshooting 3 103 Wrinkling The print is usually damaged in a corner with solid fills ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 74 Table 3 22 Wrinkling Step Question and Actions 1 Try flipping the media over or using a heavier weight 2 Try different media from a sealed package In high humidity environments paper left exposed unpacked absorbs moisture and begins to warp 3 Increase the margin size of the image if feasible Wrinkling generally occurs in solid fills near the print s edge 4 Ensure the deskew fingers inside the front cover are not damaged or missing 5 Inspect the maintenance drawer wiper blade Replace the maintenance drawer if necessary 6 The transfix spring pressure is incorrect Perform the procedure Transfix roller pressure spring adjustment on page 4 154 7 Replace the drum transfix assembly 3 104 Phaser 840 850 860 8200 Color Printer Service Manual Image is offset or cut off 1 Check the application for the correct image sizing and orientation 2 Ensure that Letter or A4 is the selected paper size Cil streaks on top of print 1 Clean the stripper fingers or the rapid release guide 2 Run chase pages through the printer to clean the drum Use the front panel menu item Remove Ink Smears 3 Clean the maintenance drawer blade
219. ontrols the engine and the PostScript processing Prominent on the main board is the ROM code DIMM and the RAM DIMM plug in modules The code ROM DIMM also contains the printer s on board fonts For the Phaser 840 alternate ROM code DIMMs contain language fonts such as Kanji or Hangul The Phaser 850 printer support two base Heisei Kanji fonts other Asian fonts are available on the internal IDE drive For the Phaser 860 all Asian fonts are available on the internal IDE drive Network connection is provided through a built in 10BaseT port in the Phaser 840 printer and a 10 100BaseT port for the Phaser 850 860 printer not enabled in the Phaser 860B For the Phaser 840 printer a plug in SCSI interface adapter board provides a SCSI port for an external hard drive or scanner The Phaser 840 printer stores unique printer status and PostScript values in its socketed NVRAM and EEPROM modules The printer s Ethernet address unique to each printer is stored in the EEPROM printer ID chip an 8 pin socketed IC For the Phaser 850 860 printer all printer NVRAM parameters such as the printer ID unique printer status and PostScript values and Ethernet address are a stored in the socketed EEPROM All socketed components should be transferred to a replacement main board to maintain customer unique settings SCSI riser RAM DIMMs board NV RAM Real Time Clock DNS S Code ROM s d b din DIMM of Les iw D lt di
220. oo TCH JS LEFT SLOW slowly Ensure the printer is not located next to an air conditioning duct Check that the printhead to drum gap is not too close the drum can act as a heatsink Inspect the printer wiring Replace the printhead 2 56 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 13 011 66 tc_bomb this 11 Bad TCH message in fault state While in the divice fault state the reervoir thermal manager received an unexpected message not a turn off or a regulate command The device fault state is entered whenever the engine firmware detects a device fault 4 13 017 47 The thermistor in the right jet stack appears to be open Check TCH JS RIGHT OPEN the printhead cabling Replace the printhead 13 018 48 The thermistor in the right jet stack appears to be shorted Check TCH JS RIGHT SHORT the printhead cabling Replace the printhead 13 019 40 The right jet stack heater is running away Unplug the printer TCH JS RIGHT HOT NOW Check the printhead cabling Replace the printhead 13 020 41 The right jet stack heater is not heating at all or is not heating as TCH JS RIGHT SLOW quickly as it should 13 033 45 The thermistor in the reservoir appears to be open Check the TCH RESERVOIR OPEN printhead cabling Replace the printhead 13 034 46 The thermistor in the reservoir appears t
221. or If the disk touches the sensor it can scratch the disk and result in erroneous drum position readings Note Do not rotate the encoder wheel on the drum shaft Altering the position of the encoder wheel relative to the drum shaft will alter the location that the stripper fingers Phaser 840 printer or rapid release guide Phaser 850 860 printer contact the drum Any marks on the drum left by the stripper finger or rapid release guide in their original position would then appear in the printed area of the drum With a marker pen draw an alignment mark on the shaft end and the encoder wheel to help ensure their positions to each other do not change 1 Phaser 840 printer only Ensure that the retaining spring is not in the drum position sensor assembly s encoder wheel groove This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft If not already mounted in place secure the drum position sensor assembly onto the drum shaft and secure it to the printer frame Through the access hole in the drum position sensor assembly position the encoder gap tool on the drum shaft Reposition the drum position sensor assembly s encoder wheel on the drum shaft until it butts firmly against the encoder gap tool Phaser 840 printer only Holding the gap tool in place with a small flatblade screwdriver slide the encoder wheel s retaining spring into the encoder wheel s groove 6 Remove the gap tool Reass
222. or replace the maintenance kit Poor ink adhesion poor image durability 1 For transparencies verify that the media tray is set to Transparency 2 Verify the paper preheater temperature using diagnostics 3 The drum is too cold Verify the drum temperature using diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 4 Try a different paper if a specialty coated paper is being used Tektronix transparency film provides the best ink adhesion versus off the shelf transparency film 5 The transfix spring pressure is incorrect Perform the procedure Transfix roller pressure spring adjustment on page 4 154 Troubleshooting 3 105 Evaluating the printhead and cap wipe purge system A close relationship exists between the printhead and the cap wipe purge assembly The reliability and print quality of the printhead depends a great deal on the effectiveness of the cap wipe purge assembly If the cap wipe purge assembly is damaged poorly adjusted or if the vacuum system is not performing properly the printhead will likely suffer lost unrecoverable jets In some cases the printhead can even be damaged by the cap wipe purge assembly Before replacing a printhead always verify that the cap wipe purge assembly is correctly adjusted and performing properly 1 Check printhead drive voltage Head Adjust It is critical for new printheads to run at the factory defau
223. or spring tension slightly too much tension may cause jams on light weight media 22 613 16 same as 22 613 05 22 614 06 Unexpected duplex sensor event Same as 22 514 05 22 638 14 Time out on preheat entry sensor duplex with media in exit cover 1 More than one sheet of paper in path a Media was pulled from exit into duplex while printing Multiple pick a Empty exit b Run again 2 Skew oop p Last sheet in tray First sheet in tray Failure of deskew system a Refill tray s b Make sure tray s is loaded properly and media is square in tray c Check deskew fingers If chronic check preheat entry assembly for deformation 3 Media perfectly straight Media path motor stall a Use diagnostics to run verify drive current requirements or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed Check electronics if needed 22 644 11 Time out on duplex sensor 1 Printer is pulling the paper from the customer a Customer tried to remove media after first side and didn t let it enter the duplex path a Train the customer 2 Media damage left lead corner a Hitting the left wall under control panel a Move front panel to left If necessary replace front panel assembly Replace printer if chassis warped 3 More than one sheet in duplex path 2 66 a Media was pulled from e
224. ory default values Navigation buttons Power ser Help Select button button 0388 10 Fig 1 15 Printer front panel General Information 1 23 Front Panel Phaser 860 These front panel features are found on the printer 128 x 64 pixel backlighted graphic display Four push buttons and two arrow buttons One LED status indicator LCD The backlighted LCD serves two purposes displaying the current image processor and print engine status information and displaying an interactive menu Status information includes an image processor status suchas Ready to print Receiving data and Printing Print engine status includes messages such as Out of paper Paper Jam Add ink and error messages Customers can review and modify certain I O ports and peripheral parameters Buttons Status Indicator light LCD Display Screen Cancel Back or Exit Scroll Up and Scroll Down OK P will display additional or help infromation regarding the message or menu item currently displayed on the screen Refer to Front Panel Shortcuts on page 4 119 for details on using the front panel controls to enter special printer modes The topic Resetting NVRAM on page 4 156 explains how to use the front panel buttons to reset the NVRAM to its factory default values 0726 42 1 2 4 6 7 Fig 1 16 Front Panel Phaser 860 1 24 Phaser 840 850 860 8200 Color Printer
225. ot directly sense the size or type of media Ensure the correct weight of paper is being used Refer Specifications on page 1 31 or the built in embedded page Paper Tips Ensure that envelopes are of the acceptable size and orientation with the side flap up Paper pick errors Paper pick errors occur when the media in the media tray mispicks or the printer double picks two or more sheets of paper 1 2 Inspect the paper path for obstructions Ensure that the media fits properly in the tray With the left edge of the stack of paper flush against the tray rail there should be a small gap between the opposite edge of the stack of paper and the opposite side rail The Phaser 860 has tabs on the back stop to prevent over filling the tray In humid environments keep media sealed in packaging until it is needed for printing Flip over the media in the tray When installing paper push down the stack of paper until the tray s lift plate locks to the bottom of the tray This prevents the top sheet of paper from being mis positioned as the tray is inserted in the printer Ensure the High Capacity Paper Tray lower tray assembly pick roller is installed correctly It can inadvertently be installed backwards Clean the pick roller using the cleaning procedures Pick Roller Cleaning Method on page 6 175 Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of the tray Als
226. own static b Someone opened a door a Run again b Close door 2 70 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 7 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 23 000 NVRAM SYSTEM FAULTS 23 003 65 SYS NVRAM PROG FAULT 3 Head Tweak Read Failed A read of the head tweak value from non volatile memory failed The tweak value is saved twice in NVRAM If the two values are different then this error is generated The most likely cause of this error is a corrupt NVRAM part 23 089 61 same as 23 003 65 SYS NVRAM PROG FAULT 0x59 23 133 60 NVRAM Corruption Detected On powerup the firmware checks SYS NVRAM PROG each NVRAM variable for validity Usually when this fault is FAULT 0x85 reported the printer has already wiped out the NVRAM contents to clear up the corruption Any user configurations will need to be reset 31 000 MOTOR FAULTS 31 001 4x MP FAULT AUX MOTOR ERROR Not used as a device fault condition 31 002 4x MP_FAULT_PROCESS_ MOTOR_STALL Not used as a device fault condition 31 003 4x MP_FAULT_PREHEAT_ EXIT_SENSOR_BAD Declared when the sensors around the preheater exit sensor indicate the presence or absence of media contrary to that indicated by the preheater exit sensor This is usually caused by a piece of media stuck in the preheater exit sensor 31 003 42 Use diagnostics
227. own reason T indicates whether a timeout or an event occurred 0 event An unexpected event occurred 1 timeout Time expired without the expected event occurring C indicates checksum Refer to the fault history when troubleshooting media jams this offers the quickest and easiest method of troubleshooting For the Phaser 840 printer 1 Pull the paper tray out about 1 inch 2 5 cms This activates all three tray sensors 2 Hold down the left arrow and press the help button This displays the fault history menu with the most recent code at the top For the Phaser 850 printer 1 Hold down the left arrow and press the help button This displays the fault history menu with the most recent code at the top For the Phaser 860 printer 1 Hold down the Scroll Up button and press OK Error Codes and Messages 2 59 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 22 101 06 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 2 Tray pulled out during printing a Tray not present b Static rear tray sensor a b Put tray back Use anti static spray made for office equipment or replace lower feeder 22 102 07 Sticky pick flag in Lower Feeder 2 with media picked from Lower Feeder 2 Use diagnostics to verify sensor operation 1 Media flat in tray a Excess friction in pic
228. p Question and Actions 1 No drive voltages to printhead Check for a loose connector leading to the printhead 2 Replace the Power Contol Board 3 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation 4 Replace the Printhead 3 88 Phaser 840 850 860 8200 Color Printer Service Manual Missing ink or light colored ink band running length of print Possible missing or weak jet ABCDEFGH JKLMNOPQRSTUV abcdefghijk mnopqrstuvwxyzab ABCDEFGH JKLMNOPQRSTUV abcdefghijki mnopqrstuvwxyzab 0388 42 Table 3 7 Missing or light colored ink band Step Question and Actions 1 Inspect the exit area for anything that may be touching the drum 2 Print the Service Test Print 2 Weak or Missing Jet to determine which jet is not performing If not already tried perform up to three printhead cleaning cycles to try to clean a clogged jet If unsuccessful turn off the printer and allow the printhead to cool for 4 hours Perform another cleaning cycle 3 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation See SF147 4 If weak or missing jet cannot be recovered replace the printhead Troubleshooting 3 89 Color is uneven This may be due to poor thermal regula
229. place maintenance drawer Try again cycle power or NVRAM reset d Check front panel sensors or replace front panel assembly e Replace power supply ooo 22 501 01 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in the front door area Same as 22 101 06 22 503 03 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in the front door area Same as 22 101 06 22 505 05 Unexpected standard tray sensor event with media in the front door area Same as 22 105 01 22 506 06 Unexpected standard tray pick flag event 1 Paper found in the front door and lower tray at the same time multipicks or 22 721 05 in the fault history a Standard tray pick roller a clutch slipping Replace the pick roller clutch see Service Bulletin 462 22 508 08 Unexpected preheat entry sensor left side event Can be caused by media off the sensor too soon a Verify that the lower tray is properly loaded 1 Skew a Last sheet in tray a Refill tray s b First sheet in tray b Make sure tray s is c Failure of deskew system loaded properly and media is square in tray c Check deskew fingers If chronic check preheat entry assembly for deformation 2 Media deformed or a Left trailing edge bent a Remove and inspect damaged in media tray b Hole or tear in media media and reload b Remove and inspect media and reload May be caused by 3 hole p
230. pplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 016 1875 00 Standard Transparency 50 sheets A4 size Phaser 860 016 1194 00 A size transparency pockets 016 1130 00 A size transparency sleeves 016 1131 00 A4 size transparency sleeves 016 1987 00 Premium Greeting Cards w envelopes letter 016 1988 00 Premium Greeting Cards w envelopes A4 Parallel Cable 013 0299 00 Parallel cable adapter 1284C to 1284B Kits and Guides 070 9102 00 Phaser 840 User Guide English 070 9102 10 Phaser 840 User Guide French 070 9102 20 Phaser 840 User Guide Italian 070 9102 30 Phaser 840 User Guide German 070 9102 40 Phaser 840 User Guide Spanish 070 9102 70 Phaser 840 User Guide Simplified Chinese 070 9102 80 Phaser 840 User Guide Traditional Chinese 070 9102 90 Phaser 840 User Guide Korean 070 9102 05 Phaser 840 User Guide Russian 061 4200 00 Z840 Designer Edition Manual Pack Welcome Kit User Guide Driver CD ROM 061 4201 00 Z840 Designer Edition Country Kit Cleaning Kit Setup Poster Parallel Cable Adapter ATM CD ROM 070 9103 00 Advanced Topics and Troubleshooting Manual English 063 3126 01 Adobe Type Manager CD SW 063 3166 00 Phaser 840 Drivers and Utilities CD SW 063 2627 00 Phaser 840 Drivers and Utilities Diskettes English 063 2627 10 Phaser 840 Drivers and Utilities Disk
231. printer does not power back on after waiting at least 10 seconds replace main board X 2 inch wide black stripe on every print ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 Black stripe is A Damaged printhead data 1A Reseat the printhead data composed of all 4 cable cable Replace the printhead colors and extends Failed main board data cable from very top edge 1B Reseat the main board of page to very Replace the main board bottom edge of page XI Squiggly vertical lines across entire print image ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 X axis motor not A Blown x axis fuse on 1A Replace the moving 840 only power control board 840 power control board 840 only only Appendix 259 XII False Jam Message Media Jam Remove Lower Tray to Clear ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 No paper present in A Lower Tray Assembly s paper path paper pick flag is hung up C Lower Tray Assembly fuse in power control board D Damaged Lower Tray Assembly connector located in back left corner of printer 1A See SF152 Locate the flag on the far left end of the Lower Tray Assembly s feed roller shaft Toggle the flag and make sure it rotates freely 1B See SF152 Cycle the printer s power a resettable fuse is in 840 printers with s n B9B1458 and above and all 850 printers If serial number is below B9B1458
232. printer exits the Energy Star mode m When customers initiate the Eliminate Light Stripes automatic cleaning procedure from the front panel Vacuum Vacuum dust from the top cover the metal heat duct over the printhead and plastic dust cover under the stripper fingers or rapid release guide Drum temperature sensor With a dry swab clean any buildup around the drum temperature sensor You can access the sensor through the opened exit cover Also make sure the sensor rides evenly on the drum surface You can remove the sensor if necessary to clean under it Cleaning and Maintenance 6 175 Maintenance Maintenance roller The printer uses the maintenance roller as part of its self maintenance routine to coat the print drum with oil before each print Table 6 1 Maintenance Kit Life Standard Startup Phaser 840 Phaser 850 Phaser 860 Phaser 860 Maintenance Kit Life Legal Size Any Coverage 10 000 10 000 10 000 10 000 Time Limit NA 24 Months 15 Months 15 Months Extended Phaser 840 Phaser 850 Phaser 860 Phaser 860 Maintenance Kit Life Legal Size 0 10 Coverage 30 000 45 000 40 000 30 000 10 25 Coverage 30 000 32 000 30 000 25 000 25 100 Coverage 30 000 23 500 20 000 18 000 Time Limit NA 24 Months 15 Months 15 Months Note The image coverage is determined by counting the number of pixels imaged Therefore higher resolution print modes will result in higher coverage calculations Prints made in High
233. printhead is installed Replace the printhead 4 016 68 PC_PROG_FAULT 0x10 Bad Message in main pc ready loop The main message loop in ready received an unexpected message while the printer was in ready state waiting for a command from PostScript Typically this message is an unexpected or out of order RESULT OK message that is the result of a previous command to one of the server tasks to accomplish some action like tilt the head back The odd behavior is that PC not waiting for the operation to finish 4 017 47 PC DEV FAULT AMBIENT TOO COLD Ambient temperature has fallen to less than 10 C Something may be wrong with a heater 4 018 48 PC DEV FAULT LATE CLEAN REQUEST After the printer determined at power up that the printhead was warm enough not to need cleaning and while the printer was warming up the printhead temperature dropped below the head clean needed threshold Something may be wrong with a heater 4 019 40 Calibration Failure Target Volt Sec Area of Fast Color mode PC DEV FAULT could not be achieved Check the printhead cabling Replace the 193DPI CAL printhead 4 020 41 Declared when the printer is booted and the head cap contact PC DEV FAULT FTTR H EADCAP flag is setin NVRAM The printer cannot run with the head and cap wipe purge unit in contact because it would be unwise to separate the two when the printhead is cold 4 021 42 PC DEV FAULT FTTR D IRTYDRUM
234. printhead mounting screws to 20 in lbs 6 Tilt the printhead back and install a gap clip on each end of the printhead When installed properly each clips hooks under BOTH metal edges on the corner of the printhead and touches the hard stop the inner edge of the sheet metal notch Try wiggling the clips sideways If properly installed they will not snap off Attach a gap clip to each end of the printhead Clips should touch hard Hook under both metal edges Partially installed lt f Ns 0388 85 Fig 4 5 Attaching clips 4 146 Phaser 840 850 860 8200 Color Printer Service Manual 7 Install the adjustment tension spring by hooking one end through the backside of the tilt arm stretching the spring and hooking the other through the hole in the printer frame bracket Note Due to the spring force stand in front of the printer to hold it in place while you pull the spring toward you to install it Hook through uu inside of tilt Grasp spring at this point Hook other end of spring through frame bracket Adjustment F Cv tension NN EN gt spring A Fig 4 6 Adjusting the tension spring Diagnostics and Adjustments 4 147 8 Loosen the four locking screws 1 2 turn Insert a screwdriver into the printhead adjustment slot and twist the screwdriver to adjust the printhead forward until the right gap clip is tight against the drum Use screwdriver in adjusting slot to push
235. product into a power source Terms on product CAUTION A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area Also applies to a hazard to property including the product itself DANGER A personal injury hazard exists in the area where you see the sign Care of product Disconnect the power plug by pulling the plug not the cord Disconnect the power plug if the power cord or plug is frayed or otherwise damaged if you spill anything into the case if product is exposed to any excess moisture if product is dropped or damaged if you suspect that the product needs servicing or repair and whenever you clean the product Ground the product Plug the three wire power cord with grounding prong into grounded AC outlets only If necessary contact a licensed electrician to install a properly grounded outlet Symbols as marked on product DANGER high voltage Protective ground earth terminal Use caution Refer to the manual s for information WARNING If the product loses the ground connection usage of knobs and controls and other conductive parts can cause an electrical shock Electrical product may be hazardous if misused Service safety summary For qualified service personnel only Refer also to the preceding Users Safety Summary Do not service alone Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or
236. pt Network or Operating System The PowerPC 603e processor used in the Phaser 850 and 860 can detect a number of exceptions that occur as a result of external signals on the Print Engine Controller Board other errors or unusual conditions during the execution of instructions A CPU exception can either be caused by hardware or firmware error Refer to infoSMART for descriptions of the most common faults 2 44 Phaser 840 850 860 8200 Color Printer Service Manual Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 2 000 SYSTEM FAULT I O BOARD 2 001 40 SY DEV FAULT IO RIGHT The engine cannot detect the presence of the right I O board Ensure the connections are sound 2 002 40 SY DEV FAULT IO LEFT The engine cannot detect the presence of the left I O board Ensure the connections are sound 2 002 61 SY PROG FAULT 2 Queue Initialization failure during execution of sy app init early initialization code the engine firmware was unable to initialize the queues used for inter task communication This indicates a failure in the call to function sy creat queues 2 003 62 SY PROG FAULT 3 Can t start service diagnostic tasks while booting into diagnostic mode during execution of sy app init early initialization code the engine firmware was unable to start the service diagnostics task 4 000 PC PROCESS CONTROL SUPERVISOR
237. r 860 Tray High volume transparency A size 436 0338 00 Tray High volume transparency A4 size Phaser 840 850 436 0412 00 Phaser 860 Tray High volume transparency A4 size 214 4595 01 Tray type sensing plugs 436 0413 00 Tray paper Legal size with Bail Phaser 860 381 0497 00 Legal size Paper Output Tray Bail Phaser 860 116 0838 00 Separator pad paper 016 1727 00 Extended maintenance cartridge kit roller and counter Phaser 840 016 1822 00 Standard maintenance cartridge kit roller and counter Phaser 840 850 016 1834 00 Extended maintenance cartridge kit roller and counter Phaser 850 016 1933 00 Standard maintenance cartridge kit roller and counter Phaser 860 016 1932 00 Extended maintenance cartridge kit roller and counter Phaser 860 436 0370 01 Waste ink tray Phaser 840 850 436 0315 00 Waste ink tray Phaser 860 Media 016 1368 00 A size paper 500 sheets 016 1369 00 A4 size paper 500 sheets 016 1724 00 Premium Transparency 50 sheets A size Phaser 840 850 016 1725 00 Premium Transparency 50 sheets A4 size Phaser 840 850 016 1720 00 Standard Transparency 50 sheets A size Phaser 840 850 016 1721 00 Standard Transparency 50 sheets A4 size Phaser 840 850 016 1876 00 Premium Transparency 50 sheets A size Phaser 860 016 1877 00 Premium Transparency 50 sheets A4 size Phaser 860 016 1874 00 Standard Transparency 50 sheets A size Phaser 860 FRU Parts List 8 229 Table 8 11 Su
238. r Bands RGBK Dither Reverse Text aen i Big Bands Hand fed sss ener 66 Gray dot size uniformity esssseseseeee eren 5 163 Manuf Dot position scanner eene 5 164 YMCKRGB Solid rtr pe e tr reines 5 164 9 Drum Seal oen ees 10 Manuf paper path 11 Head to Drum Gap 12 Manuf x axis scanner ennt 5 166 13 Black Solid OT rr 14 Red Solid Fill essere nennen 15 Green Solid Fill jase iia Rosas Era ERAS Rear 16 Blue Solid 172 Cyan Solid EP 18 Magenta Solid Fill i 19 Yellow Solid Fill eter ntt ttt reete te tede 20 OHP Color Ree m tits 2 Primary Solid Fills 10 rene eee e iren 5 171 Contents iii 22 Manuf Skew Margins sees eren entente ia a E 5 171 232 Manus Banding erii rd eie tete hti cit et dee ERO e 5 171 Cleaning and Maintenance 6 173 Cleaning X 6 174 Pick Roller Cleaning Method 9 26 175 Cleaning Page Phaser 840 printer 6 175 iat AE 6 175 Drum tem perature sSensOF ues teres esten e de deo ree Eee TES MAR M Vea bre geepus 6 175 Maintenance utet dmi ptem edendi mou ni 6 176 Mamtenance roller eei trie tr intent tet ereiaro 6 176
239. r appears to be shorted Replace the TCD THERMISTOR drum temperature sensor SHORT 15 003 44 The drum heater is running away Unplug the printer NOW TCD THERMISTOR Verify that the vent on the right side of the printer is not blocked HOT Ensure that the drum fan rotates and is installed correctly Error Codes and Messages 2 57 Table 2 4 Front Panel amp Fault History Log Error Codes and Messages Error code Definition 15 004 45 TCD THERMISTOR SLOW Most likely cause is a failed drum heater The head to drum gap should only be checked or adjusted on the Phaser 840 The Phaser 850 and 860 have a pre adjusted head 16 000 PREHEATER THERMALS Preheater thermal faults are determined by a thermistor in contact with the preheater Ensure that there is adequate clearance for airflow at least 4 inches 10 cms on all sides and that the room temperature is below 90 F 35 C 16 000 40 TCD_THERMISTOR_ FAULT The preheater temperature is incorrect as sensed by the a thermistor in the preheater Ensure that there is adequate clearance for airflow at least 4 inches 10 cms on all sides and that the room temperature is correct 16 001 43 TCP_THERMISTOR_ OPEN The preheater thermistor appears to be open Check the preheater cables on the right side of the printer Replace the paper preheater Replace the power supply 16 002 44 TCP_THERMISTOR_ SHORT The preheater thermistor appears to
240. r feeder 1 1 Media perfect in media path a A paper tray or door was a Avoid opening trays or open doors during printing b Worn maintenance drawer b Replace Maintenance lift pins Drawer c PostScript Fault c Try again cycle power or d Front Panel error NVRAM reset e Power Supply problem d Check front panel f Possible ESD event affecting sensors or replace front Lower Feeder Sensors panel e Replace power supply f Use anti static spray for office equipment 22 201 08 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 1 Same as 22 101 06 22 203 00 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in Lower Feeder 1 Same as 22 101 06 22 204 00 Sticky pick flag in Lower Feeder 1 with media picked from Lower Feeder 1 Same as 22 102 07 22 204 12 Time out on pick flag of Lower Feeder 1 with media picked from Lower Feeder 1 Same as 22 102 18 Verify that the lower tray is properly loaded Use diagnostics to verify pick roller motion 22 205 02 Unexpected standard tray sensor event with media in Lower Feeder 1 Same as 22 105 01 22 206 14 Time out on pick flag of main printer with media picked from Lower Feeder 1 Same as 22 104 11 Verify that the lower tray is properly loaded Use diagnostics to verify pick roller motion 22 301 01 Unexpected Lower tray present sensor event in Lower Feeder 2 with
241. r to Test Prints on page 5 159 Note Refer to Service Bulletin 447 for additional information 4 148 Phaser 840 850 860 8200 Color Printer Service Manual X axis scale adjustment This adjustment sets the gain or rate of travel of the printhead s x axis movement Perform this adjustment To correct thin parallel pin stripes running the length of the page appearing evenly spaced across the width of the page not due to a weak or missing jet m Anytime the NVRAM chip Phaser 840 printer or BootROM Printer ID chip Phaser 850 860 printer is replaced W Anytime an X axis component is replaced Allow the printer to warm up to its idle Ready to Print state Enter the Hidden Service Menu for all printers for more information on accessing the Hidden Service Menu go to page 4 119 Scroll to the service menu item Test Prints and press Select or OK Choose the test print X axis Motion and press Select or OK to print it Interpret the second of the two X axis motion prints The print features four purple columns each containing a jagged black band The black bands should all align horizontally with each other 5 If an adjustment is needed scroll to the menu item Set X axis Scale Change the displayed value to a new value if necessary as indicated by the test print A N Increase scale Correct Decrease scale adjust to raise adjust to lower center bars center bars 0388 67 Fig 4 8 Adjusting th
242. r to print brilliant colors on plain paper Each Xerox solid ink printer s inks are especially formulated for that printer the inks are NOT interchangeable Using the wrong ink in a printer may damage the printhead or other subsystems The Phaser 860 uses the ColorSticks II ink formulation which enables solid ink documents to be fed through auto document feeders on copiers Note Turning the printer off and allowing it to cool causes it to perform a printhead cleaning and purge cycle upon power up The printer s purge cycle consumes a significant amount of ink During normal use and servicing turn the printer off and allow it to cool only when necessary 1 6 Phaser 840 850 860 8200 Color Printer Service Manual Phaser 840 850 RAM and Printer Capabilities The Phaser 840 printer features two DIMM connectors which accept both 32 or 64 Mbytes RAM DIMMs 16 Mbyte RAM DIMMs work but are not offered The Phaser 850 printer features two DIMM connectors which will accept both 64 or 128 Mbytes RAM DIMMs The printers can use SDRAM DIMMs meeting these specifications 168 pin DIMM Synchronous DRAM 3 3 volts 10 nsec speed Valid on board Serial Presence Detect ROM Unbuffered Latency of 2 9 address columns Phaser 850 printer allows 32 Mbytes DIMM to be in 8 columns Maximum of 2 8 cm 1 1 in in height Phaser 840 printer only SDRAM DIMMs from other Phaser printers such as the Phaser 740 and Phaser 780 color printers may be too
243. rd PhaserShare Series B Network Card One card provides a LocalTalk port A second alternative card offers a 10 100BaseT 10Base2 Ethernet board providing standard protocol support for EtherTalk Novell NetWare NDS TCP IP and DHCP When installed this card disables the standard 1ObaseT port A third card provides a Token Ring board providing protocol support for TokenTalk Novell NetWare NDS and TCP IP When inserted this card also disables the standard 10baseT port A second rear panel slot accommodates an internal IDE hard drive for print job collation job accounting and font storage The printer features Job Accounting which maintains from 50 to 5000 records of processed print jobs depending on memory options and hard drive options The record contains information such as time and duration of the print and the percentage of color coverage on the print The log of records can be retrieved using PhaserLink PhaserShare or CentreWare IS software General Information 1 3 Phaser 850 Printer Overview The Phaser 850 Color Printer is an Adobe PostScript Level 3 Version 3010 color solid ink printer It also supports color PCL 5c at 600 x 600 dots per inch resolution The Phaser 850 printer prints at a number of resolutions A 13 9 page per minute ppm Fast Color Mode a standard 7 9 ppm mode an Enhanced mode of 450 x 818 dpi with dot size switching at 4 ppm and a High Resolution Photo mode of 600 x 1200 dpi at 2 2 ppm The printer also
244. re An attempt to read the non volatile memory on the printhead via the I2C interface failed This can happen if the wires are loose to the printhead or if the NVRAM part does not ACK the read request 12 000 INTER TASK COMMUNICATION PROGRAM FAULT CODES 12 002 62 ITC PROG FAULT 2 This is a secondary failure Something failed resulting in the message stack overflowing Unable to Send Message The ITC send message function itc send msg was unable to place the specified message in the destination message queue msgQSend returned fail code A full message queue is most likely the cause 13 000 PRINTHEAD THERMAL CONTROL TASK PROGRAM FAULT CODE Printhead thermal faults are determined by a thermistor in the printhead Ensure that there is adequate clearance for airflow at least 4 inches 10 cms on all sides and that the room temperature is below 90 F 35 C Use diagnostics to verify that the thermals are changing 13 001 40 The thermistor in the left jet stack appears to be open Check the TCH JS LEFT OPEN printhead cabling Replace the printhead 13 002 41 The thermistor in the left jet stack appears to be shorted Check TCH JS LEFT SHORT the printhead cabling Replace the printhead 13 003 42 The left jet stack heater is running away Unplug the printer TCH JS LEFT HOT NOW Check the printhead cabling Replace the printhead 13 004 43 The left jet stack heater is not heating at all or is heating t
245. ries Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 016 1845 00 Cleaning Kit Ink 016 1604 00 Phaser 840 Black Ink 3 pack 016 1605 00 Phaser 840 Cyan Ink 5 pack plus 2 black sticks 016 1606 00 Phaser 840 Magenta Ink 5 pack plus 2 black sticks 016 1607 00 Phaser 840 Yellow Ink 5 pack plus 2 black sticks 016 1608 00 Phaser 840 Rainbow pack 1 stick each color 016 1582 00 Phaser 840 Cyan Ink 2 pack plus 1 black sticks 016 1583 00 Phaser 840 Magenta Ink 2 pack plus 1 black sticks 016 1584 00 Phaser 840 Yellow Ink 2 pack plus 1 black sticks 016 1831 00 Phaser 850 Black Ink 3 pack 016 1825 00 Phaser 850 Cyan Ink 5 pack plus 2 black sticks 016 1826 00 Phaser 850 Magenta Ink 5 pack plus 2 black sticks 016 1827 00 Phaser 850 Yellow Ink 5 pack plus 2 black sticks 016 1833 00 Phaser 850 Rainbow pack 1 stick each color 016 1828 00 Phaser 850 Cyan Ink 2 pack plus 1 black sticks FRU Parts List 227 Table 8 11 Supplies and accessories Parts Part number Serial number Qty Name and description Effective Discont d 016 1829 00 Phaser 850 Magenta Ink 2 pack plus 1 black Sticks 016 1830 00 Phaser 850 Yellow Ink 2 pack plus 1 black sticks 016 1902 01 Phaser 860 Black Ink 3 pack 016 1903 01 Phaser 860 Cyan Ink 5
246. rmance clutch disengage ID 6 time Wipe to Home 6 return time Oil to home return 7 time Wipe to Home 8 cycle time Wipe to Home 9 cycle position Oil to Home cycle 10 time Oil to Home cycle 11 position Wipe drag 12 High values may indicate a mis installed Maintenance Roller though some failures have been gt 19 seen within the normal operating range 13 Oil drag Lower values may indicate worn lt 9 or broken maintenance drawer lift ears though some failures have been seen within the normal operating range Diagnostics and Adjustments 4 131 Table 4 4 Check Menu Value Key Test ID Cap Vacuum IDs 7 assembly Test ID Cap Axis Geometry IDs 8 Test ID Cap Axis Drive ID 9 R 0 Cap Vacuum Test ID 7 This test uses the head tilt mechanism to measure the vacuum decay time Refer to the printhead troubleshooting section or the Printhead checklist for detailed troubleshooting steps Results gt 200 lt 20 Definition No vacuum pull current Interpretation Actions Something may be obstructing the printhead tilt mechanism gt 1600 lt 40 Slack take up postion Something may be obstructing the printhead tilt mechanism Cap Axis Geometry Cap Axis Drive Test at low current levels to dete Test gt 8000 There may be a problem with the air solenoid or clogged tubbing
247. rmed up and the temperatures are stable before taking the measurement 5 Drum 60 2 4 134 Phaser 840 850 860 8200 Color Printer Service Manual Check Value Menu Parameters How to change parameters Pressing OK will initiate the current test using the indicated parameter values Pressing the Down and Up buttons may be used to review and or modify the parameter values The current parameter if any is indicated by a gt symbol If there is no gt symbol present pressing OK will initiate the current test using the indicated parameter values Parameters may be integers floats neumonics or strings Pressing i with a gt symbol present but not blinking will provide a description of the indicated parameter Pressing OK with a gt symbol present will open the indicated parameter for modification it begins blinking Pressing i with a parameter open will provide a description of the parameter modification process Pressing Cancel with a gt symbol present but not blinking will reset the indicated parameter to its default value While a parameter is selected blinking the value may be modified Modifications are restricted so that the value stays within the minimum and maximum limits for the parameter Button presses are ignored if the resulting value would violate the limits Integer Parameters The value may be modified on a per character basis The initial character selected is the least significant charac
248. rted media and Paper Path Timing properly seated 3 Tray 3 feed motor ID 17 to tray 1 pick flag The paper is not being picked 4 Tray 2 pick motor gt 850 reliably Ensure that the paper is to tray 2 pick flag not too heavy and the tray is properly loaded 5 Tray 2 feed motor to tray 1 pick flag The paper is not being picked reliably Ensure the paper is not 6 Tray 1 pick clutch gt 800 too heavy The pick roller may be to tray 1 pick flag contaminated with paper debris and coatings from specialty media try cleaning the roller and pick pad 4 128 Phaser 840 850 860 8200 Color Printer Service Manual Table 4 4 Check Menu Value Key Test ID Paper Path Timing IDs 4 Definition Tray 1 pick flag to preheat entry flag Results gt 1000 Interpretation Actions Paper is not feeding smoothly through the paper path or is skewed If the paper came from a lower tray ensure the tray is loaded properly to eliminate skew Check the paper path for obstructions and verify the front door deskew fingers are not damaged Preheat entry flag to width A flag gt 20 lt 10 Paper may be excessively skewed or damaged bent or torn corner Ensure proper tray loading and verify media is in good condition Feed clutch to width A4 flag gt 210 lt 180 Media was deskewed successfully Ensure proper tray loading and verify front door deskew fingers are not damaged This may
249. s There are four clutches the paper pick roller clutch the upper feed roller clutch the maintenance drawer cam clutch and the cap wipe purge clutch Symptoms of a malfunctioning clutch are the printer not picking paper from the tray or other paper jams Also the cap wipe purge system could fail In such cases replace the clutch Intermittent jams are often caused by failing clutches 6 178 Phaser 840 850 860 8200 Color Printer Service Manual Key FRU Removal and Replacement This topic illustrates how to remove and replace key printer Field Replaceable Units FRUs For more detailed removal replacement procedures refer to the Color Printer Service amp Support Resources CD ROM Procedures included here are E Main board and its components Power supply Power control board Upper feed roller assembly Preheat drum heater assembly B Drum transfix assembly Drum position sensor assembly E Printhead E X axis motor and drive assembly Y axis belt drive assembly Cap wipe purge assembly This topic concludes with a discussion about printhead locking 7 180 7 183 7 184 7 185 7 187 7 188 7 192 7 196 7 199 7 200 7 202 Removal and Replacement Procedures 7 179 Main board and its components Phaser 840 printer 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges Remove the interface cables Loosen the two rear panel securing screws S
250. s F1 F2 and F3 to line If open replace power supply 2C Check for shorted motor drivers on power control board as in step 1a Appendix 253 Il Blank Display Front panel Lights ON Rear LEDs static ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS follow in order 1 Condition started after recent upgrade A Main board not seated correctly B Code DIMM not seated correctly C Possible bad upgrade D ESD damage to main board 1A Remove and reseat main board 1B Check for shorted motor drivers on power control board by removing 40V jumper and replace it with 40V Service Plug 1C If the printer powers up with 40 V Service Plug put the 40 V jumper back in place and systematically remove cables from power control board until the printer does power up replace the appropriate part If printer still does not work after removing cables from the power control board replace the power control board 1D If the printer does not power up with 40 V Service Plug replace the power supply If it still does not power up with new power supply replace main board 2 Noreaction to power switch fan does not move lights don t blink A Main board secondary component failed B Failed I O board 2A Replace main board 2B Replace I O Right or I O Left Laptop based diagnostics may help determine which has failed 3 PS amp PELEDs stay on never toggle A Code ROM DIMM mis
251. s not where it should be YA POS FAIL Something is blocking the motion of the drum the y axis belts or motor have failed or there is a problem with the Y axis encoder signal Run the Y axis Encoder and Y axis Geometry Tests 5 005 67 Bad ITC command in home state The YA task received a YA BAD MESSAGE IN HOME YA CMD INIT command or a unrecognized command while in the home state 5 026 61 YA NO RENDEZVOUS IN IMAGE Missed ITC message during rendezvous The YA task failed to receive the rendezvous message to sync the drum motion to paper path motion during transfix at the end of a print This is probably caused by the printer unexpectedly entering a fault condition and not sending a rendezvous message 6 000 X AXIS TASK PROGRAM FAULT CODES 6 000 41 XA FAULT MCURRENT Indication that the motor coil s is open or shorted or the X axis motor fuse has opened Follow the procedure Testing motor and solenoid resistances on page 84 of this manual Try diagnostics to verify X axis movement If there is not any movement it is propable that the fuse is defective The fuse is located in the power control board the whole baord should be replaced Some Phaser 840 printers in the serial number range of B9B1372 to B9B3218 may have a problem with the Power Controller Board that will result in a fault code 6 000 41 see SF146 for more details 6 001 42 Indication that the motor coil s is open or shorted or the X
252. s of memory standard PA 242 Phaser 840 850 860 8200 Color Printer Service Manual Appendix This section contains the Printhead and Electronic checklists for the Phaser 840 850 and Phaser 860 8200 Phaser 340 350 360 380 840 850 Printhead Checklist W Electronics Checklist Phaser 860 8200 Printhead Checklist W Electronics Checklist Disclaimer These checklists were current as of May 2001 if the checklist included in the FRU is a newer version it supercedes the checklists included here Appendix 243 ON SITE PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 340 350 360 380 840 850 Version 2 4 NAME OUT REQUEST ID DATE SERVICE COMPANY if no OUT REQUEST ID PHONE IMPORTANT This checklist outlines proper printhead troubleshooting procedures and should be performed by all Xerox employees and any other service personnel on any job involving printhead replacement The completed checklist and sample test prints are to be returned with each printhead Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed checklist and a sample print with each returned printhead As the On site Printhead Troubleshooting Checklist is a complex procedure it has been organized into three sections the Initial Checklist the Cap Wipe Purge Checklist and the Non Xerox Tektronix Ink Failure Checklist Please return the following items with the defective printhead Wi Service Print 2 not
253. s the tool firmly against the printer frame to set tension 4 143 Setting the Y axis belt tension Phaser 850 860 4 145 Attaching clips 4 146 Adjusting the tension spring 4 147 Drum adjustment 4 148 Adjusting the x axis scale adjustment 4 149 Aligning timing the cap wipe purge assembly drive belts 4 151 Setting the drum position encoder gap 4 153 Adjusting the transfix roller pressure springs 4 154 Connecting the vacuum gauge to the printer 4 155 Resetting print engine menuitem 4 157 Clearing PostScript menuitem 4 157 Lubricating the transfix cam 6 177 Removing the Phaser 840 printer main board 7 180 List of Figures ix Removing the Phaser 850 printer main board 7 181 Removing the Main Board Phaser 860 7 182 Removing the power supply 7 183 Removing the power control board 7 184 Remove the upper feed roller assembly left side 7 185 Removing the upper feed roller assembl
254. sembly motion is performed and the assembly is returned to its home position 12 After the print engine is in a known valid state The AC heaters are enabled and the front panel display shows the warm up progress The Ready LED flashes when warm up completes the Ready LED lights solid 13 The drum begins to rotate 14 If the temperature of the printhead ink reservoirs or jetstack are below the purge threshold then the printer performs a head clean cycle a When the ink in the printhead is molten and printhead temperatures are correct the cap wipe purge assembly is positioned to the purge position b The printhead tilts forward against the cap wipe purge assembly and a purge cycle begins C The front panel indicates the printer is in a clean cycle 15 The temperature of the printhead drum and paper preheater are allowed to stabilize at their operating temperatures and ink is melted if needed 16 If needed a cleaning page is printed at this time 17 A start page is printed if enabled 18 The front panel displays a message that the printer is initializing and then ready The print engine is initialized Troubleshooting 3 79 Inoperative printer problems Refer to Appendix Electronics Troubleshooting Checklist The printer shuts down with the power switch on The printer may have experienced a spurious over current event If the printer powers up within 2 seconds do nothing If the printer powers up after 6 seconds th
255. sensor s flag when CAP FAULT HOME _ expected The home sensor may be faulty or the paper feed SENSOR motor may not be operating The cap wipe purge clutch may be see SB464 failing or the assembly may be jammed and unable to move Inspect check the paper exit drive belt and the gear on the right end of the duplex roller shaft next to the paper path motor Ensure that the paper path is free of media For the Phaser 860 only run the Cap Axis Geometry and Cap Axis Drive diagnostic tests 8 001 44 C W P can t find home Check alignment of C W P assembly belts Align the C W P Does belts aligned assembly belts error clear OK With C W P out of home position observe exit roller while turning on the printer Inspect paper path Does the motor drive train and exit roller turn exit roller drive belt gears and bushings Replace or reseat defective parts Drive train OK With C W P out of home position observe C W P Measure resistance assembly motion while of paper path motor turning on the printer Does C W P assembly move at all Replace C W P clutch or reseat belt Resistance approximately 2 Ohms Replace paper path motor Is C W P home sensor flag functional Replace I O right board 0388 84 Replace power control board Replace or reseat flag Error Codes and Messages 2 53 Ta
256. sensor tests to locate the blocked sensor 31 044 60 Bad Message in mp_sleep_for While the media path task was in the process of delaying for acertain period of time it received an unexpected inter task communication message This error can occur due to a bad sensor like the preheat exit flag 31 049 65 31 058 65 Bad message during auxillary tray pick This is a program fault from the media path task It most likely indicates a problem with a sensor while feeding paper from an auxillary tray While the media path task was in the process of picking paper out of the auxillary tray it received an unexpected inter task communication message This error can occur due to a bad sensor or sensor bouncing for example the auxillary tray pick flag Error Codes and Messages 2 71 Blank Page 2 72 Phaser 840 850 860 8200 Color Printer Service Manual Troubleshooting The troubleshooting section discusses Repair Analysis Procedures RAPs for the Phaser 840 850 860 printers This section is broken into the following groups W Network Event Logs Electrical Interface Problems Media and Paper Path Problems Printing and Print Image Quality Problems Windows Printing problems Macintosh Printing problems Cap Wipe Purge Troubleshooting Evaluating and troubleshooting the printhead cap wipe purge system can be found on page 106 Electrical Interface Problems RAP Table Table 3 1 Electrical Interface RAP Table
257. sing B Main board critical component failed 3A Reseat the Code ROM DIMM Replace the Code ROM DIMM 3B Reseat the main board Replace the main board 4 Condition started after printhead was replaced A Printhead data cable is disconnected or power control board connector has a bent pin B Power supply connector C Power control board pin D Contaminated edge connector on the main board 4A Confirm the printhead data cable is connected and seated properly to the power control board If it already is then remove the cable and inspect for bent pins on the power control board s connector If possible straighten pins If not then replace the power control board 4B Remove the power supply inspect connector If it is damaged replace the power supply 4C Remove the power supply and inspect the power control board pins where the power supply connects If the pins are bent bend them back into place if possible If not possible replace the power control board 4D Inspect the main board s edge connector If residue is present clean 254 Phaser 840 850 860 8200 Color Printer Service Manual Blank Display Front Panel Lights ON Rear LED flashing Confirm that all DIP switches are up ADDITIONAL CLUES PROBABLE ROOT CAUSE NOTE On the Z850 the SDRAM error codes will also flash on the front panel error LED ACTIONS follow in order SDRAM Error Codes 2 6 See page 29 in the
258. sion spring bracket Note A metal clip attaches the spring to the Y axis drive assembly the spring DOES NOT attach directly to the plastic housing of the Y axis drive assembly Refer to the illustration on page 7 201 3 While the belts are under tension rotate the drum pulley 5 times to rotate the belts and seat them in place For an old Y axis drive assembly continue rotating the pulleys until the index marks on each pulley align next to each other 4 Beginning with the upper right screw tighten the three mounting screws to 30 in lbs to secure the Y axis drive assembly in place 5 For new Y axis drive assembly Phaser 850 Using PC based diagnostics run the test Position for Belt Tightening in the Y Axis Group test suite This positions the belts in the proper orientation for re tensioning Do not move the pulleys For the Phaser 860 Use the adjustment from the service menus 6 Place an index mark on the edge of each pulley Mark the Y axis drive pulley and the drum pulley where the edges are closest to one another disregarding previous marks Use a distinct color if the pulleys have been previously marked 7 Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re tighten the screws to 30 in lbs 8 Reassemble the printer and make a test print 4 144 Phaser 840 850 860 8200 Color Printer Service Manual after setting tension Mark the pulleys a Y axis belt assembly
259. sor flag Phaser 840 650 4156 00 1 Paper out sensor flag Phaser 850 860 8200 5 650 3618 00 1 Paper pick flag Phaser 840 650 4156 00 1 Paper pick flag Phaser 850 860 8200 6 650 3618 00 1 Hand feed sensor flag inside front access cover Phaser 840 650 4156 00 1 Handfeed sensor flag inside front access cover Phaser 850 860 8200 7 351 1047 00 1 Preheat entry left edge sensor A size sensor hand feed sensor Phaser 840 351 1106 00 1 Preheat entry left edge sensor A size sensor hand feed sensor Phaser 850 860 8200 8 119 5803 00 1 Preheater exit sensor assembly 9 119 4968 00 1 Process gear sensor 10 650 3622 00 1 Y axis encoder kit Phaser 840 650 4144 01 1 Y axis encoder kit Phaser 850 860 8200 11 650 3618 00 1 Transfix exit sensor flag Phaser 840 650 4156 00 1 Transfix exit sensor flag Phaser 850 860 12 Part of Front cover Control Panel 650 4028 00 1 Front cover open sensor Phaser 840 650 4121 00 1 Front cover open sensor Phaser 840GP 650 4143 00 1 Front cover open sensor Phaser 850 650 4216 00 1 Front cover open sensor Phaser 860 8200 13 Duplex paper sensor flag part of Front Cover Control Panel 14 Part of Front cover Control Panel 650 4028 00 1 Duplex paper sensor Phaser 840 650 4121 00 1 Duplex paper sensor Phaser 840GP 650 4143 00 1 Duplex paper sensor Phaser 850 650 4216 00 1 Duplex paper sensor Phaser 860 8200 15 Part of Front cover Control Panel 650 4028 00 Exit cover open sensor Phaser 840 650 4
260. spect inside the cap for ink build up a lot of built up ink inside the cap indicates that the heater is not melting it out The ink built up interferes with the wiper compressing and can prevent the cap wipe purge assembly from sealing on the printhead 8 Another way to evaluate a cap wipe purge assembly gasket leak is to examine the distribution of ink in an empty waste bin following a purge cycle When the system is sealing properly a purge cycle produces approximately 18 mm 3 4 in of ink across the waste tray Note The purge mass for the Phaser 860 will be approximately half the volume due to new ink saving features Fig 3 5 Maintenance tray showing good purge If the vacuum system suffered from low vacuum either caused by a poorly sealed gasket a failing vacuum pump or a clogged vacuum tube then you will see significantly less waste ink in the waste tray Troubleshooting 3 111 Troubleshooting following cap wipe purge installation After installing a new cap wipe purge assembly up to 6 front panel initiated clean cycles may be required before the cap wipe purge assembly gasket seals properly 1 Be sure to verify the new cap wipe purge assembly performance by completing the vacuum and decay time checks discussed earlier 2 Test for print quality After installing a new cap wipe purge assembly test its performance by printing Service Test Print 2 to check for weak or missing jets If print quality is not satisfactory
261. t Level 3 Version 3010 color solid ink printer It also supports color PCL 5c at 600 x 600 dots per inch resolution The Phaser 840 printer prints at a number of resolutions A 10 page per minute ppm Fast Color Mode a standard 5 7 ppm mode an Enhanced mode of 491 x 982 dpi at 3 3 ppm and a High Resolution Photo mode of 600 x 1200 dpi at 2 2 ppm All printer models but the standard version feature built in automatic two sided printing Standard Phaser 840N The Standard Phaser 840 printer features 136 built in fonts and is equipped with 32 Mbytes of RAM It can be upgraded to as much as 128 Mbytes of RAM using any combination of two 32 and 64 Mbyte RAM DIMMs The Phaser 840DP The Phaser 840 DP printer option upgrades the base printer to 64 Mbytes of RAM It includes a SCSI port daughter card to support an external SCSI disk for additional font storage as well as a scanner Special circuitry on the SCSI port daughter card enables additional features like duplex printing job pipelining and First page Preview mode With job pipelining the printer can print one image and process the data for the next image at the same time First Page Preview mode prints the first page of a multiple page print job while holding the remainder of the job pending front panel approval The Phaser 840DX The extended features option has all the features of the Phaser 840 Plus printer but includes additional RAM to bring the printer to 128 Mbytes of RAM It also i
262. t History Log Error Codes and Messages Error code Definition 11 033 65 DMC PROG FAULT 33 Motion Control Event Missed A missed control store event was detected A health check routine is called every 400 milliseconds the A D update period and checks that all the currently pending hardware motion profile events are for some time in the future If one is pending for a time in the past then it generates this error A missed DMC interrupt due to interrupts disabled too long by any region is a probable cause 11 034 66 PROG FAULT 34 Motion Control Done Timer Too Late A motion control profile done event could not be programmed It was too late for the software to program the done event for a motion profile handled by control store event hardware This error indicates that DMC interrupts were disabled for a long period of time Almost always this happens when a non engine region generates a CPU exception during printing The operating system processes CPU exceptions with interrupts off and the processing takes a long length of time The user should check the task name saved with this fault to identify the culprit 11 038 61 DMC PROG FAULT 38 A D Input Out of Range This error is generated during MEDUSA ASIC analog to digital calibration and indicates that one or more of the A D mixed inputs 5 volt 40 volt or 3 3 volts are out of tolerance 11 039 62 PROG FAULT 39 Printhead NVRAM Read Failu
263. t panel Media jams Most media jams cannot be fixed by cleaning refer to Media and Paper Path Problems RAP Table on page 3 73 Problem type Solution Paper pick or jamming Clean the pick roller Follow the Pick Roller Cleaning Method problems at the tray on page 6 175 Paper jamming problems at Clean the transport rollers Use the blue thumbwheel on the the front door duplex roller to manually rotate the rollers Paper jamming problemsat Clean the exit rollers the stripper fingers or rapid release guide the exit Use the blue thumbwheel on the duplex roller to manually rotate the rollers Paper pick or jamming Clean the High capacity Paper Tray Assembly feed roller problems at the tray of the High capacity Paper Tray Assembly Duplex path jam Clean the preheat duplex and exit rollers Use the blue thumbwheel on the duplex roller to manually rotate the rollers Double picks Clean pick pad with clear packaging tape using the procedure Pick Roller Cleaning Method on page 6 175 6 174 Phaser 840 850 860 8200 Color Printer Service Manual Pick Roller Cleaning Method Use off the shelf clear packaging tape and follow the procedures listed below to clean the Phaser 860 Upper Tray Pick Roller and Pick pad This new cleaning method has been found to be extremely effective for removing debris Isopropyl alcohol tends to smear the debris rather than remove it Note Use extreme caution with
264. tches and Sensors on the left side of the print engine 1 18 Solenoids clutches on print engine 1 19 Features of the Phaser 840 printer main board 1 21 Features of the Phaser 860 Main Board 1 22 Features of the Phaser 850 printer main board 1 22 Printer front panel 1 23 Front Panel Phaser 860 1 24 Phaser 840 printer rear panel 1 25 Phaser 850 printer rear panel 1 26 Phaser 860 printer rear panel 1 27 Attaching the service load connector to J250 3 83 Faceplate showing blade wipe with no drops smudges streaks 3 107 Faceplate showing streaks and smudges from a poor wipe 3 107 Connecting the vacuum gauge to the printer 3 108 Maintenance tray showing good purge 3 111 Damaged printhead data cable 3 113 Inadvertently disconnected thermistor cable connector 3 114 Setting process belt tension 4 139 Setting exit roller drive belt tension 4 141 Pull the lever arm and pres
265. tems in this group passively monitor the current printer state Sensors Reports changes in sensor states interactively Temps Displays current heater temperature and the setpoint Heaters Displays current heater state on of and of power being applied Line Voltage Displays the current maximum and minimum line voltage Ink Levels Displays the current ink levels Front Panel Buttons Reports front panel button presses interactively Rear Panel DIP Switch Reports rear panel DIP switch settings interactively Exercise Menu Items in this group activate the specified device for manual verification Activators See Above Motors Shafts See Above Heaters See Above Front Panel Display Cycles through the LED s and all display pixels on off X Axis Moves the X axis through its full range of motion Transfix Axis Performs a transfix cycle DM Cam Axis Moves the drum maintenance system through its full range of motion Cap Axis Moves the cap wipe purge through its full range of motion Function Menu The tests in this group perform higher level system wide functions Chase Runs a chase sheet through the paper path Unlock DM Tray Positions the cap wipe purge to unlock the maintenance drawer Position Y Axis for Belt Adj Aligns the Y axis pulleys to achieve maximum force when tensioning the belts Display Test Fault Details Displays information about the most recent test fault message if available DM Cycle Performs a drum maintenance cycle Oil
266. ter Repeat the DOS test above Connect a different computer to the printer directly with a parallel cable Repeat the DOS test above C3 Refer to infoSMART or the on line service files for additional information on verifying communication with the printer in other environments Once the hardware is verified follow your standard procedures to assist the customer with their network or host computer or refer them to the local Xerox customer support center for software support Ifthe hardware cannot be verified using the above steps reseat the main board and try the steps again If the hardware still fails replace the main board Appendix 269 270 Phaser 840 850 860 8200 Color Printer Service Manual 071 0723 00
267. ter For the most significant character pressing Up or Down will change the selected character in the respective direction around the following ring 0123456789 The selection will not advance if the new selection would cause the value to be out of range For other than the most significant characters the and characters are not included Pressing Back or Cancel buttons moves the character selection within the parameter If the current selection is the most significant character pressing the Back button will add a leading 0 to the parameter The number of leading 0 s is limited to the remaining space on the display line Floating Point Parameters Modification behavior is the same as for integer parameters except that a decimal point may be specified at any digit postion Multiple decimal points will cause value errors Exponent notation is not supported Neumonic Parameters Pressing Up or Down will cycle through a ring of the available selections The Back and Cancel buttons are ignored String Parameters The string may be modified on a per character basis The initial character selected is the right most character Pressing the Up or Down buttons will change the selected character Pressing Back or Cancel moves the character selection within the string If the curent selection is the most significant character pressing the Back button will add a leading lt SP gt to the string if the string is less than the maximum length defined for
268. the best tensioning m Critical During the final lock down of the Y axis mounting screws make certain to press the tool forcefully against the printer chassis to ensure maximum tension Ensure that the three mounting screws that secure the Y axis drive assembly to the chassis are turn loose and that the Y axis idler bracket slides freely with respect to the chassis Attach the Y axis belt tension tool in its unloaded or folded out position to the keyholes in the side frame of the printer just below and in front of the Y axis drive assembly The tool s fish hook should engage the eyelet of the Y axis drive assembly Pull forward and down on the lever arm ofthe tension tool and keep the tool pressed against the printer frame to apply tension to the Y axis belts While the belts are under tension rotate the drum pulley 5 times to rotate the belts and seat them in place For an old Y axis drive assembly continue rotating the pulleys until the index marks on each pulley align next to each other Beginning with the upper right screw tighten the three mounting screws to 30 in lbs to secure the Y axis drive assembly in place Using PC based diagnostics run the test Position for Belt Tightening in the Y Axis Group test suite This positions the belts in the proper orientation for re tensioning Do not move the pulleys Note If there is a situation in which diagnostics are not available when 8 9
269. the type of media installed in the tray it only detects the particular tray being used by the presence of sensor flags on the side of the tray The tray sensors are located on the right side interior of the paper tray slot mounted on I O board right There are five tray types Letter A size This tray is sized for 8 5 x 11 inch U S paper as well as low volumes of A size transparency film Metric Letter A4 size This tray is used for 210 x 297 mm Metric paper as well as low volumes of A4 size transparency film High volume Transparency Label A This tray supports high volumes of U S size transparency film as well as laser quality adhesive label stock High volume Transparency Label A4 This tray supports high volumes of Metric size transparency film as well as laser quality adhesive label stock Legal Tray Phaser 860 only This tray supports Legal size US 8 5 x 14 inch paper Table 1 5 Tray switch sensor combinations Tray type Paper 4 A 4 Legal Size Transparency Transparency Top switch Closed Open Closed Open Closed Middle switch Open Closed Open Closed Closed Bottom Open Open Closed Closed Open switch The slide switch actuators on the media trays will open a switch in the forward position and close a switch in the rear position 1 20 Phaser 840 850 860 8200 Color Printer Service Manual The Main Board The main board features the printer s PowerPC 603e processor that c
270. this procedure as there are sharp and hot surfaces inside the printer near the pick roller Remove the paper tray Open the front door and remove the maintenance drawer Peel off approximately 2 inches of tape leaving the strip on the roll Holding the strip straight attach the leading edge of the tape to the top of the pick roller inside the front cover Rub the tape across the top of the roller so that the leading edge is fully adhered to the roller surface Holding the strip straight roll the tape strip onto the roller to cover the full roller circumference It does not need to be tightly attached to the roller just wind it up Continue to hold the strip straight 7 While slowly pulling back on the roll of tape rub the tape back and forth across the top of the roller This will unroll the tape strip from the roller while the rubbing action picks up the debris from the roller 8 Locate a clean section of the tape rub it onto the surface of the pick pad for the paper tray and then remove it 9 Reinsert the paper tray and maintenance drawer o kON Cleaning Page Phaser 840 printer only Under certain conditions the printer purges its ink jet nozzles to clear any jets plugged with ink When the purge is completed the printer outputs a cleaning page to clear the purge pattern from the print drum Ink jets are purged under the following conditions During warm up from a power off condition W When the
271. ting for a shorted motor or solenoid driver which shuts down the power supply W See SF 156 Phaser 840 only Measuring power supply voltages Warning AC line voltages are present on the power supply and possibly in the printer via the heaters while the printer is plugged into an AC outlet even if the power switch is off 1 Turn off the printer and unplug it from its power outlet 2 AC Input With a DMM set to measure AC voltages measure the power being supplied to the printer it should measure between 87 to 128 VAC 115 VAC nominal or 174 to 250 VAC 220 VAC nominal 3 Proceed to the step Inspecting the power supply fuses below Ifa heater shorts F2 or F3 opens The power supply does NOT shut down however aService Required error code is displayed on the front panel Troubleshooting 3 81 Inspecting the power supply fuses Three fuses F1 F3 are mounted on the power supply remove power supply Turn off the printer and remove the power cord Remove side and rear covers Remove the screws securing the power supply Disconnect the wiring harnesses plugged into the right side of the power supply and With a DMM determine that the fuses on the power supply are functional Measure the resistance of all fuses to LINE as indicated on the power supply s shield If any fuse opens the power supply does not function and should be replaced Caution Fuses F2 and F3 are used for the
272. tion in the printer resulting in uneven heating of the printhead which in turn results in uneven ink drop jetting ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghiiklmnopqrstuvwxvzab 0388 45 Table 3 8 Color is uneven Step Question and Actions 1 Clean the wiper blade of the drum maintenance drawer Inspect the operation of the drum maintenance cam roller and the left and right cam actuators it pushes against 2 Refer to the topic Evaluating the printhead and cap wipe purge system on page 3 106 A properly functioning printhead maintenance system is essential for proper printhead operation 3 Perform the procedure Printhead to drum spacing adjustment Phaser 840 Printer Only on page 4 146 and Transfix roller pressure spring adjustment on page 4 154 4 Replace the printhead 3 90 Phaser 840 850 860 8200 Color Printer Service Manual Streaks or lines down the print There are several possible causes of streaks running down the length of a print ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 0388 41 Table 3 9 Streaks or lines down the print Step Question and Actions 1 Clean the wiper blade of the drum maintenance drawer Inspect the operation of the drum maintenance kit Replace the Maintenance Kit if necessry Clean the stripper fingers or rapid release guide The
273. to prevent scratching the drum Removal and Replacement Procedures 7 205 14 Remove the guide rod connecting the bottom of the cap wipe purge assembly to the grooves in the printer frame 15 Remove the white retainer clip at the upper left end of the cap wipe purge assembly 16 Remove the metal vacuum tube from the vacuum inlet of the assembly 17 While holding onto the cap wipe purge assembly remove the guide pin that holds the cap wipe purge assembly in place 18 Push the wiring through the print engine s frame so that you can free the cap wipe purge assembly Reverse these steps to reinstall the cap wipe purge assembly Refer to Wiring Diagrams on page 9 235 for details on dressing the cap wipe purge wiring Vacuum inlet Cap wipe purge Vacuum tube Plastic retainer NS uf Fig 7 23 Removing the cap wipe purge assembly Phaser 850 860 printer 840 4 82 7 206 Phaser 840 850 860 8200 Color Printer Service Manual FRU Parts List This topic provides a list of field replaceable units for the Phaser 840 850 860 and the Phaser 8200 Color Printers Changes to Tektronix and 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 W Product type or model number W Serial number of the printer Serial numbering Phaser 840 850 CYRxxxx Phaser 860 CRPPYMDSxx Phaser 860 8200
274. ton until Xerox is displayed on the Front Panel Verify that the Hold the Left Arrow key and power N A printhead is off the printer If the head locked for successfully locks the red and shipping green front panel LEDs will blink back and forth 4 120 Phaser 840 850 860 8200 Color Printer Service Manual Hidden Service Menu Table 4 2 Hidden Service Menu Phaser 840 Phaser 850 Phaser 860 Previous Menu Previous Menu Test Prints Test Prints Test Prints Print Startup Page Fault History Energy Star Mode On Off Eliminate Light Stripes Reset NVRAM Energy Star Timeout Fault History Cool Down for Power Off Fault History Diagnostic History Reset Printer Reset NVRAM Enter Diagnostic Mode Head Adjust Cool Down for Power Off Reset NVRAM Adjust X axis Scale Reset Printer Energy Star Timeout Drift Compensation On Off Head Adjust Energy Star Mode On Off Head to Drum Adjust Adjust X axis Scale Cool Down for Power Off Execute Head Wipe Drift Compensation On Off Reset Printer Print Usage Profile Head to Drum Adjust Head Adjust Engine Copy count xxxxx Execute Head Wipe Adjust X axis Scale Head SN Xxxxxxxx Print Usage Profile Drift Compensation On Off Head Cal Date dd mmm yyyy Print OCR Usage Profile Head to Drum Adjust Head Version xx Engine Copy count
275. ts This topic illustrates the service test prints produced by the printer The test prints push the printer to the extremes of its performance to reveal possible shortcomings To Access Test Prints 1 Access the Hidden Service Menu for help accessing the Hidden Menu go to Front Panel Shortcuts on page 4 119 2 Scroll to Test Prints and press Select Phaser 840 850 or OK Phaser 860 Table 5 1 Test Print Menu X Axis Motion Weak Missing Jet Color Bands RGBK Dither Reverse Text Big bands Handfeed OHP Gray Fill Manuf Five Duplex GSF YMCKRGB Solid Fills v Drum Seal 10 Manuf paper path 11 Head to Drum Gap 12 Manuf x axis 13 Black Solid Fill 14 Red Solid Fill 15 Green Solid Fill 16 Blue Solid Fill 17 Cyan Solid Fill 18 Magenta Solid Fill 19 Yellow Solid Fill 20 OHP Color Bands 21 Primary Solid Fills 10x 22 Manf Skew Margins 23 Manuf Banding Test Prints 5 159 Note Defects revealed by the prints may not show up at all in the course of ordinary printing In servicing the printer you should minimize the defects shown by the prints but not necessarily eliminate them 1 X axis motion These prints reveal problems with the X axis motion of the printhead Look for 1 Athin white line and black
276. ty at the brush commutator interface Y axis motor 1 4ohms 15 Difficult to 1 4ohms 15 Difficult to measure due to variability at the measure due to variability at the brush commutator interface brush commutator interface X axis motor 12 5 ohms phase red to yellow 12 5 ohms phase red to yellow and blue to orange and blue to orange Paper feed motor 1 5 20 ohms phase 1 5 20 ohms phase Maintenance drawer camshaft electric clutch 186 ohms 15 132 ohms 15 Paper pick electric clutch 186 ohms 15 186 ohms 15 Phaser 850 only Cap wipe purge clutch feed clutch and Phaser 860 pick clutch 125 ohms 12 124 ohms 5 Transfix cam solenoid 108 ohms 10 108 ohms 10 3 64 Phaser 840 850 860 8200 Color Printer Service Manual Paper Path and Media based Problems Media based problems 1 Check that the correct type of media is being used for information on the correct media type and sizes refer to the Paper Tips page which is printable from the printer Front Panel Menu See also SB403 amp SB409 2 Inspect the paper for bent torn or folded corners Check for stuck sensor flags 6 Check to ensure no small pieces of paper are in the paper path Ensure that the correct media is in the correct media tray The tray switch actuators indicate the size and the type of media loaded in the tray the printer does n
277. u Press and hold the left arrow and then press the Select button Bypass Mode Manufacturing Mode Bypass mode allows you to access the front panel menus bypassing the engine and PostScript initializing processes without having to wait for the printhead to warm up This way you can reset NVRAM or read fault codes immediately Meanwhile the printer continues to warm up and initialize in the background 1 Atthe rear ofthe printer set DIP Switch 2 into the down position Ensure Switches 1 3 and 4 are up Normal operation is all switches up 2 Turn on the printer The printer will not print a Cleaning Page Phaser 840 printer nor a Startup Page when placed in Bypass Mode Restricted Menu Bypass Press and hold Cancel or Scroll Up then press the Back button When the front panel is locked the 1 Printer Configuration menu will not show the Default Printer Settings and Network Settings 1 Scroll to the Printer Configuration menu 2 While holding the left arrow button press Select The front panel will display the complete menu list 3 Exiting from the submenu returns the printer to the short version of the Printer Configuration menu Diagnostics and Adjustments 4 119 Table 4 1 Front Panel Shortcuts Phaser 840 850 Phaser 860 Hidden Service Menu You must be in the Service Tools Menu Press and hold the Cancel or Scroll Up button then press the Scroll Down button Scroll
278. ubber wiper especially at the ends for signs of separation Gently probe the cap wipe purge assembly gasket with fingers or a blunt tool for signs of damage or separation from the cap assembly Replace if defective Refer to SF147 5 Check vacuum and decay time For the Phaser 860 do not perform this step see the next page With a T connector connect the vacuum gauge to the between the vacuum pump module and the cap wipe purge unit Vacuum guage T connector Vacuum assembly Cap wipe purge vacuum hose 0388 35 Fig 3 4 Connecting the vacuum gauge to the printer Note 3 108 Always use a vacuum gauge to test the performance of the vacuum system Simply listening for the kiss sound at the end of a purge cycle as the printhead separates from the cap wipe purge assembly gasket is not enough to verify the vacuum system 5 performance Phaser 860 Only Step 5 is as follows for the 840 850 go to step 6 a Note Check the purge performance BEFORE running the diagnostic test empty the Waste Bin Enter diagnostic mode and select the Cap Vacuum test from the check menu Results should be RO normally 20 200 R1 normally 40 1600 R2 normally 3000 8000 Select Unlock DM Tray from the function menu Remove the maintenance tray and note whether or not a normal volume of ink was purged from the printhead The purge volume for the 860 is about half as much as the 840 or 850 Are either RO or
279. ull The log is stored in RAM only so new data is stored each time the printer s power is cycled Phaser 860 The Phaser 860 printer maintains four logs in memory detailing network functions The logs contain Netware TCP IP AppleTalk and Hardware initialization landmarks and limited print time processes The logs can be accessed throught the front panel menu 1 Navigate to Menu Support Network Questions 2 Scroll to the appropriate Network Runtime Log for you network and press OK The log can also be accessed remotely via CentreWare IS The logs lists events chronologically The log is limited in length logging stops when the log is full The log is stored in RAM only so new data is stored each time the printer s power is cycled Troubleshooting 3 75 Electronics Troubleshooting System power up sequence The following lists the chain of events that occur when you turn on a printer You can follow this list as one means of determining if the printer is operating correctly The exact chain of events depends upon the DIP switch settings the last power down condition and where the printer believes the printhead is positioned The printer records in non volatile RAM the last known position of the printhead and the cap wipe purge assembly The Electronics Troubleshooting Checklist is the primary reference for troubleshooting power up problems see On site Electronics Troubleshooting Checklist Phaser 840 850 on page A 250 or O
280. um position sensor E i assembly 840 4 18 Fig 7 12 Removing the drum position sensor assembly Phaser 840 printer Reverse these steps to reinstall the drum position sensor assembly The drum must be in the same position relative to the drum position encoder wheel when the drum position sensor assembly was removed This ensures that the stripper fingers contact the drum in the same location as before otherwise print artifacts will result W Install the encoder wheel on the drum shaft precisely aligning the home flag to the alignment mark drawn on the shaft Use the encoder wheel gap tool to space the encoder wheel to the drum position sensor Removal and Replacement Procedures 7 193 Drum position sensor assembly Phaser 850 860 1 Remove the left cover 2 Remove the top cover Caution Unhook the head tilt spring to avoid possible damage to the printhead and drum 3 Disconnect the drum position encoder sensor cable at the drum position assembly 4 Remove the clear plastic dust cover from the drum position assembly 5 Precisely mark the end of the drum shaft where it aligns with the home reference line on the encoder so that the encoder can be reinstalled in the same position on the shaft This is not necessary if you are also replacing the drum as part of the drum transfix assembly Mark the drum shaft where it aligns with the home reference mark Drum position encoder wheel 840 4 77 Fi
281. unch media 22 508 10 Time out on preheat entry sensor left side a Verify that the lower tray is properly loaded 1 Media came from the lower Low stack of media in tray feeder with corner fold b Sticky lower feeder pick flag Refill tray can be common with low media c Missing support foil clear L shaped plastic media guide on front left side of the lower tray Error Codes and Messages Stack Replace lower feeder Replace lower tray 2 63 Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 2 Media came from lower feeder and missed preheat entry flag a Lower feeder bias problem a Make sure media is on the left side of the tray 3 Media damaged in center a Pick pad a Don t load too close to fill line Replace pick pad if needed 4 Media is folded damaged or deformed in tray a Media makes it out of tray but cannot trip preheat entry flag a Remove and inspect media and reload tray 5 Media is excessively skewed Tray overfilled Media was hand fed and was loaded skewed c Last sheet in tray om a Make sure tray isn t overfilled and media is Square b Reload media more carefully c Refill tray s 6 Media really skewed with side edge damage a Problem with pick guide assembly a Make sure pick guide is snapped into the printer s frame 22 511 02 Unexpected A A
282. ure that the cap wipe purge assembly activates its home position sensor If the printhead is in the cap wipe purge position a The heaters in the printhead and cap wipe purge assembly are activated as a precaution to melt the ink which may have cooled and solidified thus gluing the cap wipe purge and printhead together 10 minutes pass while the cap wipe purge assembly heats up b The printhead is tilted back C ink is allowed to drain from the cap wipe purge assembly d The cap wipe purge assembly is lowered to its home position The process motor is activated to rotate the head tilt gear into its home position Ifthe printhead is in the locked position it will not tilt forward The process motor also rotates all the rollers to their ready positions disengage the transfix roller and lower the maintenance drawer blade and wiper 3 78 Phaser 840 850 860 8200 Color Printer Service Manual 9 The x axis motor activates to move printhead off its locking post The x axis motor activates for three short bursts to ensure the printhead is in its far left travel printhead home position Then the x axis motor is reversed to move the printhead to the center the of the x axis travel 10 The process motor is again activated to tilt the printhead forward into the print position The drum is rotated to sense it home position The Phaser 850 printer uses a slower rotation to find its home position 11 A short cap wipe purge as
283. utch repeatedly until a button is pressed Feed Clutch Actuates the paper feed clutch repeatedly until a button is pressed Transfix Solenoid Actuates the vacuum solenoid repeatedly until a button is pressed Vacuum Solenoid Actuates the vacuum solenoid repeatedly until a button is pressed Motors Shafts Verifies motion of motors and shafts Exercise all Motors Shafts Actuates each device 4 times Process Motor Actuates the process motor repeatedly until a button is pressed Standard Pick Shaft Actuates the standard pick shaft repeatedly until a button is pressed DM Cam Shaft Actuates the drum maintenance shaft repeatedly until a button is pressed Paper Path Motor Actuates the paper path motor repeatedly until a button is pressed Cap Drive Shaft Actuates the cap wipe purge drive shaft repeatedly until a button is pressed Lower Transport Shaft Actuates the lower transport shaft repeatedly until a button is pressed Diagnostics and Adjustments 4 123 Table 4 3 Diagnostic Menu Map Y Axis Motor Actuates the Y axis motor repeatedly until a button is pressed X Axis Motor Actuates the X axis motor repeatedly until a button is pressed Vacuum Pump Motor Actuates the vacuum pump motor repeatedly until a button is pressed Drum Fan Motor Actuates the drum fan motor repeatedly until a button is pressed Electronics Fan Motor A
284. utdown state sequencer when a request during the enter state is made while the printer is already in the halt state I O Right has been known to cause this fault code 4 046 62 PC PROG FAULT 0x26 Dangerous Process Motor Detected The PC task is about to send a command to the process motor task to move the print head into standby home the print head or turn the process motor while the PC task detects that the printer is in a dangerous position damage could result from such a move typically this happens when a soft shutdown request is issued when the x axis is in a position where the print head would bind against the left side ot the frame if the process motor were moved 4 051 67 PC PROG FAULT 0x33 Bad Command Result during Drum warm up processing of a PostScript command message in pc process message returned SERVICE NEEDED during the drum warm up period This should never happen and is flagged by pc warmup seq as an error 4 059 66 PC PROG FAULT 0x3b Bad Command Result during Big Drop Flush Processing of a PostScript command message in pc process message returned SERVICE NEEDED during the big drop flush This should never happen and is flagged by do big drop flush as an error 4 064 62 PC PROG FAULT 0x40 Bogus Thermal State The thermal state value stored in non volatile memory was not valid This error is detected in show thermal state and probably indicates a corrupt NVRAM device
285. valid state the AC heaters are enabled and the front panel display shows the warm up progress The Ready LED flashes when warm up completes the Ready LED lights solid 10 The drum begins to rotate 11 If the temperature of the printhead ink reservoirs or jetstack are below the purge threshold then the printer performs a head clean cycle a When the ink in the printhead is molten and printhead temperatures are correct the cap wipe purge assembly is positioned to the purge position b The printhead tilts forward against the cap wipe purge assembly and a purge cycle begins C The front panel indicates the printer is in a clean cycle d Ifthe printer senses ink or debris on the drum a drum cleaning page is printed Phaser 840 printer only 12 The temperature of the printhead drum and paper preheater are allowed to stabilize at their operating temperatures and ink is melted if needed 13 If needed a cleaning page is printed at this time 14 A start page is printed if enabled 15 The front panel displays a message that the printer is initializing and then ready The print engine is initialized Troubleshooting 3 77 Phaser 860 Customer Mode Power Up Sequence Power switch is turned on e Power supply senses AC line voltage conditions 110 VAC or 220 VAC and enables DC voltages If an overload occurs the printer turns off the DC supplies giving a blink effect to the front panel LEDs BIST test flashes the PE
286. wer control board behind the printhead to simulate a load on the power supply Attach the service load connector s ground clip to the printer frame Do not leave the service load connector in place and powered up for longer than 5 minutes it gets hot from the current load Warning AC voltage N hazard Never attempt to plug service load connector here Service load N f 0388 66 Fig 3 1 Attaching the service load connector to J250 4 Turn on the printer If the rear panel LEDs illuminate indicating power the power control board or its loads are current limiting the power supply Go to Step 5 If no power is evident no lighted LEDs replace the power supply 5 Turn off the printer Reconnect the 40 volt loopback connector to the power control board then disconnect all load connectors from the power control board Turn on the printer If the rear panel LEDs still do not illuminate the power control board has a shorted driver and must be replaced If the LEDs do illuminate isolate which motor or fan is overloading the power control board and power supply Turn off the printer Sequentially plug each cable in one at a time and turn on the printer until the power supply is disabled Replace the defective component Also refer to the next topic Testing motor and solenoid resistances on page 3 84 6 Turn off the printer Disconnect the two I O board ribbon cables from the power control board This isolates the I
287. wer cord Remove the right cover Remove the left cover Remove the upper feed roller as described in the topic Upper feed roller assembly on page 7 185 Disconnect the locking wiring harness from the right side of the paper drum heater At the front of the paper drum heater remove the two screws securing the heater to the inside of the printer frame Do not confuse the mounting screws with the nearby smaller brass colored assembly screws oc Paper Drum heater Fig 7 8 Removing the paper drum heater Removal and Replacement Procedures 7 187 Drum transfix assembly 1 Turn off the printer and remove the power cord 2 Remove the right cover 3 Remove the left cover 4 Remove the front panel Left side 5 Free the wiring harness leading from the drum transfix assembly along the left side of the print engine to the power control board and left I O board 6 Remove the drum position sensor assembly 7 Remove the upper feed roller assembly 8 Remove the paper drum heater 9 Remove the drum temperature sensor 10 Remove the C clip securing the compound gear and remove the gear and drive belt 11 Loosen the exit roller drive belt tensioner Remove the exit roller drive belt 12 Remove the duplex roller pulley and keyed bushing from the left end of the shaft 13 Remove the three screws securing the paper path motor in place Remove the motor so you can access the gear and keyed bushing from
288. x axis drive is not functioning correctly If the X axis drive does not slew the printhead smoothly and evenly during printing vertical lines appear in the print Print Service Test Print 1 X axis to reveal an X axis problem Ensure that no wiring harnesses are interfering with the horizontal slewing of the printhead Replace the X axis drive if indicated Calibrate the x axis scale as described in the topic X axis scale adjustment on page 4 149 Check for media in the exit path If streaks are on the front side of a 2 sided print the paper preheater may be scraping ink off the print Look for ink shaving alongside the streak Clean the preheater using the front panel initiated cleaning process Remove ink smears Smears on a duplex print can also be caused by the paper preheater operating at a too high temperature Use the PC diagnostics to check the paper preheater s temperature Replace if necessary Possible missing weak or contaminated jet Print the service test print Weak Missing Jet to determine if a jet is not performing Refer to the following procedure Missing ink or light colored ink band running length of print on page 3 89 Replace the power control board Troubleshooting 3 9 Scratches parallel to the long axis of printing particularly with film Usually caused by foreign debris in the paper path The scratch extends into non printed areas ABCDEFGHIJKLMNOPQRSTUV abcdefghijklIm
289. xit into duplex while printing a Empty exit tray Phaser 840 850 860 8200 Color Printer Service Manual Table 2 6 22 000 Fault Codes and Actions Error code Additional clues Probable cause Action 4 Excess skew a Last sheet in tray a Refill tray s b First sheet in tray b Make sure tray s is c Failure of deskew system loaded properly and d Exit roller is out of position media is square in tray c Check deskew fingers If chronic check preheat entry assembly for deformation d Reseat exit roller 5 Media deformed or a Left corner folded in tray b Remove media inspect damaged in media tray simplex trailing edge and reload 6 Media perfectly straight a Media path motor stall a Use diags to run verify b Bad gear in drive train drive current c Duplex sensor not snapped requirements from the into front panel assembly paper path group to d Bad duplex sensor check for stall or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed Check electronics if needed b Replace stripped gears c Reassemble front panel d Replace front cover display assembly 7 Media goes back down a Roller slip a Replace exit roller insure simplex path b Media impeded from exiting exit idler rollers are by top cover providing adequate force c Media impeded from exiting b Reassemble top cover by a tall stack of paper c Remove media from output tray 22 700 02 Co
290. y front 7 186 Removing the paper drum heater 7 187 Removing the drum transfix assembly left side 7 189 Removing the drum transfix assembly right side 7 190 Marking the drum home flag sensor alignment 7 192 Removing the drum position sensor assembly Phaser 840 printer 7 193 Marking the shaft for drum home alignment 7 194 Removing the drum position sensor assembly Phaser 850 printer 7 195 Plugging the reservoir holes 7 196 Removing the printhead 7 197 Removing the x axis motor and drive assembly 7 199 Removing the Y axis belt drive assembly Phaser 840 printer 7 200 Removing the Y axis belt drive assembly Phaser 850 860 printer 7 201 Removing the cap wipe purge assembly Phaser 840 printer 7 203 Removing the lower cap wipe purge retainer clip 7 204 Removing the lower cap wipe purge retainer clip 7 205 Removing the cap wipe purge assembly Phaser 850 860 printer 7 206 Cabinet FRUs 8 208 Imaging FRUS 8 210 Paper path FRUs

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