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Phaser 8400/8500/8550/8560 Color Printer Service Manual

1. l 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual 701P27910
2. 4 16 Phaser 8400 8500 8550 8560 Color Printer Service Manual Wiper Shaft Continued General Troubleshooting R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions CCW On fe ripple 25 to 100 08 to 31 Reports the variation of effort needed to rotate the wiper shaft in the CCW direction at a constant velocity A larger value could indicate particles in the gears or non uniform contamination of a roller causing a lump CCW Off fe setting time sec 0 004 to 0 15 015 to 20 Reports the time it takes the MP motor servo system to settle down after the sudden release of the wiper shaft load A larger value may show a dragging or slow to release clutch Time to CW On peak fe sec 0 005 to 0 20 02 to 045 Reports how long it takes the MP motor servo system to react to the sudden addition of the wiper shaft load Larger values may indicate a slipping or slow to engage clutch CW On peak fe 275 to 10 15 to 0 4 Reports the peak effort required to accelerate the wiper shaft load A smaller value could indicate a Slipping clutch CW On fe settling time sec 10 to 1 04 to 23 Reports the time it takes the MP motor servo system to settle down following the sudden addition of the wiper shaft load A longer time could indicate a looseness in the wiper shaft assembly or a slipping
3. 0 0 0 eet teens 3 36 36 002 44 Errors Drum Maintenance Program Fault 0 0 00 cece cee eee eens 3 36 37 0XX xx Errors PEST FaultS 0 occ eee eee e eben eee e enn 3 36 xij Phaser 8400 8500 8550 8560 Color Printer Service Manual Contents JIM G OES wx sh creas datie esc ha x sed saul sia ra Seve ede bab ire at a a wal ae von one midis dotdobtc aa E tte lowed 3 48 Jam Code Definition Table 20 0 0 cee eee e teen e eee eevee 3 49 4 General Troubleshooting INGFOGUCHON ries dora eka owed pantaran e naa PREC RRL EE Red eO ale Phaies weed Wiade alee nds 4 2 Hidden Service Menu 1 0 ne ene n nnn e aerea rreren 4 2 SERVICE DiaGNOStICS s 5 0 5 vaih debs Liat de Aad ad dated ASS hen eh oe ee de 4 4 Service Diagnostics Mode Menu 10 0 0 ccc ce ene eee teen ene teens 4 5 Service Diagnostics Menu Map 6 cc cece nent teen ene teens 4 6 Check Menu Definition Tables 0 0 0 cent ene een nnn deeb teen ene e teenies 4 10 Check Activators Menu 2 0 cece nee e eee eee n eee tenn nes 4 10 Check Shafts Menu 0 0 nnn eee een n nee eee e dene ete een eens 4 13 Check Paper Path Menu 1 eee teen eee eee n nent nnn ne es 4 16 Check Drive M nW saci sched Sleek RelM wet Gok dees innota iea tA a backs iw visendi Sols 4 31 Check Drum Menu 0 eee en een eee nee eee e edb eee t eens 4 37 Check Motors Menu 0 ccc ce een ee nee taraa i Dee aa aa 4 43 Check Misc Menu 0
4. Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 11 Parts Lists PL 5 0 Circuit Boards 8500 121 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 12 Parts List 5 0 Circuit Boards and Cables Parts Lists No Name Description Qty Part Number 1 Cable Y Axis Motor Ground 1 117E34880 2 Wiring Harness Left Side Power 1 174449480 8400 Control 117E29800 8500 8550 8560 3 Cable Wave Amp Signal 1 174446580 8400 117E34870 8500 8550 8560 4 Wave Amp 1 671522380 8400 960K21181 8500 8550 8560 5 Electronics Module no RAM 1 119649580 8400 NVRAM or Configuration Card 137E14020 8500 8550 137E24440 8560 6 Cable Printhead Interface 1 117E29840 7 Hard Drive 1 097803172 8400 121K44411 8500 8550 121K45340 8560 Hard Drive with Japanese Fonts 097803173 8400 121K44420 8500 8550 8 128 MB SDRAM 1 156483700 8400 256 MB SDRAM 156466300 8400 128 MB SDRAM 237E23890 8500 8550 8560 256 MB SDRAM 237E23640 8500 8550 8560 512 MB SDRAM 237E23650 8550 8560 9 8 pin NVRAM 1 856476800 10 Configuration Card B 1 650431200 8400 Configuration Card BD 650431300 8400 Configuration Card N 650431400 8400 069E00360 8500 069E00550 8560 Configuration Card DP 650431500 8400 Configuration Card DX 650431600 8400 Configuration Card DN 069E00370 8500 Configuration Card DP DT
5. A 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference e Es TER if Line 631 Printhead ID Profile Itis Printhead ID 00 09 l cate d in the lists a date record the date 10 29 front panel month day year here ce menu Troubleshooting If Line 636 IDU Service Tools IDU lists any values record 00 09 the numbers here 10 29 30 99 100 Xerox U S personnel please record these dates in the FIST system as well as in this document Step Does the printer YES If YES please write down the error code 3 display an error NO code indicating 3a If error code 13 264 4x is present in the Fault History replace the a problem with Circle electronics module continue to 3b the printhead One 3b If a printhead thermistor open or shorted error code 13 195 45 13 197 47 13 259 46 13 261 48 13 323 47 13 325 49 is displayed or a PEST error code 37 002 47 37 003 48 37 004 40 or 37 005 41 perform the following steps 3c Inspect and reseat the printhead interface cable gray ribbon cable and retest 3d Replace the electronics module and retest 3e Replace the printhead Step Visually inspect If NO replace the printhead The repair is complete 4 the ink ves En ccs i lan iam reservoirs Do NO Ink visible in reservoirs they all contain ink Circle one No ink ina reservoir accompanied by many missing jets before and after a purge cycle indicates that
6. e O AL QO Q L QO 50 V Supply 3 3 V 15 High Side Active LED Supply Active 12 Power Take 20 Seconds LED 5 Supply to Drain Off Active LED s8500 031 Measuring AC Power Supply Voltages 1 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 The power switch is detected by software a proper shut down follows a power off signal to the power supply The printer may operate for a considerable time after this procedure 2 Turn off the printer wait for shutdown and unplug it from the power outlet 3 AC Input With a DMM set to measure AC voltages measure the power being supplied to the printer it should measure between 90 to 140 VAC 115 VAC nominal or 180 to 264 VAC 220 VAC nominal 4 Proceed to the step Testing Motor and Solenoid Resistances below 5 If a heater shorts F2 or F3 opens The power supply does NOT shut down however a Service Required error code is displayed on the Control Panel 4 64 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Detecting condition of Fuse F2 and F3 The Drum and Preheater connect to F3 The Printhead and Ink Loader connect to F2 Turn the power switch Off and wait for the printer to shut down Unplug the Power Cord Remove the Ink Loader page 8 7 oa hwnd From the back of
7. Exit Transfix Roller xI Preheat Sensor Sensor Paper Preheater s8500 027 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 29 Theory of Operation 2 30 Duplex Printing When duplex printing the Exit Rollers pull the media to a predetermined location such that the trailing edge is adjacent to the Exit Rollers Then the Exit Rollers pull the media back into the duplex path The media deskews against a non rotating deskew nip From this point on the print is processed through the Preheater and transfix system to the Output Tray in the same manner as a single sided print Phaser 8500 8550 8560 models include a Preheater Lift Solenoid mounted to the Transfix Load Module that increases the physical spacing between the Preheater plates when printing the second side of duplex prints The increased spacing prevents the paper from rubbing as hard against the plates which can cause smearing to occur Since the 8400 models operate at a lower temperature the solenoid is not needed Exit Sensor Strip Sensor Preheat Sensor Duplex Roller Deskew Sensor Preheater Lift Solenoid Exit Roller Duplex Roller JN aS SS d SS LY ONA iy y s sr W DA GA D D f j K 6S SE J P 22 m s8500 028 Phaser 8400 8500 8550 8560 Color Printer Service Manual Transfix and Print Speeds Transfix Speeds Theory of Operation Characteristic Setpoint Paper Media
8. Fast Color Standard Enhanced High Res Photo Peak Transfix Speed 20 ips 8400 17 ips 8400 13 ips 8400 7 ips 8400 Simplex tray feed 25 ips 8500 25 ips 8500 20 ips 8500 10 ips 8500 8550 8560 8550 8560 8550 8560 8550 8560 Peak Transfix Speed 5ips 8400 5ips 8400 5ips 8400 5 ips 8400 Duplex 10 ips 8500 10 ips 8500 10 ips 8500 10 ips 8500 8550 8560 8550 8560 8550 8560 8550 8560 Peak Transfix Speed 20 ips 17 ips 13 ips 7 ips Legal Peak Transfix Speed 13 ips 7 ips 7 ips 7 ips Tray 1 First Sheet Transfix 7 ips 7 ips 7 ips 7 ips Speed Setpoint OHP Media Peak Transfix Speed 5 ips Approximate Print Speeds 8400 Series Tray Source 3 Resolution Simplex A4 Paper Auto Duplex A4 Paper Tray 1 Fast Color 300x300 dpi 10 pages per minute 10 sides per minute spm ppm Standard 300x450 dpi 9 ppm 9 spm Enhanced 563x400 dpi 8 ppm 4 spm High Res Photo 525 x 6 ppm 3 spm 2400 PCL 600 x 300 Mode 6 5 ppm PCL 600 x 600 Mode 3 ppm Tray 2 4 Fast Color 300 x 300 dpi 24 ppm 15 spm Standard 300 x 450 dpi 18 ppm 13 spm Enhanced 563 x 400 dpi 12 ppm 11 spm High Res Photo 7 ppm 7 spm 525x2400 PCL 600 x 300 Mode 13 ppm PCL 600 x 600 Mode 6 ppm Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 31 Theory of Operation Approximate Print Speeds 8500 8550 8560 Tray Source Resolution Simplex
9. 0 cc cece eee teeta 8 25 Drum Maintenance Pivot Plate PL2 0 16 0 0 cece tet eee nee 8 26 Drum Assembly PL2 0 3 0 00 cece cece eee eee e eee e ete e eens 8 27 Purge Pump PE2 O 7 irridet ceeded aed wanda heeded peed Weed bagel 8 31 PADD eA erste thats ers eo gees apes dre cds Nose cde asp ets E T lyege 8 wcithos tanga oe od EE eee 8 32 Exit Module PLIO TS lt 2acect ernie rtavectaarnia how dese bbe a E ned ewr E AA e chee 8 32 Inner Simplex Guide PL3 0 1 2 2 0 e eee eee 8 33 Lower Inner Duplex Guide PL3 0 2 00 00 nnana 8 33 Lower Exit Guide Assembly with Strip Flag PL3 0 3 0 cece cece eee e ee 8 33 Outer Duplex Guide With Safety Interlocks PL3 0 4 n on 22 cee eee eee 8 34 Upper Duplex Guide with Solenoid PL3 0 5 0 0 cece eee tenn eee ens 8 34 Take Away Roller PL3 0 7 2 205000 ches ese ade ee hoes Oh edad ows cae baa ewe dae awigew ees 8 36 Pick Assembly PL3 0 10 0 0 0 eee eee eee e tenet e eens 8 37 Tray Lift Motor and Gear PL4 0 6 2 eee eee e eee 8 39 Motors Gears Solenoids Clutches and Fans 0 0 0 e eee een eens 8 40 Media Drive with Two Clutches and Solenoid PL4 0 5 0 2 cece eects 8 40 Tray 1 Pick Solenoid PL4 0 3 onnon eee eee eee e eee 8 41 Preheater Lift Solenoid PL4 0 1 0 ccc eee eer ee teet eee eee aee 8 42 Process Drive PL4 0 14 0 0 ccc eect teen eee eae 8 43 K AxiS Motor PL4 Q T2 esient ee
10. To select Jet Substitution Mode for 8500 8550 8560 models 1 Select Troubleshooting and then press the OK button 2 Select Print Quality Problems and then press the OK button 3 Select Eliminate Light Stripes and then press the OK button 4 5 Follow the prompts to select the color and malfunctioning jet number Select Jet Substitution Mode and then press the OK button indicated on the Light Stripes Test page Disabling Jet Substitution Mode 8400 Note Turn Jet Substitution Mode Off will only become available if Jet Substitution Mode has been turned on If the option to turn off is not available then Jet Substitution Mode is not turned on After the Printhead is replaced disable Jet Substitution Mode to restore normal operation Using the hidden Jet Substitution Mode Menu select Jet Select is Select Print Quality Problems and then press the OK button Press and hold the Up Arrow button and then press the Back button Select Jet Substitution Mode and then press the OK button Select Jet Select and then press the OK button Select Turn Jet Substitution Mode Off and then press the OK button Select Print the Eliminate Light Stripes to print the test page and verify NO of fB WO DN Select Troubleshooting and then press the OK button that Service Mode is disabled for all jets Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 13 Adjustments and Calibrations Disabling Je
11. a 2 p E EEEE EQ Double check PS and PE indicators for any error code information The printer self test is usually able to detect a failure that would cause this symptom Looking up the error code may save debugging time If the PS and PE indicators are steady and dimly on replace the Electronics Module reassembly and retest printer If the PS and PE indicators are blinking brightly on or totally off continue debugging A dim but steady on condition indicates some firmware was not properly loaded into a logic circuit With Power Cord connected touch the metal Electronics Module to discharge any static electricity Turn Off printer and wait 30 seconds for power supply capacitors to discharge Unplug Power Cord and remove printer s covers Unplug the following Electronics Module connectors Power Control to I O Board J800 Power Control right J400 Printhead data J130 Wave Amp signal J790 Power Control left J390 Y Axis motor J280 This step removes all other circuits so the Electronics Module can be tested alone h E E E E E EHE 7 Plug in Power Cord and turn on power to the printer The PE and PS indicators should flash an error code reporting that the Control Panel is missing If the proper error message is not flashed replace the Electronics Module and retest the printer If PE and PS indicators flash continue with debug Turn Off printer and wait 30 seconds for power supply capaci
12. Release the front latching tab and pull out on the top to remove the Right Side Cover oak wn Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 5 Service Parts Disassembly Left Side Cover PL1 0 9 1 Remove the Control Panel Cover page 8 5 2 Open the Exit Cover and Front Door 3 Remove the rear screw 4 Release the latching tabs and remove the Left Side Cover Exit Cover PL1 0 7 1 Remove the Right Side Cover page 8 5 2 Remove the Left Side Cover page 8 6 3 The Exit Cover will now just lift off the printer Replacement Note Lift the upper exit guide slightly and engage the pins on the upper exit guide with the slots on the Exit Cover before inserting the cover hinge pins into the pivot points in the printer frame 8 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Ink Loader PL1 0 8 Remove the Right Side Cover page 8 5 Remove the Left Side Cover page 8 6 Remove the Exit Cover page 8 6 Lift the Ink Loader clear of the chassis and hold it in position against the rear of the chassis to allow access to the connectors For 8400 the Ink Loader disconnects from the printer frame For 8500 8550 8560 the harness that plugs into the right side frame disconnects directly from the Ink Loader A OQ N Note Hooks on the bottom of the Ink Loader allow it to hang on the rear of the printer chassis while the connectors are removed 5 Di
13. 1 12 Functional Specifications Characteristic Specification Printing Process Solid ink Color Medium Yellow cyan magenta and black ink sticks each shape coded The printer uses the subtractive color system to produce the colors red green and blue Operating Modes and Resolutions 8400 Fast Color 300x300 dpi Standard 300x450 dpi Enhanced 563x400 dpi High Resolution Photo 525x2400 8500 8550 8560 Fast Color 225x400 dpi Standard 300x450 dpi Enhanced 525x400 dpi High Resolution Photo 525x2400 Maximum Operating Printing Speed 24 ppm 8400 and 8500 series 30 ppm 8550 series First Print Out Letter A4 As low as 6 seconds Warm Up Time From Off cold start From Power Saver 12 minutes 8400 15 minutes 8500 8550 8560 4 minutes Electrical Specifications Characteristic Specification 115 Volt 230 Volt Primary line voltages 90 140 VAC 180 264 VAC Primary line voltage 47 63 Hz 47 63 Hz frequency range Power consumption 1250 W peak 1000 typical 1250 W peak 1000 typical 180 W idle 180 W idle 230 W average during 230 W average during printing printing Energy Star 43 W 43 W Environmental Specifications Nominal Operating Environment Temperature 10 32 C 50 90 F operating 20 25 C 68 77 F Best jam performance Humidity 10 80 RH Non Condensing oper
14. Actions 8 Duplex Turnaround Reports the interval from the Interval us time the engine software is commanded to start the duplex exit process until the Strip sensor deactivates 9 Duplex Pick Reports the interval from the Interval us time the engine software is commanded to start the duplex pick process until the Deskew sensor activates 10 Duplex Stage Reports the interval from the Interval us time the engine software is commanded to start the stage process until the Preheat sensor activates part way through the stage paper motion 11 Duplex Transfix Reports the interval from the Interval us time the engine software is commanded to start the transfix process until the Strip sensor activates part way through the paper transfix motion 12 Duplex Exit Interval Reports the interval from the us time the engine software is commanded to start the transfix process until the Exit sensor activates part way through the paper transfix motion 13 Duplex Exited Reports the interval from the Interval us time the engine software is commanded to start the exit process until the Exit sensor deactivates Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor R values have alternate definitions
15. Actions 0 Peak Power watts 20 0 to 30 20 to 25 Reports the max power value 1 Average Power 20 0 to 30 19 to 26 Reports the average power watts 2 Min Power watts 5 0 to Reports the min power 0 4 following power off 3 Peak Power Time 0 05 to Reports time after solenoid on sec 0 19 that peak power occurred 4 Initial Average 17 to 26 Reports the average power Power watts following power on Gathers data on the performance of the pick clutch coil for Trays 2 through 4 The same type of clutch is used for each tray Tray 2 Tray 3 Tray 4 Pick Clutch watts Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Peak Power watts 2 5t05 5 3 0to6 0 Reports max power value 1 Average Power 2 5t05 5 2 0t06 5 Reports the average power Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 11 General Troubleshooting Gathers data on the performance of the stripper solenoid coil and plunger Strip Solenoid Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Peak Power watts 8 0 to15 22 to 27 Reports the max power value 1 Average Power 8 0t015 20 0 to Reports the average power watts 30 0 Gathers data on the performance of the purge vent solenoid coil Purge Vent Solenoid Typical Typical Value Value 8500 R Definition 8400 8
16. Error Messages and Codes 3 6 POST Error Reporting Blink Pattern Definition Table Continued 8400 PS PE and Control POST 8500 Error Panel LEDs for Error 8550 8560 Code 8400 Type Description Error Code 15 04 Flutter then 15 blinks Hard CPU interrupt error timer no assertion 19 6 15 05 Flutter then 15 blinks Hard CPU interrupt error spurious 19 7 assertion 15 06 Flutter then 15 blinks Hard CPU interrupt error no assertion 19 8 15 07 Flutter then 15 blinks Hard CPU interrupt error spurious 19 11 assertion 15 08 Flutter then 15 blinks Hard CPU interrupt error no assertion 19 12 15 09 Flutter then 15 blinks Hard CPU interrupt error spurious 19 13 assertion 15 10 Flutter then 15 blinks Hard CPU interrupt error no assertion 15 11 Flutter then 15 blinks Hard CPU interrupt error IRQ spurious assertion 16 01 Flutter only Soft Real time clock read failure 11 1 16 02 Flutter only Soft Real time clock write failure 11 2 16 03 Flutter only Soft Real time clock re read failure 11 3 16 04 Flutter only Soft Real time clock does not tick 11 4 Soft Trickle charge failure 11 5 17 01 Flutter then 17 blinks Hard Memory test less than 128 MB of RAM 13 1 detected This is the minimum RAM required Add more RAM Reseat the RAM then replace the RAM 18 01 Flutter then 18 blinks Hard IPCB ID read failure 18 02 Flutter then 18 blinks Hard IPCB ID mismatch 18 03 Flutter then 18
17. White Axis Motor or Stripes Pinstripes on page 5 30 Electronics Did this correct the problem Module 4 Try the procedure listed on Black Red Complete Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 19 Print Quality Troubleshooting Ghosting The image from a previous print is on the current print This problem can occur from prints being stacked in the output tray causing the pressure of the stack and the heat of the printer to cause blocking which has the appearance of ghosting Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Drum Maintenenace Kit Drum Maintenance Pivot Plate Drum Maintenenace Camshaft Drum Temperature Sensor ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 040 Ghosting Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Try printing the images again without Complete Go to Step 2 letting them stack in the output tray 2 Try different paper Ink may have a problem adhering to smooth impervious surfaces of some paper Did this correct the problem 2 Run multiple prints the first 2 sided pri
18. value within the 169 254 xxx xxx range Note To comply with industry standards Phaser 8400 printers cannot be manually configured for IP addresses within the LOCAL LINK range Note Always print the Configuration Page to obtain a record of the printer settings before changing the IP address After testing the printer be sure to restore the printer s original network settings 1 Connect a crossover cable between the PC and printer 2 Verify the printer is Ready To Print 3 Use the printers Control Panel to enable AutolP Select the Printer Setup menu Select the Connection Setup menu Select the Network Setup menu Select the TCP IP Setup menu Set AutolP to On f Exit the menu so the printer is Ready To Print 4 Reset the printer to cause AutolP to assign a new IP address cycle power or select Restart Printer from the Shutdown menu 5 After the printer s IP address is set test communication by sending the PING command 6 If the test fails install a different cable and retest oan USB Port Verification 1 Verify that the printer is Ready To Print 2 Insert the Printer Installer and Utilities CD ROM 8400 and Software and Documentation CD ROM 8500 8550 8560 into the computer 3 If the installer autoruns exit the installer window 4 Connect a USB cable between the printer and computer USB ports The computer automatically detects the new hardware and creates a driver Note If the fi
19. 2 Motordrivevoltage 0 34t01 3 3to 1 5 Reports amount of variation ripple volts of the motor drive voltage 3 Motordrivevoltage 1 4 to 0 8 1 6 to 8 Reports average value of volts motor drive voltage 4 Motor drive power 0 25to1 8 06to 13 Reports variation of motor ripple watts drive power 5 Motor drive power 1 25to2 6 1 3 to 2 5 Reports average value of average watts motor drive power This test turns on the X Axis motor and runs it very slowly for one revolution X Axis Motor Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Motor Voltage A 84 to 86 59 to 62 Reports amount of variation of Ripple volts the motor phase A drive voltage 1 Motor Voltage A 0 120to 10 to 05 Reports the motor phase A Average volts 0 13 drive voltage average value 2 Motor Voltage B 84 to 86 59 to 62 Reports amount of variation of Ripple volts the motor phase B drive voltage 3 Motor Voltage B 012 to 04 to 11 Reports the motor phase B Average volts 0 1 drive voltage average value 4 Motor Drive Power 0 5to0 2 0 1to 5 Reports amount of variation of Ripple watts the motor drive power 5 Motor Drive Power 9 to 13 5 5 to 7 5 Reports the motor drive power Average watts average value Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 43 General Troubleshooting 4 44 This te
20. 3 coarse thread and 1 fine thread from the spring arm The 3 screws securing the arm to the motor remain in place Y Axis Motor Assembly s8500 071 8 If replacing the motor remove 3 motor screws to separate the motor from the arm and remove the spring arm Replacement Note Check that the spring arm screws are in the right locations the grounding connection is attached and that the arm floats freely Screws in plastic are torqued to 12 in Ibs metal to 15 in Ibs unless otherwise specified Also if the spring arm has been removed from the motor torque the motor screws securing the spring arm to 20 in lbs Irreversible damage can result from over tightening screws into plastic parts Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 9 Service Parts Disassembly Printhead Right and Left Printhead Restraints PL 2 0 4 PL 2 0 5 and 2 0 6 Warning Allow components adaquate time to cool before servicing the printer Caution Perform the steps in the order given to prevent damage to the printer 1 Remove the Ink Loader page 8 7 Caution Place several sheets of paper between the faceplate of the Printhead and the Drum to protect the Drum from damage 2 On the right side lift up on the wiper lock to unlock the Wiper Assembly gear train Wiper Assembly Lock Gear Printhead Restraint Printhead Restraint Arm Printhead Restraint Printhead Restraint Arm 8500 073 3
21. 4 Run the Media Drive Motor test Replace the Go to Step 5 Does the Media Drive Motor run extremely Media Drive fast Assembly 5 1 Remove the Media Drive Assembly and Complete If the path is manually rotate each paper path roller 2 Identify any roller that may be binding and Causing drag 3 Repair or replace as necessary Did this correct the problem clear of debris and the rollers rotate normally replace the Media Drive Assembly 3 34 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 31 0XX 6x Errors Program Faults 1 Reset NVRAM and then retest 2 Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 33 0XX xx Errors Tray Manager Device Faults 33 001 42 Tray 1 width value too low 33 002 43 Tray 1 width value too high Troubleshooting Procedure for Tray 1 Step Questions and Actions Yes No 1 Check the wiring and connectors fromthe Go to Step 2 Replace the Front Door to the 1 0 Board harness Are the wires connected properly 2 Run the Test Tray 1 Width Sensor test Replace the Replace the Did the test pass 1 0 board Front Door 34 0XX xx Errors Printhead NVRAM Faults 34 001 43 An error occurred while attempting read write access to the Printhead calibration partition in NVRAM The Printhead cable may be unplugged 34 002 44 An error occurred while attempting read write access to the Pr
22. 8400 8550 8560 Actions 0 Min Resonant 10to 150 4 5to 175 Reports the min resonant Frequency hz frequency over the data set 1 Max Resonant 175 to 4400 to Reports the max resonant Frequency hz 3000 10000 frequency over the data set 2 Min Resonant Reports the number of full Y Frequency Revs Axis revs required to locate the revs min frequency configuration 3 Min Resonant 0 001 to 33 to 20 Reports the amount of Frequency Angle 0 2 additional Y Axis rotation required to locate the min frequency configuration 4 40 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting This test holds the drum stationary while the stripper solenoid is activated and released The drum servo error signal illustrates activation deactivation timing and how strongly the drum was contacted by the blade Stripper Contact R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Engage Displacement mpts 10 to 2 15 to 8 0 Reports the static difference between the average ya_fe before and after the blade contacts the drum indicating how strongly the blade is interacting with the drum while pushing onto the drum May be an indication as to the condition of the blade stiffness dirty bent delaminated etc Another potential factor could be the solenoid range of travel or engagement force solenoid solenoid drive strength or return spr
23. 8500 R Definition 8400 8550 8560 Actions 0 Tray Reports the tray picked from 1 Paper Size Reports the media size picked 2 Unused 3 Unused 4 Tray 2 Pick Average Reports average power over Power watts the pick interval begin pick to Deskew Sensor Paper is picked and moved through either simplex or duplex paper path to determine leading edge arrival time at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected Paper Lead Edge Times Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Common 0 Tray Reports the tray from which the test paper was picked 1 Paper Size Reports the size of the picked paper Phaser 8400 8500 8550 8560 Color Printer Service Manual Paper Lead Edge Times Continued General Troubleshooting R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Tray 4 Pick 2 Tray 4 Pick Interval us Reports the interval from the time the engine software is commanded to start the tray 4 pick process until the Tray 4 Pick sensor activates Tray 4 Transport Interval us Reports the interval from the Tray 4 Pick sensor activation until the Tray 3 Pick sensor activates Tray 3 Transport Interval us Reports the interval from the Tra
24. 9 01x 41 where x 5 for cyan 6 for magenta 7 for yellow and 8 for black 9 025 4x through 9 028 8500 8550 8560 only When the inkloader door is opened for a second time the following codes are recorded 9 02x 41 where x 5 for cyan 6 for magenta 7 for yellow and 8 for black 9 035 43 through 9 038 8500 8550 8560 only Ink count sensor flags are stuck after melting 2 5 ink sticks The following codes are recorded 9 03x 41 where x 5 for cyan 6 for magenta 7 for yellow and 8 for black Features on the bottom of genuine Xerox ink sticks actuate the Ink Out Sensor located at the forward end of each ink channel of the Ink Loader The sensor indicates the passage of ink to provide a count of ink consumption Damaged or non genuine ink sticks may not reliably actuate the sensors This can lead to false Ink Out messages as well as Ink Stick count faults Using 8400 model ink in a 8500 8550 8560 models will also cause 9 03x 4x ink stick count faults Troubleshooting Procedure for Ink Loader Step Questions and Actions Yes No 1 Is the ink Genuine Xerox Are they the Goto Step 2 1 Advise customer correct sticks for the model 2 Replace the Ink with Xerox Ink 3 Run Clear ISC Fault test to clear the error The Clear ISC Fault is located in the Internal Diagnostics Function menu 2 Manually verify that the ink stick is able Go to Step 3 1 Remove any to advance in the ink loader chute blockage and or Check f
25. DIMMs 2 Is the power supply within specification 3 Turn Off the printer and wait 30 seconds for the capacitors to discharge 1 Unplug the following Electronics Module GotoStep3 Replace the connectors This step disconnects all Electronics other external circuits so the Electronics Module Module can be tested alone Power Control to I O board J800 gray ribbon cable on right side m Power Control right J400 16 wire multi color a Printhead data interface J130 gray ribbon cable on top side Wave amp signal J790 short gray ribbon cable located on left side Printhead power connector m Power Control left J390 34 wire multi color a Y Axis motor J280 2 Turn on power to the printer Do the PE and PS indicators near the power switch flash momentarily 1 Turn off the printer and wait 30 seconds Go to Step 4 Goto Step 5 for power supply capacitors to discharge 2 Plug in the power control to 1 0 board connector J800 3 Turn on power to the printer Do the PE and PS indicators flash momentarily If the 50V Power Supply LED viewed thru the cooling grill below the power cord receptacle illuminates the short is on one of the external devices you unplugged earlier In this case systematically turn off the printer plug a wiring harness back in and turn the printer on until the 50V supply fails see Measuring DC Power Supply Voltages on page 65 Replace the
26. Definition 8400 8550 8560 Actions 0 Up Motion Drive 120 to 275 06 to 4 Reports the average following Error uin error while moving the wiper up from the low limit to the lock encounter point 1 Up Motion Drive 35 to 150 06to 2 Reports the difference between Error Ripple uin the max and min following error over the same interval 2 Up Distance uin 3200 to 4000 to Reports the difference between 4600 4350 the max and min limits of travel when moving up 3 Lock Encounter 1300 to 3500 to Reports the distance up from Distance uin 2500 4450 the lower limit of travel at which the head lock latch is encountered 4 Lock Engage 350 to 700 2500 to Reports the distance up from Distance uin 4500 the lower limit of travel at which the head lock latch engages 5 Lock Engage Peak 250 to 25 to 1 0 Reports the peak following uin 125 error at the point the latch engages 6 Down Motion 250 to 25 to 1 0 Reports the average following Drive Error uin 125 error while move the wiper up from the low limit to the lock encounter point 7 Down Motion 40 to 150 05to 8 Reports the difference between Drive Error Ripple the max and min following uin error over the same interval 8 Down Distance 3200 to 4000 to Reports the difference between uin 4600 4350 the max and min limits of travel when moving up 9 Lock Disengage 2000 to 95 to 60 Reports the distance up from Distance uin 50 the up
27. Goto Step 3 run the Y Axis Encoder test Did the test pass 2 Inspect the Y Axis Motor connector Replace the Go to Step 4 Is the wiring faulty harness or Y Axis Motor 3 Inspect the encoder harness Replace the Replace the Is the harness faulty harness Drum Assembly 4 1 Run the Y Axis Drive test Goto Step 5 Replace the Y 2 Check the current values Axis Motor Are the values within normal operating range 5 1 Run the Y Axis Belt Tension test Goto Step 6 Replace the 2 Check the current values Y Axis belt Are the values within the normal operating range 6 Run the Y Axis Motor test Replace the Replace the Y Did the tests pass Drum Axis Motor Assembly 5 0XX 6x Errors Program Faults 5 001 63 There is a problem with the Y Axis sub system 5 005 67 If not in the home or idle state the system faults out Software fault 5 006 68 Software fault 5 007 60 Software fault 5 008 61 PostScript failed to fill the race buffer during imaging Software fault 5 009 62 There were errors during imaging Possible jets on off outside of the deadband area Software fault a b c d Reset NVRAM and retest Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 Replace the EEPROM chip Reboot the printer Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 13 Error Messages and Codes 6 0XX 4x Errors X Axis Fault 6 000 41 An X Axis Motor
28. Incorporated in the United States and or other countries SWOP is a trademark of SWOP Inc UNIX is a trademark in the United States and other countries licensed exclusively through X Open Company Limited As an ENERGY STAR partner Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency The ENERGY STAR name and logo are registered U S marks Ongi ENERGY STAR PANTONE Colors generated may not match PANTONE identified standards Consult current PANTONE Publications for accurate color PAN TONE and other Pantone Inc trademarks are the property of Pantone Inc Pantone Inc 2000 ii Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Terms Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action Be aware of all symbols and terms when they are used and always read Note Caution and Warning statements Common Acronyms Product Terms The following list defines the acronyms that may be found in this manual ADC Automatic Density Control MCU Engine Control Board BTR Bias Transfer Roller NCS Non Contact Sensor CRUM Customer Replaceable Unit PHD Imaging Unit Monitor CTD Toner Density Control PL Corresponds to the FRU Parts List ESD Electrostatic Discharge ROS Laser Scanning Unit IDT Intermediate Transfe
29. Jam Code Definition Table Not all jam code combinations are documented in this manual only the codes that occur most commonly Note The following table only shows the 3 digit jam code For Phaser 8500 8550 8560 a 4th digit represents the tray number 5 represents a chase page and 6 represents duplex Numbers following the 4th digit represent the page count Jam Code Troubleshooting Procedures A2C Deskew sensor in unexpected state during mechanical recovery 1 Check the Drum Maintenance Kit NVRAM contacts during the oiling process for continuity 2 Instruct customer to remove media from Tray 1 before opening the Front Door 3 Replace the pivot arm Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 49 Error Messages and Codes 3 50 Jam Code Troubleshooting Procedures Continued A2E Deskew sensor in unexpected state at ready 1 Ensure ground integrity see page 4 65 2 Replace Tray 1 Pick Solenoid A2F Deskew Sensor in unexpected state 1 Ensure ground integrity of the printer see page 4 65 2 Verify all doors and covers are fully closed and not moving during printing A2J Deskew flag sensor event during head purge A2K _ Deskew sensor in an unexpected state during a transfix roller oiling A2M The deskew flag tripped unexpectedly while picking paper from Tray 2 A2N The deskew flag tripped unexpectedly while picking paper from Tray 3 A2P The deskew flag tripped unexpectedly while
30. Length sense 2 switch s8500 123 Phaser 8400 8500 8550 8560 Color Printer Service Manual Main Wiring Diagram Continued J620 J480 Power Control J320 ECB 50 V 12 V unreg J790 3 3 V generates J400 12 V reg Right 45V Side J390 Left Side Printer ambient temperature J280 J800 Right Side J840 J910 1 0 ECB 4 A X axis motor 2 Drum fan J1AC Inkload ECB Heaters 4 Ink out opto Ink low opto Door open opto Thermistor 4 generates 50 V 15 V unreg 43 3 V Pre heat ECB Deskew entry sense opto NOTE All items connected with RED carry line voltage Printhead AC Resv heaters 2 AC Jetstack heaters 2 Drum Heater Series parallel heater 35 Auxilary Connectors J3 Relay ECB J2 Ji J0720 Paper preheater J0670 Preheat temp therm J0660 Preheat sense opto a 3 Main tray paper height opto Main tray paper opto 3 Waste tray opto 10 3 2 Process home optional 10 5 MPT ECB Width sense var resistor Media present sense opto NOTE Thermal fuse for drum is located on Pre heated ECB Phaser 8400 8500 8550 8560 Color Printer Service Manual Control Panel ECB generates J190 5V J110 Front door sense switch 2 Top door sense switch E Front aor sense suten LCD Display J600 NOTE The numbers shown at the circuit board
31. NVRAM page 8 50 SODIMM RAM page 8 51 and Hard Drive page 8 52 if installed to the new module 8 46 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Wave Amplifier PL5 0 4 Note Do not fully remove EMI tape if included with any connector 1 Remove the Electronics Module page 8 46 2 Remove the Printhead page 8 10 3 Remove 3 screws Caution Route the ribbon cables carefully through the slots 4 Remove the Wave Amp through the back of the printer Fn 8500 111 Replacement Note Insert the ribbon cables fully and squarely into the flex connectors on the Wave Amp and Printhead If the cables are inserted incorrectly they can damage the Wave Amp Route the ribbon cables carefully through the slots Ensure that the T shaped strain relief on the cable is nearest the Wave Amp on installation Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 47 Service Parts Disassembly 1 0 Board PL5 0 13 1 Remove the Right Side Cover page 8 5 2 Disconnect all connections to the I O Board 3 Remove 2 screws to remove the board 1 0 Board Replacement Note Locate the corner of the board behind the ground tab on reassembly Install and torque the 2 screws to 12 in lbs Reconnect all connections 8 48 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Drum Heater Relay Board PL5 0 17 Warning This board is suppli
32. configuration encoding 1 Start Peak Power Reports the highest peak watts during the first quarter of the lifting interval 2 Slack Take up Time Reports the interval between sec the initial power min when the plate is not yet engaged and the point where the lifting power becomes a constant 3 Average Lift Power Reports the average power watts over the center of the lifting interval 4 Lift Contact Time Reports the interval from the sec motor start time until the required lift power starts to increase due to the initial contact with the Nudger Roller 5 Lift Time sec Reports the interval from the motor start time until plate lifted is indicated 6 Stall Power watts Reports the average stall power during the overlifting interval Phaser 8400 8500 8550 8560 Color Printer Service Manual Check Drum Menu General Troubleshooting Uses the sine and cosine sum data to determine the characteristics of the encoder disk and encoder sensors Y Axis Encoder Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Sin Sum Data 150000 to 68000 to Reports average of the max Offset sin sum 800000 160000 and min Sin Sum average units amplitude values 1 Sin Sum Data 11000 to 68000 to Reports difference between the Amplitude sin sum 350000 160000 max and min Sin Sum average units amplitude values 2 Amplitude Rippl
33. ground strap on the Y Axis motor Eliminate the possibility of internally generated ESD from affecting printer Plug in all cables removed during service Trace through all service steps performed to reattach any cables that were unplugged during debugging Attach printer covers Perform full test of printer 2 Control Panel failure a Unplug the original Control Panel at connector C J220 and plug in a known working Control Panel This step checks for a keypad or LCD failure in the Control Panel Plug in all cables removed during service Trace through all service steps performed to reattach any cables that were unplugged during debugging Attach printer covers Perform full test of printer Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 59 General Troubleshooting Display Functions but Sent Jobs Do Not Print 1 Computer driver incorrect or improperly installed a Verify printer hardware is functional by sending a test print via the printer Control Panel b Ifa test print is properly produced continue to next steps focusing on problems outside the printer network Ethernet or computer driver configuration issues c Ifa test print is not properly produced the focus of problems within the printer suggests that the internal settings are corrupt d Use a known functional computer to test printer using the printer s parallel port or USB port If test computer successfully prints pages review th
34. m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print m Drum Maintenance Kit a Drum Maintenance Pivot Plate m Drum Maintenance Camshaft ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 042 Oil Streaks on Print Troubleshooting Procedure Step Questions and Actions Yes No 1 Check and clean the Drum Maintenance Kit wiper blade Replace the kit if necessary Did this correct the problem Complete Go to Step 2 5 24 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Oil Streaks on Print Troubleshooting Procedure Continued Step Questions and Actions Yes No 2 Check the Drum Maintenance Kit ground Complete Go to Step 3 Inspect the back of the Drum Maintenance Kit to Drum Maintenance Camshaft to Drum Fan ground clip Did this correct the problem 3 Run Remove Print Smears Complete Go to Step 4 Did this correct the problem 4 Clean the Stripper Blade and exit guides Complete Go to Step 5 Did this correct the problem 5 Test Drum maintenance operation Complete Replace the 1 Run service diagnostics to verify the pivot plate or Drum maintenance system is operating Drum correctly maintenance 2 Check and if necesary replace these cam roller if parts check for crac
35. motor s windings If the windings are opened shorted or far out of tolerance replace the motor 4 Ensure the process drive gearbox is in it s proper home position refer to page page 6 8 Run the paper path drive test Run the drum maintenance drive test Run the transfix fast and transfix slow Run the process motor and media drive motor tests ono Wo Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 69 General Troubleshooting 4 70 9 10 11 Inspect the gears and mating cam gears for stripped or damaged gear teeth Replace the Process Drive Gearbox Replace the media path drive gearbox Media Skews Passing Through the Paper Path A QOQ Na S Ensure the media is supported Ensure that the side guides are properly adjusted Do not overfill the tray especially with envelopes Check to see if the media is excessively curled Curled media can get mistracked in the paper path Examine the paper path ensure it is clear of obstructions Ensure that the pick roller is not visibly dirty so that it picks up a sheet of media smoothly and evenly Check and clean or replace as required the preheater and or take away rollers Also make sure that the front door is properly closed The printer should be installed on a flat level surface Ensure the paper preheater assembly is clean and properly seated into the printer frame Phaser 8400 8500 8550 8560 Color Prin
36. recorded in Jam History In many cases Tray 1 MPT prints with no jams These symptoms indicate that the Transfix Load Module is incorrectly timed resulting in a late arrival of the leading edge at the strip flag The likely cause is the position of the Drum Maintenance Camshaft gear in relation to the Process Drive gear To correct the timing problem requires removal of the Process Drive and realignment of the Drum Maintenance Camshaft To correct the problem follow these steps 1 Using a flat blade screwdriver rotate the Drum Maintenance Camshaft clockwise to tilt the Printhead forward to its home position This disengages the Printhead and Head Tilt Gear from the Drum Maintenance Camshaft 8560 198 2 Pin the Process Drive gears using a paper clip or similar object to keep the gear set in its disengaged orientation during removal and replacement 3 Remove the Process Drive page 8 43 Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 9 Adjustments and Calibrations 6 10 4 Apply pressure in the direction indicated by the arrow to the Drum Maintenance Kit and Drum Maintenance Pivot Plate to force these components against the Drum Maintenance Camshaft This forces the cam to home position Home position is indicated by the hole in the camshaft end gear aligning with the arrow embossed on the frame s8500 140 Note When properly aligned the hole in the camshaft gear points to the 6 00 or 5 30 posi
37. 0 0 cece cee eee eee 3 24 11 100 60 Errors Temperature Error 0 ence nen ene nee 3 26 12 000 60 Errors Program Faults 2 0 ce eee cnet nen eens 3 26 13 0XX xx Errors Thermal FaultS 0 00 0 ccc ccc cee tent e teen eens 3 26 13 000 6x Errors Program Faults 2 0 en ene n een een eens 3 31 19 0XX xx Errors Printhead Calibration faults 0 0 0 0 cece eee eee nee 3 32 19 0XX 6x Errors Waveform Program Faults 0 00 c ccc eee ee een eee nee 3 33 21 000 69 Errors Diagnostic Code Version Mismatch 0 000 cece cece eee eee eee 3 33 22 0XX 6x Errors Jam Codes 0 cence nent eee eee ee een 3 33 23 0XX 6x Errors NVRAM Fault 0 0 00 c cence eee beeen een 3 33 26 0XX 6x Errors Printing FaultS 0 eee een e ene ene nee 3 33 26 962 6x Errors Fall Out Code 0 cence eet eee e ene 3 34 27 0XX 6x Errors Profile Library 0 eee eee n een e nee eee 3 34 29 0XX 6x Errors Jam Manager 0 0 00 eee nee e ene ene ene eens 3 34 31 0XX 4x Errors Mechanical Initialization Jam 0 ect eee ens 3 34 31 0XX 6x Errors Program Faults 0 2 ee eect nee ent ene n ees 3 35 33 0XX xx Errors Tray Manager Device Faults 20 0 ccc cece cee eee eee e eens 3 35 34 0XX xx Errors Printhead NVRAM Faults 000 000 c ccc eee cece e eee eee eee 3 35 36 000 40 Errors Drum Maintenance Faults 20 0 0 ce eee eee eens 3 36 36 001 67 Errors Drum Maintenance Fault
38. 1 200469480 8400 802E93870 8500 8550 8560 12 1 0 Access Door 1 200468480 8400 802E93860 8500 8550 8560 13 Waste Tray Cover 1 802E93880 14 Waste Tray 1 109R00736 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 5 Parts Lists PL 2 0 Imaging 9 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts List 2 0 Imaging Parts Lists No Name Description Qty Part Number 1 Ink Loader Assembly and Door 1 200469880 8400 133K27710 8500 8550 133K27770 8560 103K01600 Metered 8550 8560 2 Printhead 1 650430300 8400 046K00530 8500 8550 017K04540 8560 3 Drum Assembly includes Encoder 1 105115080 8400 020K15090 8500 8550 8560 4 Belt Y Axis Drum 1 214498780 8400 023E30670 8500 8550 8560 5 Printhead Wiper 1 367053480 8400 8500 8550 033E05290 8560 6 Belt Wiper Drive 1 214501280 8400 8500 8550 023E31250 8560 Purge Pressure Pump 1 094E02790 Left Printhead Restraint 1 120E29160 Right Printhead Restraint 1 120E29150 10 Transfix Camshaft Assembly 1 384187480 8400 008K02160 8500 8550 8560 11 Drum Maintenance Camshaft 1 401100380 8400 Assembly 020K14800 8500 8550 8560 12 Stripper Carriage Assembly 1 386735280 8400 041K06500 8500 8550 8560 13 Transfix Roller 1 022E32290 14 Y Axis Tension Spring 1 809E69920 15 Transfix Load Modul
39. 1 Printer configuration incorrect a Verify proper configuration of printer using Control Panel 2 Computer print driver configured incorrectly a Examine print driver setup to ensure printer driver setup doesn t override desired features set via Control Panel 3 Configuration card failure a b c Verify configuration card is properly oriented and fully inserted Verify printer model purchased corresponds to features expected Clean configuration card contacts with isopropyl alcohol reinstall and retest Swap configuration card with a known working card If printer works replace card with one containing identical features as originally purchase The configuration card enables certain optional features in the printer Care must be taken to duplicate the features of the original printer when replacing the card 525 Sheet Feeder Does Not Function 1 Thermal safety fuse blown a b Power cycle printer The safety fuse is a self resetting device Power cycling ensures the fuse cools enough to reset itself 2 525 Sheet Feeder faulty Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 61 General Troubleshooting 4 62 a b c Turn off printer and wait 30 seconds for power supply capacitors to discharge Replace 525 Sheet Feeder Perform full test of printer Printer Does Not Print LEDs are On and the Display is Frozen With No Errors 1 Nonspecific electronics failure
40. 128 MB SDRAM 097803380 256 MB SDRAM 097803381 Memory 8550 8560 256 MB SDRAM 097803381 512 MB SDRAM 097803382 525 Sheet Feeder with Tray 097803174 Wireless Network Adapter with N A Power 097803740 Converter 110V Wireless Network Adapter with Euro Power 097803741 Converter 220V Wireless Network Adapter with UK Power 097803742 Converter 220V Recommended Tools Description Part Number Torque Screwdriver 003082700 T20 Screwdriver Tip 003086600 Mechanical Parts Kit 650429700 Flashlight Grease 070E00890 Serial Cable Adapter 600780374 Consumables and Routine Maintenance Items Description Part Number Standard Capacity Maintenance Kit 108R00602 8400 108R00675 8500 8550 8560 Extended Capacity Maintenance Kit 108R00603 8400 108R00676 8500 8550 8560 Genuine Xerox Solid Ink Black 3 sticks 108R00604 8400 108R00726 8560 Genuine Xerox Solid Ink Cyan 3 sticks 108R00605 8400 108R00669 8500 8550 108R00668 8500 8550 108R00723 8560 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 17 Parts Lists Consumables and Routine Maintenance Items Description Part Number Genuine Xerox Solid Ink Magenta 3 sticks 108R00606 8400 108R00670 8500 8550 108R00724 8560 Genuine Xerox Solid Ink Yellow 3 sticks 108R00607 8400 108R00671 8500 8550 108R00725 8560 Genuine Xerox Solid Ink Black 6 sti
41. 2 inches in the tray cavity Push the Pick Assembly up into the chassis and snap it into place Then rotate the Pick Assembly up and back to latch Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 37 Service Parts Disassembly 8500 102 Retard Roller Repalcement 8500 103 8 38 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Tray Lift Motor and Gear PL4 0 6 Remove the Electronics Module page 8 46 Remove Tray 2 Disconnect the harness from the Tray Lift Motor From the rear of the printer inside the cavity remove the push nut this is a press fit 5 Remove the gear from the shaft 6 Remove 2 screws holding the Tray Lift Motor to the printer frame 7 Remove the Tray Lift Motor from the outside of the printer kr OND or Lift Motor Gear Push Nut 8500 104 Replacement Note Check that the two tabs of the bushing are seated in the chassis Install and torque the 2 Tray Lift Motor screws to 12 in lbs Position the push nut so the fingers on the inside of the nut are pointed up toward the end of the motor shaft Place a box wrench or socket wrench of the same size as the outer ring of the push nut over the nut and press firmly to seat the nut on the shaft Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 39 Service Parts Disassembly Motors Gears Solenoids Clutches and Fans Media Drive with Two Clutches and Solenoid PL
42. 4 Envelope 92 075 165 1 5 15 82 075 135 1 A6 105 148 5 5 95 138 5 1 2 Baronial 111 125 146 5 15 101 125 112 9 3x5 Card 76 2 127 5 5 66 2 117 6 x 9 Envelope 152 4 228 6 5 20 142 4 188 6 Custom 76 2 127 12 5 12 5 51 2 102 215 9 355 6 8400 190 9 330 6 5mm 8500 A 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Paper Weight Equivalence Table Reference US US Bond US Text US US US US Tag Metric Postcard Weight Book Cover Bristol Index Weight Weight Thicknes lb Weight Weight Weight Weight Ib g m s mm Ib Ib Ib Ib 16 41 22 27 33 37 60 17 43 24 29 35 39 64 20 50b 28 34 42 46 75 21 54 30 36 44 49 80 24 60b 33 41 50 55 90 27 68 37 45 55 61 100 28 70b 39 49 58 65 105 29 74 41 50 61 68 110 32 80b 44 55 67 74 120 36 90 50 62 75 83 135 0 18 39 100 55 67 82 91 148 40 101 55 68 83 92 150 0 20 43 110 60 74 90 100 163 45 115 63 77 94 104 170 0 23 47 119 65 80 97 108 176 51 128 70 86 105 117 190 53 134 74 90 110 122 199 54 137 75 93 113 125 203 58 146 80 98 120 133 216 65 165 90 114 135 150 244 Phaser 8400 8500 8550 8560 Color Printer Service Manual A 7 Reference On site Printhead Troubleshooting Checklist 8400 For the latest policy information on Non Xerox Supplies visit the Xerox Service Partners Web Site https www office xerox com smart
43. A4 Paper Auto Duplex A4 Paper Tray 1 Fast Color 225 x 400 dpi 12 pages per minute 8 5 sides per minute spm ppm Standard 300 x 450 dpi 9 ppm 7 spm Enhanced 525 x 450 dpi 6 ppm 5 spm High Res Photo 525 x 3 5 ppm 3 spm 2400 dpi PCL 600 x 300 Mode 6 5 ppm PCL 600 x 600 Mode 3 ppm Trays 2 4 Fast Color 225 x 300 dpi 30 ppm 17 spm Standard 300 x 450 dpi 24 ppm 14 spm Enhanced 525 x 450 dpi 16 ppm 10 spm High Res Photo 525 x 10 ppm 6 spm 2400 dpi PCL 600 x 300 Mode 16 ppm PCL 600 x 600 Mode 8ppm 2 32 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Printer Self Maintenance The printer has several automatic or semi automatic maintenance functions These functions may be started automatically after a certain number of prints or during printer startup or they may be started by the customer if a print quality defect is noted Printhead Maintenance Cycle Eliminate Light Stripes m Preheater Cleaning Remove Print Smears m Transfix Roller Oiling m Drum Cleaning Chase Page Printhead Maintenance Cycle Eliminate Light Stripes The Printhead maintenance cleaning cycle removes bubbles or foreign matter that cause a Printhead jet to malfunction Three basic actions take place during a cleaning cycle m Purging m Wiping Printing the Cleaning Page There is one basic type of cleaning cycle performed by the purge system The first customer purge and the manufacturing purge con
44. Card handles NVRAM differences between models Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information Routine Maintenance Items and Consumables 8500 007 Routine Maintenance Items Consumable 1 Drum Maintenance Kit 3 Ink 2 Waste tray Drum Maintenance Kit life expectancy depends on the kit capacity For example the standard capacity kits produce 10 000 prints regardless of the colors used Extended capacity Drum Maintenance Kits for 8400 and 8550 8560 models produce 30 000 pages up to 20 coverage and 20 000 pages when coverage exceeds 20 Phaser 8500 models do not support the 8550 8560 extended capacity kit Routine Maintenance Consumable Extended Drum 30 000 cycles 0 20 Ink 8400 1140 Maintenance Kit coverage prints per stick 8400 8550 8560 20 000 30 000 20 100 8500 8550 coverage 8560 1080 prints per stick Standard Drum 10 000 prints 8400 Maintenance Kit 8560 5500 color 10 000 B W prints 8500 8550 Waste Tray Empty every 7 purges Consumable capacity is based on 5 coverage per color on plain A4 paper Note Phaser 8500 models support only the standard capacity Drum Maintenance Kit Phaser 8400 and 8550 8560 models support both the standard and extended capacity kits Phaser 8400 kits and Phaser 8500 8550 8560 kits are not interchangeable Phaser 8400 8500 8550 8560 Color Printer Service Manual 1 9 General Information Printer Specifica
45. Caution Center the Printhead on its X Axis before continuing with Step 2 Check that the Printhead is clear of the frame to prevent the Printhead from binding against the frame 2 Insert a flat blade screwdriver into the end of Drum Maintenance Camshaft and rotate clockwise one revolution If the Printhead is engaged manually assist the movement of the Printhead Note The hole on the Drum Maintenance Camshaf drive gear should be at the 6 00 position after the rotation 0 Insert screwdriver and rotate clockwise Drum maintenance camshaft gear 8500 062 6 6 Phaser 84000 8500 8550 8560 Color Printer Service Manual Note Adjustments and Calibrations When the tilt gear is disengaged the two arrows on the left side of the printer are pointing at each other RS NE UY 3 XV 2 QS Ay RS ne WV NS Q ANN VE Q NN N 22 ae Tilt Gear Disengaged Tilt Gear Engaged 8500 063 Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 7 Adjustments and Calibrations Homing the Process Drive Train Examine the Process Drive gears for the following m The holes is the Process Drive frame must align with the holes in the gear m The hole in the Drum Maintenance Camshaft gear must align with the arrow on the frame m The hole in the Transfix Camshaft gear align with the hole on the frame When installing or homin
46. Connection Setup Page Network Setup gt USB Setup gt gt USB Port Reset Connection Setup PostScript Error Info Print Quality Mode TekColor Correction Image Smoothing User Defined Screens Reset PostScript Setup Printer Controls gt ______ _ _ Startup Page File Security gt Overwrite Removals Troubleshooting Remove Job Files Daily Removal Remove At HH MM Age based Removal Remove At Age Reset File Security Paper Jams gt Print Quality Problems gt Network Problems gt Service Tools gt _ gt amp Printer Status Page Shutdown a Power Saver Recommended Restart Printer Engine Error History Jam History Diagnostics History Enter Diagnostics Mode Hexadecimal Mode Service Usage Profile Email Service Report Reset NVRAM Power Down Minimizes ink usage Requires Networked printer Duplex Unit Hard Drive Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference TCP IP Setup gt _ Ethernet Speed EtherTalk Wait Timeout Page Description Language TCP IP DHCP BOOTP AutolP TCP IP Address TCP IP Network Mask TCP IP Gateway Port 9100 LPR IPP SLP SSDP CentreWare IS Font Number Pitch Point Size Symbol Set
47. Drive Train on page 6 8 4 Run the Check Y Axis Motor test replace if necessary 5 Run the Belt Slip test 6 Replace the Tray 1 Separator Pad 7 Replace the Process Drive N5T Y Axis motor out of position while the printer transfixed the print N5W Y Axis motor out of position while the printer imaged the Drum 1 Inspect the Y Axis drive belt 2 Run the Check Drum Y Axis Encoder test 3 Run the Check Drum Y Axis Drive test 4 Run the Check Drum Y Axis Belt Slip test 5 Replace the Y Axis motor or Drum assembly if necessary N6T Y Axis motor media short during transfix The media was measured to be shorter than it was believed to be 1 Measure the media to verify it matches the selected length 2 Ensure ground integrity of the printer see page 4 65 3 Run the Check Drum Y Axis Encoder test 4 Pull the preheater and check the preheater flag for ink or paper interference 5 Replace the preheater Legal size paper from Tray 4 in standard print mode may buckle Use slower print mode N7T Y Axis motor media long during transfix The media was measured to be longer than it was believed to be 1 Measure the media to verify it matches the selected length 2 Try heavier media 3 Try loading only a few sheets Some photo media may require running one sheet at a time 4 Run the diagnostic Check Drum Y Axis Encoder test 5 Replace the Pick Assembly and retard roller 6 Run the clean ink smears and che
48. Drum Temperature Sensor Y Axis Motor V Axis Tension Spring Encoder amp 8500 8550 s8500 020 Warning Always keep your fingers away from the drum drive system it uses a closed loop servo drive system which is inherently dangerous Since the motor speeds up if it senses the drum drive system slowing down fingers caught in the drum belts and gears can be severely injured Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 17 Theory of Operation 2 18 Transfix System The Transfix Roller applies pressure to the back side of the media as it moves between the Transfix Roller and Drum This pressure transfers the image from the drum to the paper A set of springs in the Transfix Load Module determines how much pressure the Transfix Roller applies to the Drum The pressure is uniform across the length of the Transfix Roller to avoid wrinkles and light spots on the prints After the Transfix Roller engages the Drum rotates to advance the media through the transfix process The Drum continues to advance the media until the Transfix Roller disengages The action of the Process Drive lifts and lowers the Transfix Roller The upper gears of the Process Drive move to rotate the Transfix Camshaft to bring the Transfix Roller into contact with the Drum The gears reverse to rotate the Transfix Roller back to its original position except when printing from Tray 1 or on envelopes The transfix load springs and double lever arm
49. FFT frequency not including the drum or motor 4 38 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting This procedure performs a 4 corner test using the minimum and maximum velocity and acceleration used during printing and minimum and maximum load for a total of eight test cycles Measures servo response parameters under various conditions Y Axis Drive Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 HAHVN CCW 4000 to 4000 to Reports average following Average Fe mpts 5700 5800 error during the last half of the first period 1 HAHVN CCW Fe 100 to 380 0 to 500 Reports following error ripple Ripple mpts during the last half of the first period 2 HAHVN CW 5200 to 5500 to Reports average following Average Fe mpts 3800 4000 error during the last half of the second period 3 HAHVN CW Fe 80 to 380 75 to 350 Reports following error ripple Ripple mpts during the last half of the second period 4 HAHVN Start Fe 0 08 to 1 0 05 to 0 2 Reports the time following the Settle time sec start of motion for the Fe value to enter the CCW ripple band 5 HAHVN Reverse Fe 0 17 to 1 1 12 to 3 Reports the time following the Settle time sec start of motion reversing that it takes the following error value to enter the CW ripple band 6 HAHVN Stop Fe 001 to 001 to 30 Reports
50. Orientation Form Length Line Termination Draft Mode Reset PCL Setup Power Saver Timeout Date and Time Intelligent Ready Language Control Panel Brightness Control Panel Contrast Accessible Control Panel Reset Control Panel Setup Metric Defaults Reset Printer Controls Paper Tips Page Troubleshoot Jams Paper Path Test amp Troubleshooting Print Quality Page Eliminate Light Stripes gt Remove Print Smears Basic Advanced Network Diagnostics Network Log Pages Jet Substitution Mode No Removes light stripes on prints A 5 Reference Media Margin Specification Table Top Side Bottom Image Image Width Length Margins Margin Width Length Media Size mm mm mm mm mm mm Legal 215 9 355 6 5 5 205 9 345 6 Folio 215 9 330 2 5 5 205 9 320 2 A4 210 297 5 5 200 287 A 215 9 279 4 5 5 205 9 256 7 Executive 187 15 266 7 5 5 174 15 256 7 B5 JIS 182 257 5 5 172 247 B5 ISO 176 250 5 5 166 240 10 Envelope 104 775 241 3 5 15 94 775 211 3 Choukei 3 Gou 120 235 5 15 105 205 C5 Envelope 162 229 5 20 157 189 DL Envelope 110 220 5 20 100 180 Statement 139 7 215 9 5 5 129 7 205 9 A5 148 210 5 5 138 200 Choukei 4 Gou 90 205 5 15 80 175 Monarch 98 425 190 5 5 15 88 425 160 5 Envelope A7 Lee Envelope 133 35 184 2 5 15 123 35 154 2 6 3
51. PERFORM THIS CHECKLIST ONLY IF YOU SUSPECT NON XEROX INK IS BEING USED Step Print Test Print 1 Weak Missing Jets CAREFULLY examine it If YES If NO 1 Does Test Print 1 show at least one color with 8 or more Go to Step 3 Go to Step 2 weak missing jets Step Run 10 solid fills in the suspected color from the front panel Does If YES If NO 2 the number of weak and missing jets noticeable increase with solid Go to Step 3 Go to B fills Step Does the printhead reservoir of the affected color have a large If YES If NO 3 visible pool of ink obscuring the surface of the filter element Go to B Go to A Ink not visible Filter viewable Visible pool of ink obscuring filter Ink passing easily thru filter Ink not readily passing thru filter A Generic Ink Failure B Does not fully meet field criteria Suspected generic ink failure e Inform the customer that service will only be provided with a credit card or purchase e Inform the customer that although the Field order The Xerox warranty Service Generic Ink Failure Test Criteria was not Agreement DOES NOT cover repair cost of satisfied engineering will further evaluate the printhead when it has been damaged by the printhead upon its return to the factory non Xerox ink and the repair cost is the It will be subjected to complete analysis at responsibility of the customer that time and if f
52. Path Menu Runs the Media Path Drive train and engages the Head Maintenance Clutch on the fly then disengages the clutch The test is repeated in both directions to determine clutch characteristics steady state drive requirements bearing status etc Wiper Shaft Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Time to CCW On 0 009 to 02 to 1 0 Reports how long it takes the peak fe sec 0 16 MP motor servo system to react to the sudden addition of the wiper shaft load Larger values may indicate a slipping or slow to engage clutch 1 CCW On peak fe 25to 100 015to 1 4 Reports the peak effort required to accelerate the wiper shaft load A smaller value could indicate a slipping clutch 2 CCW On fe settling 2 1 to 0 25 03 to 3 Reports the time it takes the time sec MP motor servo system to settle down following the sudden addition of the wiper shaft load A longer time could indicate a looseness in the wiper shaft assembly or a slipping clutch 3 CCW On average fe 10 to 50 1 to 0 Reports the average effort required to rotate the wiper shaft in the CCW direction at a constant velocity An unusual value could indicate a difference in the composition and or number of the rollers the nip pressure or out of range mechanical dimensions due to wear or contamination such as paper dust increasing the effective diameter of a roller
53. Printer Service Manual 7 3 Cleaning and Maintenance Trays 2 4 Use off the shelf clear packaging tape and follow the procedures listed below to clean the pick roller and pick pad for Trays 2 4 This cleaning method has been found to be extremely effective for removing debris Isopropyl alcohol while effective tends to smear the debris rather than remove it 1 2 3 4 Locate a clean section of the tape rub it onto the surface of the pick pad 6 7 Remove the affected tray Peel off a strip of tape Stretch the tape across the table with the sticky side up Fasten it to the table at both ends Remove the roller Roll the roller across the tape to remove the debris from the roller for the paper tray then remove it Replace the roller Reinsert the tray 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 Maintenance Drum Maintenance Kit The printer uses the Drum Maintenance Kit as part of its self maintenance routine to coat the print Drum with oil before each print Drum Maintenance Kit Life Standard Startup P N 108R00602 8400 Maintenance Kit Life P N 108R00675 8500 8550 8560 Any Coverage 10 000 cycles for black and white 5500 cycles for color 8500 8550 10 000 cycles r
54. Y Axis Motor mount and the Pick Clutch Check that this clip is installed and contacts the metallic portion of the Pick Clutch os AO UAT ANY Note The Grounding Clip is factory installed in later versions of 8500 8550 models and in all 8560 models 3 32 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 19 005 63 Wave Amplifier overcurrent This error can occur in too low humidity environments Printer self resets Troubleshooting Procedure for Printhead Calibration Step Questions and Actions Yes No 1 For 19 005 41 errors Goto Step 2 Correct or Check that the Ground Clip 650442700 is replace the properly installed at the Y Axis Motor Ground Clip mounting and contacts the metallic portion of the Pick Clutch Is the Ground Clip properly installed 2 Check and reseat all wiring to the Printhead Complete Replace in Did this correct the problem this order m Printhead Electronics Module 19 0XX 6x Errors Waveform Program Faults 19 001 68 thru 19 039 61 Waveform Printhead calibration program faults a Reset NVRAM and then retest b Replace the NVRAM chip c Replace the Printhead 21 000 69 Errors Diagnostic Code Version Mismatch The diagnostic firmware does not match the engine firmware Update the diagnostic firmware for the printer If a code updated ROM daughter board is installed on the main board remove the
55. a latching mechanism to unlatch and latch the missing tooth gear to engage the Printhead tilt drive train The cam s latching mechanism also holds the tilt gear in place A leaf spring applies constant pressure to engage the gear when the latching mechanism is released The arm of the latching mechanism is inside the frame the rest is visible outside the frame Arrows located on the latching mechanism and on the frame indicate when the Printhead is in print position When the arrows on the latching mechanism and frame align the Printhead is in the print position and the tilt gear disengages from the Process Drive Phaser 8500 8550 8560 printers have a solenoid Head Tilt Solenoid that is actuated and deactuated when the tilt cam gear rotates to the respective engaged and disengaged positions The latching mechanism is actuated by a small movement of the wiper coupled with the Head Tilt Solenoid The action of the solenoid ensures that the Head Tilt Gear engages the tilt drive gear Through a follower gear the compound gear drives the tilt cam gear clockwise A cam follower mounted on the lower end of the tilt arm follows the rotating tilt cam gear and tilts the Printhead After one revolution of the tilt gear the latching mechanism is pulled back into position by the return spring in the 8400 and by the Head Tilt Solenoid in the 8500 8550 8560 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 11 Theory of Operation As viewed f
56. all components grounded properly integrity 3 Run the Printhead Reservoir Temperature Go to Step 4 Replace the test Printhead Did the test pass 4 Check and reseat all wiring to the Printhead Complete Replace the Did this correct the problem Printhead 13 328 43 The ink loader CYAN heater is too hot 13 330 45 The ink loader CYAN heater took too long to reach its setpoint 13 387 48 The ink loader CYAN thermistor circuit is open 13 389 41 The ink loader CYAN thermistor circuit is shorted 13 391 43 The ink loader CYAN thermistor returned a bad reading or was corrupted by ESD 13 392 44 The ink loader MAGENTA heater is too hot 13 394 46 The ink loader MAGENTA heater took too long to reach its setpoint 13 451 49 The ink loader MAGENTA thermistor circuit is open 13 453 42 The ink loader MAGENTA thermistor circuit is shorted 13 455 44 The ink loader MAGENTA thermistor returned a bad reading or ESD corruption 13 456 45 The ink loader YELLOW heater got too hot 13 458 47 The ink loader YELLOW heater took too long to reach its setpoint 13 515 41 The ink loader YELLOW thermistor circuit is open 13 517 43 The ink loader YELLOW thermistor circuit is shorted 13 519 45 The ink loader YELLOW thermistor returned a bad reading or ESD corruption 13 520 46 The ink loader BLACK heater got too hot 13 522 48 The ink loader BLACK heater took too long to reach its setpoint 13 579 42 The ink loader BLACK
57. an LED blink code flashing on all three LEDs Control Panel LED PS LED and PE LED If initialization of the Control Panel fails POST errors will still report using the LED blink patterns The sum of the flashes equal the error code If the code has more than 5 flashes there is a brief pause between each set of 5 flashes to make them easier to count After all flashes occur within the code there is a long pause and then the flash pattern repeats Soft POST errors that do not prevent the printer from powering up completely are displayed on the Control Panel for 5 seconds and then the printer continues through the remainder of POST There are no rear panel LED codes associated with soft errors Most soft errors will cause the printer to print a Startup Page with the error message on it Note Before replacing the Electronics Module for any POST errors do the following 1 Disconnect all connections to the Electronics Module 2 Plug in the Power Cord and power on the Electronics Module 3 If the error blink pattern changes from the original error reported before Step 1 the problem may not be in the Electronics Module see Miscellaneous Electrical Troubleshooting on page 4 56 POST Error Reporting Blink Pattern Definition Table 8400 PS PE and Control POST 8500 Error Panel LEDs for Error 8550 8560 Code 8400 Type Description Error Code 01 01 Flutter then 01 blinks Hard Bad e
58. an ink level sensor has failed Step Has the printer If YES replace the wiper assembly Proceed to Step 9 5 had a printhead YES replaced before NO The new wiper assembly may take 6 purges to before achieving optimal for a non NXI performance Ensure the wiper assembly is correctly aligned with the related weak or Circle printhead missing jet one If the missing jet s recovers the repair is complete problem Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference Step Is the Wiper Is the wiper assembly out of alignment not parallel with the printhead 6 Assembly YES faceplate correctly NO If YES perform the wiper alignment procedure as described in the aligned Phaser 8400 Color Printer Service Guide Circle one Step Print Service Is there color mixing from one row to the next row for the same jet 7 Test Print 1 YES Note Some color mixing is normal following a purge It Weak and NO usually clears after one or two prints Missing Jets If YES replace the wiper assembly Repeat Step 6 Is severe color Circle mixing one apparent Step Visually check Are there streaks smudges or a scum of wax in the jet area outlined in 8 the printhead YES red of the printhead faceplate Is NO the faceplate contaminated Circle one ne ae If YES replace the wiper assembly Repeat the checklist starting at Step 6 Step Visually check Is there any damage or separation on the wiper
59. ated mue aTa aa nae 6 9 12 PL 6 0 Sensors and Flags Actuators 0 0 n nannaa eee 9 14 Xerox Supplies irie nnise nerne siena a eaa Denei Eie a aane a EE a VEA EE E EE E E E E A 9 16 10 Wiring Diagrams Main Wining Diapit eaea ee a eae E E E ea Da ee haa ek 10 2 Main Wiring Diagram Continued 0 00 cece eee 10 3 Right Side Wiring DidQraM 44 cc00 oo tied eddie coadaeedas oot d neudd booed Shade takni eea endo eaede eed 10 4 Right Side Wiring Diagram Continued 0 ccc cece eee n eee teen ene e ees 10 5 Left Side Wiring Diagram esie ci beta ea ke beeen ee hdd edn dane nde Sk eae aE 10 6 Left Side Wiring Diagram Continued 000 c cece ett tte e teen eens 10 7 Inside Front Wiring Diagrami seess sia des4 o duuk edn ebeteed dae Aude bidd de a eee Oe OTe ORES REGS 10 8 Inside Top Wiring Diagram 1 2 0 entree tenn ete e nent eens 10 9 Inside Top Printhead Wiring Diagram sess epas kean an tet AARAA AE eens 10 10 Reference Menu Map 8400 0 3 50 ssc ies foe Moet aaa eee tate de dw ceed a Peet aa ay ean tee mbes A 2 Menu Map 8500 8550 8560 0 ce eee enn ee een n ene et ee eee eee eens A 4 Media Margin Specification Table 0 0 eee ene eee een nent eee n eee e eens A 6 Paper Weight Equivalence Table 0 0 ent etn t nett nent nee nes A 7 On site Printhead Troubleshooting Checklist 8400 0 0 cece eee eee eee eee A 8 Ink Failure Checklist 2 0 nen eee need eee nee eaae A 12
60. attached to a wire harness It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2 Note Only parts showing part numbers are available for support Parts not showing part numbers are available on the parent assembly Legend Identifier Meaning C C ring E E ring KL KL clip S Screw Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 3 Parts Lists PL 1 0 Covers a SY vA f 4 WN 7 5 s8500 117 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 4 Parts List 1 0 Covers Parts Lists No Name Description Qty Part Number 1 Front Door MPT Assembly 1 200467880 8400 848K06520 8500 8550 8560 2 Front Door Stay Retainer Clip 2 120E29140 3 Front Door Stay with Spring 2 009K02390 4 Hinge Pins Front Door 2 029E49330 5 Control Panel Cover 1 200467380 8400 802E93850 8500 8550 8560 6 Control Panel with Bezel 1 657012880 8400 802K93650 8500 8550 8560 7 Exit Cover Assembly 1 200469380 8400 Exit Cover with Badge 802K93590 8500 802K88420 8550 848K12760 8560 Ink Loader Door part of PL 2 1 1 See PL2 0 1 Left Side Cover 1 200467680 8400 802K93660 8500 8550 8560 10 Right Side Cover Assembly with Doors 1 200467580 8400 802K93570 8500 8550 8560 11 Drum Maintenance Door Side
61. before proceeding with these steps The I O board needs to be isolated from other systems in the printer to be effectively tested Turn off printer and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully Unplug the Control Panel connector J220 on the I O board This removes the Control Panel from the I O board Plug in the Power Control to I O board connector J800 This step adds the I O board back to the working Electronics Module nothing else is connected Turn on power to the printer 5 If the PE and PS indicators do not flash momentarily the short is on the I O board or related cabling Skip the rest of this section if the PE and PS indicators flash because the problem is elsewhere in the printer a Verify short is on the I O board by using an ohmmeter to check the resistance on J270 pin 1 to ground Resistance of less than 1K ohm indicates a problem To isolate problem to I O board or related cabling unplug I O board connectors Umbilical Right J1 Waste Tray Sense J110 Stripper Solenoid J250 Paper Tray Sense J610 Front Door Sense J600 Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 57 General Troubleshooting 4 58 i j m Inkload Signal J910 m DMU Sense J860 m Drum Thermistor J870 m Exit Module J680 m Heater Relay Control J950 c Retest the resistance of the I O
62. between either supply conductor and ground For 230 VAC printers do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector This manual assumes that the reader is a qualified service technician Plug the three wire power cord with grounding prong into a grounded AC outlet only If necessary contact a licensed electrician to install a properly grounded outlet If the product loses its ground connection contact with conductive parts may cause an electrical shock A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Disconnecting Power Warning The power switch does not completely de energize the printer You must also disconnect the power cord from the printers AC inlet Disconnect the power cord by pulling the plug not the cord Disconnect the power cord in the following cases if the power cord or plug is frayed or otherwise damaged if any liquid or foreign material is spilled into the product if the printer is exposed to any excess moisture if the printer is dropped or damaged if you suspect that the product needs servicing or repair whenever you clean the product Phaser 8400 8500 8550 8560 Color Printer Service Manual Electrostatic Discharge ESD Precautions Some semiconductor components and the respective sub assemblies that contain them are vulne
63. blinks Hard IPCB PCI configuration failure 18 04 Flutter only Soft IPCB version mismatch 19 01 Flutter then 19 blinks Hard Check and reseat cables Replace Hard Drive if necessary PEST Error Reporting PEST tests occur after POST tests have been run and PostScript has been initialized PEST checks the connections and operation of various printer components Error codes for PEST tests are displayed on the Control Panel and are all in Errors PEST Faults on page 3 36 the 37 XXX xx series For troubleshooting PEST error codes 37 0XX xx Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Fault Code Error Message Troubleshooting Fault Code Error Reporting Fault codes are saved to NVRAM and can be retrieved from the printer s fault history All procedures that ask for a test to be run are referencing tests from within the hidden Service Diagnostics menu For more information on Service Diagnostics tests their results and how to enter into diagnostic mode see Service Diagnostics on page 4 4 In normal customer mode the printer will reboot each time an error occurs If three of the same errors occur within 72 hours or 1000 pages the fault is displayed on the printers Control Panel Interpreting Fault Codes Failing system XX yyy zz u Failing subsystem xx YYY zz m Checksum xx yyy zZ m Type of problem xx yyy Zx m Print engine copy count when the error occ
64. board If the resistance is still less than 1K ohm replace the I O board reinstall all cables and retest printer d If the I O board resistance is OK plug in the I O board connectors one at a time and retest the resistance e Plug in all cables removed during service f Trace through all service steps performed to reattach any cables that were unplugged during debugging g Attach printer covers h Perform full test of printer Short circuit on 3 3 V power supply within the Control Panel a Required Follow all procedures from Step 3 and Step 4 before proceeding b With power cord connected touch the metal Electronics Module to discharge any static electricity c Turn off printer and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge d Plug in the Control Panel connector J220 on the I O board This step adds the Control Panel back to a working Electronics Module and I O board in order to see if the short circuit is also removed e Turn on power to the printer f If the PE and PS indicators do not flash momentarily the short is on the Control Panel Replace the Control Panel and retest the printer Skip the rest of this section if the PE and PS indicators flash because the problem is elsewhere in the printer g Plug in all cables removed during service h Trace through all service step
65. board so the printer boots using the main board s code and diagnostics 22 0XX 6x Errors Jam Codes For jam codes Jam Codes on page 3 48 23 0XX 6x Errors NVRAM Fault 1 Reset NVRAM and then retest 2 Replace the NVRAM 26 0XX 6x Errors Printing Faults Reboot the printer if one of these faults occur Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 33 Error Messages and Codes 26 962 6x Errors Fall Out Code Check the previous error in the fault history and troubleshoot that code 27 0XX 6x Errors Profile Library Ensure the ground integrity of the printer see Ensuring Ground Integrity on page 4 65 29 0XX 6x Errors Jam Manager 1 Reset NVRAM and then retest 2 Replace the NVRAM 31 0XX 4x Errors Mechanical Initialization Jam The Media Drive motor stalled while moving the media path drive train Look for interference or debris in the paper path Check test Media Drive motor 31 001 40 Mechanical initialization jam fault Troubleshooting Procedure for Mechanical Unit Jam Step Questions and Actions Yes No 1 Check that all the main tray paper path Replace the Go to Step 2 sensor wires are clear of the Take Away wiring Rollers harness Are any wires damaged 2 Are the Take Away Rollers dirty Replace the Go to Step 3 contaminated or damaged Take Away Rollers 3 Run the Paper Path Drive test Goto Step 5 Goto Step 4 Did the test pass
66. chassis and remove the Transfix Load Arms and Transfix Roller E A lt p Loe Sf Clevis Pin A Uf y Ca on Oa Sa N N Transfix Load Arm Add Grease s8500 088 10 Remove the Transfix Camshaft page 8 25 11 Remove the grounding springs from the Transfix Load Module f P Sans ai Clim Al ee es are j a PRG or Ne LR A Grounding Springs Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 23 Service Parts Disassembly 12 Remove two screws securing each end of the Transfix Load Module to the chassis 8500 090 13 Remove the Transfix Load Module by rotating the bottom in and pulling it forward Note The Transfix Load Module is a very tight fit remove carefully Transfix Load Module Replacement Note Place a small amount of Rheolube 768 grease P N 070E00890 in the groove on the end of each Transfix Load Arm before reattaching the spring hooks After installing the Exit Module perform the Wiper Alignment procedure on page 6 2 The printer may report error 7 009 4x if the Wiper Assembly is misaligned 8 24 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Transfix Camshaft PL2 0 10 1 Perform Steps 1 through 7 remove Transfix Load Arms of the Transfix Load Module removal procedure page 8 22 2 Remove the Process Drive page 8 43 3 Slide the s
67. clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 17 General Troubleshooting Wiper Shaft Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 9 CWOnaveragefe 50to15 02to 2 Reports the average effort required to rotate the wiper shaft in the CW direction at a constant velocity An unusual value could indicate a difference in the composition and or number of the rollers the nip pressure or out of range mechanical dimensions due to wear or contamination such as paper dust increasing the effective diameter of a roller 10 CW On fe ripple 20 to 75 Oto 4 Reports the variation of effort needed to rotate the wiper shaft in the CW direction at a constant velocity A larger value may show particles in the gears or non uniform contamination of a roller causing a lump 11 CW Off fe settling 5 to 01 02 to 22 Reports the time it takes the time sec MP motor servo system to settle down after the sudden release of the wiper shaft load A larger value could indicate a dragging or slow to release clutch Runs the Media Path Drive train and engages the Tray 1 Pick SAolenoid on the fly The Pick Shaft goes through two full revolutions while drive requirements are determined Tray 1 Pick Shaft Typical Typical Value Value 8400 8500 R Definition 8550 8560 Actions 0 Off average MP fe 800
68. debris under the Printhead preventing proper motion m The Wiper Assembly not being aligned correctly or ink spilled in the wiper tracks m The Head Tilt Gear not being homed correctly m The X Axis Motor nose cone not being installed correctly The ferrite torrid on the Printhead interface cable has slipped behind the Printhead causing the Printhead to bind when it tilts backwards m The black plastic shroud on the back of the Printhead is snapped off and binding the Printhead when it tilts back Caution 3 16 After servicing the printer manually set the following assemblies to their home position before powering on the printer See Section 6 for instructions on setting these components to their home positions Printhead tilted forward and disengaged from Printhead tilt gear Head Tilt Gear disengaged from Process Drive train arrows on left frame point to each other Wiper Assembly bottom of travel Process Drive holes on Transfix Camshaft and Drum Maintenance Camshaft line up with marks on frame large gears within assembly line up with holes in Process Drive housing Phaser 8400 8500 8550 8560 Color Printer Service Manual 7 007 49 The process motor stalled while tilting the head Troubleshooting Procedure for 7 007 Error Code Error Messages and Codes Step Questions and Actions Yes No 1 1 Check the Printhead wire routing 2 Remove the Printhead and inspect the Printhead tilt and drive gears f
69. defective part Retest the printer Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 50V Power Supply Fault Troubleshooting Procedure Continued Step Questions and Actions Yes No 5 Toisolate the problem to the 1 0 Board or its Replace the Go to Step 6 related cabling unplug these 1 0 Board 1 0 Board connectors a Umbilical Right J1 Waste Tray Sense J110 Stripper Solenoid J250 m Paper Tray Sense J610 a Ink load Signal J910 DMU Sense J860 Drum Thermistor J870 a Exit Module J680 Heater Relay Control J950 Test the resistance of the 1 0 board to Pint of J270 Is the resistance still less than 1K ohm 6 1 Plug in the I O Board connectors one ata Leave power Go to Step 7 time and retest the resistance on to ensure 2 Replace components until you find one the problem is that creates a short at J270 Pin 1 fixed Find any shorted components 7 Connect the Wave Amp Leave power Goto Step 8 Any problems On to ensure the problem is fixed 8 Connect the Printhead Apply power Complete and retest 8400 PEST Description 8500 8550 8560 PEST description 37 017 44 Deskew Clutch Disconnect Head Maintenance Clutch The Deskew Clutch is not Disconnect The Head Maintenance drawing the expected power Clutch is not drawing the expected power 37 018 45 Main Tray Pick Clutch Main Tray Deskew Clutch disconnect The Main Tray Pick Disconnect The Main Tray Deskew Clutch is not
70. eee n ene e eens 2 2 Process Drive capeneri Vike bed tanhede don CS od ekg See Se ben hee ee Me oh aed 2 4 Media DINE i mocne raanei enea a 2a males Sunes E a ates oa ecd added ad doe mew awed deena 2 5 INK LOADER a2 ccdceo coed ower orndigectaaeagad Sean heared Meee eghase Dea basa oleae atade hae 2 6 Printheads ee ered bos aj svene dog a hea dona awe bad dua ated s kw ieee are ba hee aie adobe aut es 2 7 Printhead Tilt enya seco itis boa a E duck be Lad teed conte bono dae gb ale he 2 10 Drum Maintenance Kit 2 2 een ee een teen etn een eens 2 13 Purge System o eies doe dd hats bowed Jinks Madd dees Mada dieds Mea badiee hlhde dled eavhe eee 2 14 Drum Assembly And Transfix System 0 0 cece enn e teen nee eens 2 16 Electonics Module isere eaan edna Mh dacks MAGUS nite ei bs Heedea ia bbe 4 2 19 WOSBOAN eienn E ancuceae a a cuadeo anion nora Sissaun ante a 2 22 SENSOMNS lt c s54 Soros a iewh Award adtad Movda baad dbase oaiaddalnamardad dosha anihddalandoatna aoe 2 22 Print PROCESS ai 2 5 s2682 aa jhaaaadus on fib caakihe ea aiea a kite budoeebreia be adla Sieh a e a a aaa Sues 2 23 PRINTING oc boittacas th aealee i a bduaieiced addy aE Lack doeducnayh Mead a aaa Doda he til an eccs 2 24 Paper PICK On Tray 1 ecco nue os aise a ini aiena died Daw ed dae ed Reed teed Ge een eee es 2 25 Paper Pick for Tays 2 4 oes divedt pews td Reed baad ede RA dole dee pee dade eee oo 2 26 Transfixing and Exiting 0 ete tenet nee tne RAAEN RAEG 2
71. fills and a band of 50 blue as this is a popular background color for overhead transparencies 8500 052 Look for Scratching on the print 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 Confirm that you are using the transparency that is supported for this printer Clean or replace the paper release blade For more information about scratches see Scratches or Marks Parallel to the Long Axis of Printing Particularly with Film on page 5 13 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Gray Fill Dot Size Uniformity This print consists of a 66 black fill It reveals thermal variations transfix roller pressure variations or Drum oiling variations Light band 8500 053 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 3 the width of the page running the length of the page Also look for small light spots or irregular white lines vertically aligned every125 mm 5 0 in Also look for ink on the top and bottom margin of the page or ink on the back of the page This pattern is sensitive to the density variations in the paper it is printed on Use high quality pa
72. from Tray 1 Go to Step 5 Go to Step 4 to see if the scratch appears Is there a visible scratch NOTE To determine where the scratch is originating place a small drop of water on the scratch on the transparency If the scratch disappears the scratch is on that side If the scratch does not disappear test the other side This can help to determine where the problem is originating 4 1 lf there is no scratching on the Complete Go to Step 5 transparency the defect occurred during pick or early transport from Tray 2 3 or 4 2 Change the paper pick guide Front Door or Drum Maintenance Kit Did this correct the problem 5 A scratch or smear can be caused by debris Complete Go to Step 6 build up on the Preheater s surface Run Remove Print Smears Did this correct the problem 6 1 Force a sheet of thick 65 to 80 Ib paper Complete Go to Step 7 through the Preheater to buff the Preheater heating surfaces 2 With the leading and trailing ends of the sheet of paper extending from the entry and exit of the Preheater gently pull the sheet of paper back and forth several times and then remove the paper Be careful of the sensor flags Did this correct the problem 7 Inspect all paper guides for nicks cuts or Clean or replace any defective debris paper guide s 5 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting I
73. in the Parts List A replacement procedure is included when necessary Section 9 Parts List This section contains exploded views of the print engine and option FRUs as well as part numbers for orderable parts Section 10 Wiring Diagrams This section contains the plug jack locations and the wiring diagrams for the print engine Appendix A Reference This section provides an illustration of the printer s menu structure a listing of printer status codes and a list of Service Diagnostics tests Phaser 8400 8500 8550 8560 Color Printer Service Manual Contents Contents SGV LMS aieea ae a Tie daewend PoGhI seek dei deestakdesGhedihae tian ahi tewwiawed eels t iii Symbols Marked on the Product 0 0 ccc ene nee eee n ene e teen nee eee nes iv Power Safety Precautions 0 ccc ccc ee ene ene n ene teen eee enn eet nes iv Electrostatic Discharge ESD Precautions 00 c cece eect tenet ete eeeeees V Servi Safety SUMMALY so Jonrsrcissroiitr crin eia hoon tes e Deini aa e a a a EEE vi Regulatory Specifications nnan nunnana anea viii Manual Organizations sic isser ivirsinoniare ei apiri n inea DE eda Sade hide a ea X 1 General Information Printer Introduction and OvervieW 0 0 ccc eee ene eee ene ene et ee eee eee eens 1 2 Printer Configurations eskas os i0s ood oeudid oad ponds Mend pag db dlade MS odode Eke eeode goede dod 1 3 Control Panel Configuration 0 0 0 eee een een nen
74. in the reservoirs If necessary the ink loader adds ink At the ready state the print process consists of the following steps m Drum Preparation m Printing m Paper Pick m Transfixing and Exiting Warning Keep your fingers away from the Y Axis Motor while the motor is in operation The motor s closed loop servo system is inherently dangerous Drum Preparation To prepare the Drum the drum maintenance system applies a thin coating of silicone oil to the surface of the Drum The Process Drive first rotates the Drum Maintenance Camshaft As the drum rotates the cams on the ends of the camshaft push against followers on each side of the drum maintenance system forcing the oil roller and blade against the Drum The saturated roller evenly distributes oil on the Drum as it rotates Joe Drum Oil on Drum Drum Maintenance Maintenance Roller Camshaft Drum Maintenance Pivot Plate 8500 016 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 23 Theory of Operation 2 24 Printing To print the Drum rotates at a speed dependent upon print resolution As the Drum reaches the correct speed the jets begin to fire to deposit the image on the oiled portion of the Drum As the jets fire the Printhead moves from right to left to complete the image on the drum When printing the printer performs a six jet interlace in which each jet lays down a particular number of pixel columns depending on the print
75. installing a part is usually simply a reversal of the disassembly Replacement procedures are included where this is not the case and special steps are required Replacement notes are included when they can help ease or shorten the reassembly process Standard Orientation of the Printer When needed the orientation of the printer is called out in the procedure for locating printer parts Refer to the printer orientation graphic for locating the right left front and back sides of the printer 8500 002 8 2 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly General Notes on Disassembly Caution Follow the steps of all disassembly procedures in the order given to avoid damaging printer components 1 Before servicing the printer switch Off the printer power wait until the printer completely shuts down and disconnect the power cord from the wall outlet 2 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards 3 Upon reassembly of printer components be sure the components are all in their home positions otherwise damage to the printer will occur See Chapter 6 Adjustments Home Position page 6 2 for information on the home positions Special Notes Regarding Screws Used in This Equipment Caution Screws in plastic are torqued to 12 in Ibs metal to 15 in Ibs unless otherwise specified The screws for the Printh
76. is being used Follow the instructions on the Printhead Troubleshooting Checklist Note Include two prints of this test print with any returned Printhead Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting X Axis Motion 8400 Only Note For X Axis Motion problems see Analyzing Service Test Prints on page 5 34 solid fill prints This print is used by Engineering and Manufacturing The print must be printed on Xerox Photo Paper Using a lower grade paper will result in inaccurate measurements 8500 049 Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 35 Print Quality Troubleshooting 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 A weak jet can cause banding see the Weak Missing Jets test print on page 5 34 Banding can also be caused by color to color misregistration Use the diagnostics to ensure that the Printhead and Drum thermals are correct Follow the instructions on the On site Printhead Troubleshooting Checklist 8400 on page A 8 8500 050 5 36 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Reverse Text The print indicates if the Printhead is produc
77. jets print the solid fill test print in the color with the discolored jets In the following example the yellow stripe has discolored jets therefore you would print the yellow solid fill For instructions on printing solid fill test prints see Black Red Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Discolored jets usually clear after two or three prints using the problem jets XEROX Light Stripes Test Clean the exit path and Stripper Blade with a lint free cloth Did this correct the problem Complete Go to Step 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 3 Print Quality Troubleshooting Random Light Stripes Trou bleshooting Procedure Continued Step Questions and Actions Yes No 4 Remove the Drum Did this correct the Maintenance Kit and Complete clean the wiper blade with a lint free cloth or replace the maintenance kit problem Go to Step 5 5 For the 8400 Customer Support Select Advanced page After selectio the selected jet pri Did this correct the Download the latest Jet Fix snippet from the readme instructions For the 8500 8550 8560 choose the color and number of the problem jet based on the Light Stripes Test temporarily increases the drive voltage to then performs a cleaning cycle Site and follow the You are prompted to ns are made the printer nts severa
78. out following Tray 2 Pick Exit flag timed out following Tray 3 Pick Exit flag timed out following Tray 4 Pick Exit flag timed out following Tray 1 Pick Exit flag timed out during duplexing D3T Exit flag time out during transfix 1 Inspect the exit path for obstructions 2 Inspect and clean the exit roller ensure the exit roller rotates 3 Inspect and clean the stripper blade 4 Replace the Drum maintenance unit 5 Run the diagnostic Paper Path Drive test E2D E2E Tray 1 width sensor during warm up Tray 1 width sensor during Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 53 Error Messages and Codes 3 54 Jam Code Troubleshooting Procedures Continued E2Q Tray 1 width sensor during Tray 1 pick 1 Examine the Tray 1 width guides for proper movement and ensure the side guides are not being adjusted while printing 2 Ensure the Front Door is closed and the wiring is connected and seated 3 Run the Tray 1 Sensor test 4 Inspect the Tray 1 wiring to the 1 0 board 5 Replace the 1 0 board then retest F2D The Front Door open flag unexpectedly tripped while warming up F2F The Front Door open flag unexpectedly tripped while in a fault state F2M The Front Door open flag unexpectedly tripped during a pick from Tray 2 F2N The Front Door open flag unexpectedly tripped during a pick from Tray 3 F2P The Front Door open flag unexpectedly tripped during a pick from Tray 4
79. picking paper from Tray 4 A2S Deskew sensor in unexpected state during media stage for transfix A2Q The deskew flag tripped unexpectedly while picking paper from Tray 1 1 Try using different supported media 2 Ensure the paper guides are snug against the media in the tray 3 Push up on Tray 2 4 Nudger Roller until captured by the actuator arm 4 Run the following diagnostic tests Deskew Flag Tray 2 4 Pick Clutch and the Tray 2 4 Solenoid 5 Ensure ground integrity of the printer see page 4 65 6 Verify all doors and covers are fully closed and not moving during printing 7 Replace the Tray 2 4 Pick Clutch 8 Replace the Retard Roller 9 Replace the Preheater A3G Deskew Sensor time out during an auto Drum maintenance cycle A3M A3N A3P A30 The deskew flag timed out waiting for the paper picked from Tray 2 The deskew flag timed out waiting for the paper picked from Tray 3 The deskew flag timed out waiting for the paper picked from Tray 4 The deskew flag timed out waiting for the paper picked from Tray 1 1 Verify media is appropriate for the tray 2 Verify the tray is not overfilled and the guides are positioned correctly 3 Check for obstructions in the paper path 4 Test the appropriate Tray Solenoid 5 Test the appropriate Tray Pick Clutch 6 Ensure the Take Away Rollers are in good condition 7 Test the Take Away Roller using the diagnostic Paper Path Drive test 8 Replace the appropriate S
80. problems and electrical failures see General Troubleshooting on page 4 1 or Print Quality Troubleshooting on page 5 1 Check the main menu for current data and historical error data m Status Page m Usage Profile m Fault History m Diagnostic History 3 2 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Power Up Error Messages and LED Codes The printer has three sets of tests that are run when first powered on Built In Self Tests BIST m Power On Self Tests POST m Print Engine Self Tests PEST Note BIST and POST errors are not stored in the fault history logs BIST Error Reporting BIST verifies basic Electronics Module CPU operation and reports failures by utilizing the rear interface panel PS and PE LEDs These tests occur immediately at power up before POST tests are run or the Control Panel is initialized The following table defines the blink patterns associated with a failure BIST Error Reporting Blink Pattern Definition Table Description The power supply could not remain regulated when DC power was applied so it was shut down Follow the troubleshooting procedures for electrical shorts see Miscellaneous Electrical Troubleshooting on page 56 and check the power supply fuses Initialization failure The printer is held in reset mode This can be caused by an Electronics Module fault or a 3 3 V power supply regulation failure see Mis
81. provides a temporary solution for print quality problems when weak or missing jets cannot be recovered When Jet Substitution Mode is active adjacent jets are used to print over the area covered by the problem jet to restore the print quality Jet Substitution Mode reduces the maximum imaging speed by 50 or more and has other limitations that affect printer performance Jet Substitution Mode on 8500 8550 8560 models is in the Eliminate Light Stripes menu Although it does not slow down the imaging speed as it does on 8400 models it still provides an end solution to eliminating light stripes Phaser 8500 8550 8560 printers feature a Jet Substitution mode that is similar to Phaser 8400 printers but with two important differences m Jet Substitution mode on 8500 8550 8560 models can provide an end solution instead of serving as a temporary fix as for Phaser 8400 printers Because Jet Substitution mode can provide an end solution it is located in the Eliminate Light Stripes menu instead of requiring a hidden push button sequence as is the case with Phaser 8400 printers Most 8500 8550 8560 users will not notice changes to print quality or speed when using the Jet Substitution mode It typically increases the imaging time by no more than one or two seconds per page compared to a 50 increase on 8400 modles The knowledge base provides new procedures for determining when to use Jet Substitution mode Factors such as the use of the Bi
82. resolution Each jet lays down one pixel column for each Drum rotation which varies from eight to 16 rotations depending on the print resolution Interlacing averages out the variability between jets as it interlaces each jet with other jets In some test prints the Printhead moves to the right and lays down 309 parallel bands of ink Each band is composed of 15 pixel columns of dots from an individual jet Jet substitution allows a better performing jet to be used in place of a missing or poorly performing neighboring jet When the printer is in the jet substitution mode the Printhead makes a second right to left movement to deposit the pixel columns of the substituted jets See Jet Substitution Mode on page 6 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Paper Pick for Tray 1 To pick a sheet of paper the Tray 1 solenoid actuates and the drive gear rotates slightly to engage with the drive train A bias force from the lift plate against a rotating cam causes the roller to rotate enough so the missing tooth gear engages the drive train This allows the lift plate and paper stack to rotate against the Pick Roller The Pick Roller then rotates to pick the paper A Separator Pad prevents multiple sheets from being picked by the Pick Roller Key differences in the Tray 1 pick process include Increased lift plate force to support heavier paper 100 sheet capacity Pick Roller to create t
83. specifications and the fans run correctly If OK then replace the Electronics Module 12 000 60 Errors Program Faults 1 Reset NVRAM and retest 2 Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 13 0XX xx Errors Thermal Faults 13 000 48 Thermal fault Troubleshooting Procedures for Error Code 13 000 Printhead Step Questions and Actions Yes No 1 Ensure ground integrity for the printer Complete Go to Step 2 Did this correct the problem 2 Reset NVRAM and retest Complete Go to Step 3 Did this correct the problem 3 Check and reseat all data cables to the Complete Replace the Printhead Printhead Did this correct the problem 13 003 42 13 007 46 Troubleshooting Procedures for 13 003 to 13 007 Error Code Step Questions and Actions Yes No 1 Ensure ground integrity for the printer Complete Go to Step 2 Did this correct the problem 2 Reset NVRAM and retest Complete Replace in Did this correct the problem this order a NVRAM Electronics Module 13 008 47 The Drum heater is too hot 13 010 49 The Drum heater took too long to reach its setpoint 3 26 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Troubleshooting Procedure for 13 008 to 13 010 Error Code Drum Heater Step Questions and Actions Yes No 1 Check that the ambient room temperature is Advise Go t
84. supply high switch will not activate 12 15 and 50 volt missing This may be due to a short or disconnected power supply reset line Vss measurement too low The Printhead power cable may be disconnected NOTE Later version Printheads feature a lock connector on the printhead data cable Vpp measurement too low The Printhead power cable may be disconnected NOTE Later version Printheads feature a lock connector on the printhead data cable Troubleshooting Procedure for Power Supply Error Messages and Codes 8500 8550 8560 PEST Description Power supply 50 volt under limit Power supply 15 volt over limit Power supply 15 volt under limit Power supply 15 volt over limit Power supply 15 volt under limit Power supply 5 volt over limit Power supply 5 volt under limit Power supply high switch will not activate 12 15 and 50 volt missing This may be due to a short or disconnected power supply reset line Vss measurement too low The Printhead power may be disconnected Vpp measurement too low Printhead power may be disconnected Wave amp drive cable may be damaged or disconnected at head driver board or wave amp board The Wave Amp may be shorted Check the Wave Amp drive cable lifted ends of conductors Step Questions and Actions Yes No 1 Run the Voltages check test Goto Step 2 Replace the Did the test pass Electronics Module 2 Check the Printhead power cable Re
85. text Cancel Cancels certain functions of the printer Help Provides help information if available Press any key to advance through the help text Up Scrolls up one menu item within a menu list This control does not wrap Used to increment data in tests requiring user input Down Scrolls down one menu item within test results This control does not wrap OK Enters the highlighted menu Executes the current test item NOTE Pressing any key may cause an abort if allowed by the test being performed A power cycle is used to arbitrarily stop a test Service Diagnostics Mode Menu This mode can be entered from the Hidden Service Menu All diagnostics are available in this mode The printer reboots 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 button you can still continue to run diagnostics under this condition Note If the heaters are On while entering diagnostics they will remain On while diagnostics are being run If the heaters are Off while entering diagnostics they will remain Off Utilize the Exercise Heaters function if it is necessary to turn On Off the heaters Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 5 Gen
86. that all warning labels remain in place Safety Interlocks Make sure all covers are in place and all interlock switches are functioning correctly after you have completed a printer service call If you bypass an interlock switch during a service call use extreme caution when working on or around the printer Servicing Electrical Components vi Before starting any service procedure switch off the printer power and unplug the power cord from the wall outlet If you must service the printer with power applied be aware of the potential for electrical shock Warning Do not touch any electrical component unless you are instructed to do so by a service procedure Phaser 8400 8500 8550 8560 Color Printer Service Manual Servicing Mechanical Components When servicing mechanical components within the printer manually rotate drive assemblies rollers and gears Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running Servicing Heated Components Warning This printer uses heat to fuse the image to media Several components are heated during operation Turn the printer power off and wait at least 10 minutes for these components to cool before you attempt to service the Fuser or adjacent components Phaser 8400 8500 8550 8560 Color Printer Service Manual vii Regulatory Specifications viii Xerox has tested this product to electromagnetic emission and immunity stan
87. the process drive gears and the mating camshaft gears is critical The Process Drive gearbox is mechanically keyed upon installation via gear orientations These gear orientations allow the printer subsystems to self home during operation If either the gearbox or cam gears is out of home during installation the printer does not function properly Process Drive Swing Gear ae lransfix Camshaft oe a J Drum Maintenance pa 8500 009 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Media Drive The Media Drive assembly drives each roller in the media transport path A gear train located behind the motor connects it to the Exit Rollers which are built into the Exit Module Gear trains located within the Media Drive along with two clutches and a solenoid allow the motor to control the Pick Take Away Duplex and Deskew rollers A unique swing gear allows the Pick Roller and Take Away Roller to rotate in the same direction regardless of the direction the motor is rotating ey Q Duplex Roller Z SO A A y y Deskew Roller NL 6 2 AN Lx oS WW 4 Take Away Roller Pick Roller s8500 010 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation 2 6 Ink Loader The Ink Loader consists of four parallel channels with an ink melting element at the end of each channel Coil springs exert pressure on four
88. the cable into the printer while sliding the Drum Maintenance Pivot Plate out the Drum Maintenance Kit cavity Grounding Clip 8500 095 Replacement Note Lightly grease the metal plates on which the cams ride using a small quantity of Rneolube 768 grease P N 070E00890 Also fill the pocket under the shaft ground with grease 8 26 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Drum Assembly PL2 0 3 Remove the Front Door page 8 4 Remove the Right Side Cover page 8 5 Remove the Left Side Cover page 8 5 Remove the Exit Cover page 8 6 Remove the Ink Loader page 8 7 Remove the Lower Inner Duplex Guide page 8 33 Place the Printhead in the park position tilted back and the Wiper Assembly in the home position all the way down 8 Insert a T 20 Torxbit through the right slotted hole in the Transfix Load Module engage the hole on the back of the module and lever the module s spring cam toward the center of the printer to release unhook the spring hooks from the Transfix Load Arms Slowly relax the lever to return the spring cam to the relaxed position See the figure on page 8 22 Repeat for the other side NO oo fF WD Note Ensure that you lever the spring cam towards the center Applying the pressure in the wrong direction can damage the Transfix Load Module 9 From the right side remove 3 screws from the Drum Fan and allow the fan to h
89. the digital x CentreWare infoSMART Made For Each Other PagePack Phaser PhaserSMART and Walk Up are trademarks of Xerox Corporation in the United States and or other countries Acrobat Adobe Reader Adobe Type Manager ATM Illustrator PageMaker Photoshop PostScript Adobe Brilliant Screens Adobe Garamond Adobe Jenson Birch Carta IntelliSelect Mythos Quake and Tekton are trademarks of Adobe Systems Incorporated in the United States and or other countries Apple AppleTalk Bonjour EtherTalk LaserWriter LocalTalk Macintosh Mac os TrueType Apple Chancery Chicago Geneva Monaco New York and QuickDraw are trademarks of Apple Computer Inc in the United States and or other countries HP GL HP UX and PCL are trademarks of Hewlett Packard Corporation in the United States and or other countries IBM and AIX are trademarks of International Business Machines Corporation in the United States and or other countries Windows Vista Windows Server and Wingdings are trademarks of Microsoft Corporation in the United States and or other countries Novell NetWare Npps NDSs Novell Directory Services 5 IPX and Novell Distributed Print Services are trademarks of Novell Incorporated in the United States and or other countries SunS Sun Microsystems and Solaris are trademarks of Sun Microsystems
90. the left and right ends of the print A difference indicates the Printhead gaps at each end of the Printhead are not equal The ends of this printers Printhead rests on two spacers on the ends of the Drum that hold the head to drum gap under much tighter control than in previous solid ink printers There is no head to drum adjustment possible in this printer If the gap is suspect check that the Printhead is correctly and completely installed Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 41 Print Quality Troubleshooting Black Red Green Blue Cyan Magenta and Yellow Solid Fills These prints show uniformity of fill Check for the following 1 Even uniform fills throughout the print 2 There should be no wrinkling or deformity of the paper throughout the print 3 Poor transfer on one side 4 Repeating white stripes 8500 056 Primary causes 1 Weak jets or uneven Drum heating may cause uneven fills 2 To solve wrinkling try different print media Replace the Drum Maintenance Kit to correct streaking Check the Drum Temperature Sensor for debris build up on the sensor or the sensor is not in proper contact with the Drum See the Reverse Text test print on page 5 37 3 If there is poor transfer on one side check to see if the transfix load arm assemblies are moving easily Clean any contamination that may be interfering with the Transfix Arm move
91. the pick pad nudger roller friction Tray 2 Tray 3 and Tray 4 Pick Shaft R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions sec Time to On peak fe Reports how long it takes the MP motor servo system to react to the sudden addition of the Tray 2 pick shaft load Larger values may indicate a slipping or slow to engage clutch On peak fe Reports the peak effort required to accelerate the Tray 2 pick shaft load A smaller value could indicate a slipping clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Tray 2 Tray 3 and Tray 4 Pick Shaft Continued Typical Typical Value Value 8400 8500 R Definition 8550 8560 Actions 2 On fe settling time Reports the time it takes the sec MP motor servo system to settle down after the sudden addition of the Tray 2 pick shaft load A longer time could indicate looseness in the Tray 2 pick shaft assembly or a slipping clutch 3 On average fe Reports the average effort needed to rotate the Tray 2 pick shaft in the pick direction at a constant velocity An unusual value could indicate a binding shaft missing pressure springs hard dirty rollers extra friction in the pick truck assembly 4 On fe ripple Reports the variation of effort required to rotate the Tray 2 pick shaft in the pick direction at a constant velocity A
92. the time following the Settle time sec 0 15 start of motion stopping that it takes the following error value to enter the idle ripple band 7 HAHVN Delta Print 0 02 to Oto 11 Reports the time following the Velocity Settle Time 0 10 start of motion that it takes Y sec Axis delta velocity to enter the CCW delta velocity ripple band Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 39 General Troubleshooting This test does a chase using a special sheet of preprinted media and records the y axis following error Y Axis Belt Slip Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Initial Peak Y Axis O to 12000 1200 to 8000 Reports the amplitude of the FE mpts first Y Axis following error peak 1 Max Following O to 11000 1100 to 7500 Reports the amplitude of the Peak Y Axis FE maximum Y Axis FE peak after mpts the first 2 Average Y Axis FE 0to4000 2200 to 3500 Reports the average of the Y mpts Axis following error during the roller down portion of the transfix operation This test modifies the Y Axis servo loop so that it is unstable and oscillates The oscillation frequency is recorded while the drum is advanced for two revolutions Checks for correct belt tension and variations in tension during operation Y Axis Belt Tension deg Typical Typical Value Value 8500 R Definition
93. thermistor circuit is open 13 581 44 The ink loader BLACK thermistor circuit is shorted 13 583 46 The ink loader BLACK thermistor returned a bad reading or ESD corruption 3 30 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Troubleshooting Procedure for 13 326 to 13 583 Error Code Ink Loader Step Questions and Actions Yes No 1 Check that the ambient room temperature is Advise Go to Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Ensure ground integrity see Ensuring Goto Step 3 Resolve Ground Integrity on page 4 65 ground Are all components grounded properly integrity 3 Inspect and reseat the wiring to the ink Goto Step 4 Replace the loader Check for open wires 1 0 board or Did this correct the problem the Combined Right Cable 4 Run the appropriate Ink Melt test Replace the 1 Yellow Ink Loader 2 Cyan 3 Magenta 4 Black Did the test pass 13 000 6x Errors Program Faults 13 001 62 Thermals failed to read from printer NVRAM 13 002 63 Value is not in valid range 13 003 64 Thermal control task received an unexpected message 13 004 65 Thermal control task was expecting initialization message but received other 13 005 66 Thermal code tried to command a segment ID that did not exist 13 006 67 Thermal code tried to command a segment ID that did not
94. 0 cc ce ene ene nen e ee eee een e bene tennnees 4 46 Electronics Troubleshooting a2 idacvcaeeewoeweacew ese a edoe baa ea dhs beter ede ee dead es 4 51 Printer Power Up Sequence 0 ccc ccc cence eee n ene e tenn nent nas 4 51 Miscellaneous Electrical Troubleshooting 0 nunna 4 56 Verifying Power Supply Operation 0 0 ccc eee eee ene n een nee e ees 4 64 Measuring AC Power Supply VoltageS 00 ccc cece eee eee teen ene e eens 4 64 Measuring DC Power Supply Voltages 0 ccc ccc cece cece eect tenn eee ten nas 4 65 Ensuring Ground Integrity 0 0 eee een e nee tent eee t enna 4 65 Testing Motor and Solenoid Resistances 0 cc ccc eee e nent e eens 4 67 Paper Path and Media Based Problems 0 0 c cece cee tect nett eect teen nent nee 4 68 Media Based Problems 0c cece cece EEEN EE E EDA E e ene eens 4 68 Pick Errors Trays 2 3 ANd 4 eee net e nen n een en eees 4 68 Paper Piek Emors TAY T score fae dort verdes aA bare AE OSS age h Vania depen EE do Da deed 4 69 Preheater and Transfix J MS suenan adaa eee a keda Kenara a aaa 4 69 Checking the Process and Media Path Drive 0 ccc cece eee e nee es 4 69 Media Skews Passing Through the Paper Path 0 ccc ccc cece eee teen ene tee aae 4 70 Operating System and Application Problems 1 0 0 0 ccc ccc cece eee e tenn nee teens 4 71 Testing Communications Ports 0 ccc eee nee t
95. 00 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Key Table Process Event Process Event 8500 8550 8400 8500 8550 8560 Basis for Jam Printer State 8560 A Deskew Flag A Deskew Flag 2 Sensor Event A Printer 1st Init Abnormal 1 Tray 1 B Preheat Flag B Preheat Flag 3 Timeout Shutdown 2 Tray 2 C Strip Flag C Strip Flag 4 Motor Stall B Printer 1st Init Normal 3 Tray 3 D Exit Flag D Exit Flag 5 Motor Position Shutdown 4 Tray 4 6 Length Short C Mechanical Recovery 5 Chase page E Tray 1 Width Sensor E Tray 1 Media Present 7 Length Long D Warmup 6 Duplex E Ready F Front Door Event F Front Door Event F Fault G Tray 2 Media Sensor G Exit Cover G Auto Drum Maintenance H Tray 3 Media Sensor H Tray 3 Media Sensor H Printhead Maintenance J Tray 4 Media Sensor J Tray 4 Paper Sensor J Printhead Purge K Exit Flag K Oil Transfix Roller L Standby Print Process Substates M Paper Path Motor M Paper Path Motor M Pick from Tray 2 N Y Axis Motor N Y Axis Motor N Pick from Tray 3 P Process Motor P Process Motor P Pick from Tray 4 Q DMU Missing Q Pick from Tray 1 T Exit Cover Event R Pick from Duplex T Exit Cover Event V Tray 2 Event U Pipeline Resource S Stage for Transfix W Tray 3 Event V Tray 2 Event T Transfix X Tray 3 Pick Flag W Tray 3 Event Y Tray 4 Event X Tray 3 Pick Flag V Print Drum Maintenance Z Tray 4 Pick Flag Y Tray 4 Event W Imaging Z Tray 4 Pick Flag X Exit Z Shutdown
96. 1 5 Reports the average drive Error Ripple watts ripple in the forward direction 4 Swing Arm 03 to 06 Reports the time that the lower Transition Time portion of the paper path drive sec is disconnected while the swing arm transitions to the other drive position Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting This test drives the X Axis Motor in each direction until the Printhead stalls into the stops Next the test moves the Printhead into the clear and performs an on the fly reversal X Axis Drive Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Right Stall Power 5to 10 5 to 3 3 Reports the motor drive Level watts electronics stall power An abnormal level may indicate a motor motor drive problem 1 Left Right Distance 0 32 to 15 to 5 Reports the distance between in 0 48 the left and right stall points An abnormal value may indicate an problem that restricts the range of motion pinched cable etc 2 Right Left Traverse 3 5t08 5 5to 1 55 Reports the average power Average Power required to move the printhead Level watts from the right hard stop to the left hard stop An abnormal value may indicate a problem with the lead screw or printhead bearings lubrication etc 3 Right Left Traverse 20 to 1 8 0 5to 1 0 Reports ripple in the power Power Ripple level needed to move
97. 11 HTTP Admin_HostAccessList 256 HTTP KeyUser_HostAccessList 256 Notify On 1 IPP Authentication Scheme 1 IPP IPP user name 11 IPP IPP password 11 FTP Login Password 33 Security Print Hosts 256 AppSocket On 1 AppSocket Enabled 1 LPR On 1 LPR Enabled 1 FTP On 1 FTP Enabled 1 IPP On 1 IPP Enabled 1 MIME On 1 MIME Enabled 1 EtherTalk On 1 EtherTalk Enabled 1 PSERVER On 1 PSERVER Enabled 1 PSERVER_IPX Enabled 1 Notes 1 Parallel and USB On and Enabled parameters have not been identified as personality parameters They are not tied to networking 2 36 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes In this chapter Introduction Power Up Error Messages and LED Codes BIST Error Reporting POST Error Reporting PEST Error Reporting Fault Code Error Message Troubleshooting Jam Codes Chapter Error Messages and Codes Introduction This section covers troubleshooting procedures utilizing Control Panel error messages and codes Some procedures require running Service Diagnostics test functions to verify that a specific printer component is operating correctly For information on Service Diagnostics and all internal printer test functions see Service Diagnostics Mode Menu on page 4 5 For troubleshooting printer problems not associate with or displaying an error code or message such as startup or power on media paper path print quality or image
98. 197 47 The Printhead left jetstack thermistor circuit is shorted 13 199 49 The Printhead left jetstack thermistor returned a bad reading or the reading was corrupted by ESD Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Troubleshooting Procedure for 13 136 to 13 199 Error Code Printhead Step Questions and Actions Yes No 1 Check that the ambient room temperature is Advise Go to Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Ensure ground integrity see Ensuring Goto Step 3 Resolve Ground Integrity on page 4 65 ground Are all components grounded properly integrity 3 Use Service Diagnostics to run the Left Goto Step 4 Replace the Jetstack Temperature test Printhead Did the test pass 4 Check and reseat all wiring to the Printhead Complete Replace the Did this correct the problem Printhead 13 200 41 The Printhead right jetstack heater is too hot 13 202 43 The Printhead right jetstack heater took too long to reach its setpoint 13 259 46 The Printhead right jetstack thermistor circuit is open 13 261 48 The Printhead right jetstack thermistor circuit is shorted 13 263 41 The Printhead right jetstack thermistor returned a bad reading or the reading was corrupted by ESD Troubleshooting Procedure for 13 200 to 13 263 Error Code Printhead Step Questions and Ac
99. 2 Clear ISC Fault 4 9 clevis pins 8 23 8 28 8 30 communication ports 2 19 4 71 configuration card 8400 series 1 3 8500 series 1 4 theory 2 19 view 1 8 configuration control panel 1 5 consumables 9 17 diagram 1 9 life counters 1 9 control panel LED indicators 1 5 menu map 1 6 covers control panel 8 5 exit 8 6 front door 8 4 left side 8 6 right side 8 5 D DC power 2 21 deskew clutch 4 13 deskew clutch test 4 11 deskew clutch disconnecting 8 40 deskew process 2 26 deskew rollers 2 27 diagnostic firmware 3 33 diagnostic history 3 2 diagnostic test functions 3 2 diagnostics process motor 3 15 tilt axis 3 15 transfix drive 3 15 x axis 3 14 y axis encoder 3 13 diagnostics menu hidden service 3 7 diagnostics service 4 4 DIMM 1 8 disassembly notes 8 3 disassembly procedures control panel cover 8 5 covers 8 5 DIMM chips 8 51 drum heater relay 8 49 drum maintenance assembly 8 25 duplex roller 8 20 exit module assembly 8 32 front door assembly 8 4 hard drive 8 52 head tilt compound gear 8 45 head tilt solenoid 8 15 1 0 board 8 48 ink loader assembly 8 7 l 2 media release blade and roller 8 19 NVRAM 8 50 pick assembly 8 37 pick solenoid 8 41 preheater and deskew assembly 8 20 preheater lift solenoid 8 42 purge pressure pump 8 31 takeaway roller 8 36 wave amp board 8 47 x axis bias spring 8 16 x axis motor assembly 8 44 y axis motor ass
100. 27 Duplex PRIMING esea E dda ckd ded gentile adh ait acon E E ns dae de ack BAR Mes 2 30 Transfix and Print Speeds 0 eee een eee ene e ee eee n eben es 2 31 Phaser 8400 8500 8550 8560 Color Printer Service Manual xi Contents Printer Self Maintenance 0 ccc nn ee eee nee ene tebe beet teenie tees 2 33 Printhead Maintenance Cycle Eliminate Light Stripes 0 0 cece cece eee tenes 2 33 Paper Preheater Cleaning Remove Print Smears 00 0 nenene 2 34 Transfix Roller Oiling 0 eee ne ene n nnn ete n nee teen eens 2 34 Drum Cleaning Chase Page 2 cence ene n ene e teen eee e teens 2 34 Configuration Card Personality Parameters 0 00 0 ccc cee cent ene n nee e nnn 2 35 3 Error Messages and Codes INTOGUGUION e oei csi tone Gece cptanos eee eda ee eae ede Phos Oe acd Madde oon aaa a guage Mead nde 3 2 Power Up Error Messages and LED Codes 0 ccc ccc eee ete nnn e ee eee nee eee nee 3 3 BIST Error Reporting iess isinin tiw aie saci iiwald owned Pode aa pea eee eden ds 3 3 POST Error Reporting eeren cc ccc ene eee nent EAE TE ett e nes 3 4 PEST ErrOmMReponing sii p00 ae0db dreka ated diotdeoriacd ide bale nd Ma eonteg hide eane 3 6 Fault Code Error Message Troubleshooting 0 ccc cece eee een eee een e ee eeas 3 7 Fault Code Error Reporting 0 ccc cc ccc cee eee te ene n cette ene ennes 3 7 Interpreting Fault Codes 0 1 eee ene ee eee enn n eet ee nee eee ee
101. 4 0 5 1 Remove the Left Side Cover page 8 6 2 Remove the Exit Cover page 8 6 3 Disconnect the fan Media Drive motor deskew clutch pick clutch and Tray 1 Pick Solenoid harnesses 4 Remove the 6 screws securing the Media Drive Media Drive Gearbox 8500 105 Replacement Note Remove the tray then rotate the Pick Roller Shaft until the clutch seats Working upwards rotate the Take Away Roller and Duplex Roller until all shafts seat properly Check that the Media Drive is correctly positioned on the side frame Install and torque the 6 screws to 12 in lbs Finally check that all rollers rotate freely 8 40 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Tray 1 Pick Solenoid PL4 0 3 1 Remove the Left Side Cover page 8 6 2 Disconnect the solenoid harness 3 Remove 1 screw from the solenoid and remove the solenoid Tray 1 Pick Solenoid 38500 106 Replacement Note Align the hole on the solenoid with the boss on the Media Drive Install and torque the screw to 12 in lbs Reconnect the harness Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 41 Service Parts Disassembly Preheater Lift Solenoid PL4 0 1 1 Open the Front Door 2 Remove the Control Panel and cover page 8 5 3 Remove 4 screws disconnect 2 connectors and remove the Exit Module page 8 32 4 Remove the Outer and Upper Duplex Guides page 8 34
102. 4 sheets of paper through the print path The first few sheets absorb and remove ink from the Preheater The printer continues to pass sheets of paper though to cool the Preheater until normal operating temperature is reached If duplex capability is enabled 5 sheets of paper go through the simplex path and up to 20 sheets go through the duplex path 4 The printer returns to the Print Quality Problems menu Because of the higher paper temperatures involved this function can clean the Drum of ink deposits caused by a contaminated blade on the Drum Maintenance Kit Transfix Roller Oiling Oiling the Transfix Roller prevents ink from sticking to it Every 50 prints the printer performs a Transfix Roller oiling cycle During this cycle oil is applied to the Drum as it would be during a print cycle The Transfix Roller then lowers against the Drum and the Drum rotates transferring some of the oil to the Transfix Roller Finally the Transfix Roller raises to its standby position Drum Cleaning Chase Page The printer performs a Drum cleaning with a chase page automatically anytime a paper jam occurs The chase page collects any image which may not be complete off the Drum The printer then attempts to reprint the print that jammed The chase page is processed the same as a regular print except that the Drum is not oiled and no image is printed on the drum since an image is already printed on the Drum 2 34 Phaser 8400 8500 8550 8560
103. 45 Upper 525 sheet feeder PLD version mismatch 11 018 46 Titan version mismatch Troubleshooting Procedure for Electronic Module Interface Step Questions and Actions Yes No 1 Ensure ground integrity for the printer Did this resolve the error Complete Go to Step 2 2 1 Inspect and reseat all connectors 2 Inspect the gray cable between the 1 0 board and the Electronics Module 3 Ensure the cables are properly dressed in the wiring raceway as detailed in the wiring diagram section of this manual Did this correct the problem 3 Reset NVRAM and retest Did this resolve the problem Complete Go to Step 3 Complete Go to Step 4 m 11 001 47 and 11 017 45 Replace Tray Lift Motor or the Electronics Module m 11 002 48 and 11 016 44 Replace the optional tray or check wiring m 11 003 49 and 11 0014 42 Replace the 1 0 board m 11 004 41 and 11 013 41 Replace the 1 0 board or the Control Panel m 11 006 43 and 11 015 43 Replace the Printhead m 11 009 46 Replace the 1 0 board or the Electronics Module m For all other 11 000 4x errors Replace the Electronics Module Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 25 Error Messages and Codes 11 100 60 Errors Temperature Error The root problem for this error is temperature sensitivity with the power supply s opto isolator chips Check that the room temperature does not exceed
104. 50 8560 Color Printer Service Manual Inside Top Wiring Diagram The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel a VVE CU LU aH Jy J1AC 37009 4x Ink Load Power ri 37010 4x Qe Ink 1 HeaterN B a Alli J2AC 37002 4x JSL Heater ipae iM i 130 34062 4x Data Cable VALUE LH 8500 8550 ga j i 3 WH ae St S E _ ol MAI Wot s7010 4x _ 4 lA Ink 1 Heater 7 l j 7 I WD aa mE A F J2AC 37002 4x L Ji i J1AC 37009 4x JSL Heater Ink Load Power N J130 34062 4x Data Cable saso0 130 Phaser 8400 8500 8550 8560 Color Printer Service Manual 10 9 Inside Top Printhead Wiring Diagram The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel Cable Restraint Out of Ink J180 32064 4x Heater Cable 8500 131 10 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference Contents Menu Map 8400 Menu Map 8500 8550 8560 Paper Weight Equivalence Table On site Printhead Troubleshooting Checklist 8400 On site Printhead Troubleshooting Checklist 8500 8550 8560 Appe
105. 550 8560 Actions 0 Peak Power watts 0 5to1 2 12to1 2 Reports the max power value 1 Average Power 0 4to 1 2 15t01 2 Reports the average power watts Gathers data on the performance of the drum heater dual relay assembly by energizing each relay for a short time and capturing the resulting power draw Drum Heater Relay Power watts Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 220 V Coil Peak 2 to 1 2 Reports the max power value Power watts 1 220 V Coil Average 2 to 1 2 Reports the average power Power watts 2 220 V Coil Min 2 to 45 Reports the min power Power watts following power off 3 220 V Coil Peak Reports time after solenoid Power Time sec power on that the peak power occurred 4 220 V Coil Initial 2 to 45 Reports the average power Average Power following power on watts 5 110 V Coil Peak 2 to 1 0 Reports the max power value Phaser 8400 8500 8550 8560 Color Printer Service Manual Drum Heater Relay Continued General Troubleshooting Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 6 110 V Coil Average 2 to 1 0 Reports the average power Power watts during the constant portion of the profile 7 110 V Coil Min 2 to 45 Reports the min power Power watts following power off 8 110 V Coil Peak Reports time after solenoi
106. 550 8560 Head Tilt Solenoid Did the test pass 2 Check the wiring for the affected clutch or Replace the Replace the solenoid harness affected Is the wiring damaged component 8500 8550 8400 8560 PEST Description 37 021 48 37 024 48 Tray 1 elevator disconnect The main tray elevator is not drawing the expected power from the supply Troubleshooting Procedure Step Questions and Actions Yes No 1 Run the Tray 2 Lift Motor test Replace the Go to Step 2 Did the test pass Electronics Module 2 Check the wiring to the Tray 2 Lift Motor Replace the Replace the Is the wiring damaged wiring harness Tray Lift Motor 3 42 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 8500 8550 8400 8560 8400 PEST Description 37 022 40 37 025 43 Pressure pump motor disconnect The Purge Pump is not drawing the expected power Troubleshooting Procedure for Purge Pump Step Questions and Actions Yes No 1 Run the Pressure Pump Motor test Replace the Go to Step 2 Did the test pass Electronics Module 2 Check the Purge Pump wiring Replace the Purge Pump Is the wiring damaged 8500 8550 8400 8560 PEST Description 37 023 41 37 026 44 Purge valve disconnect The purge valve is not drawing the expected power from the supply Troubleshooting Procedure for Purge Valve Step Questions and Actions Yes No 1 Run the Purge Vent Solenoid test Goto Step 2 Repl
107. 550 8560 8560MFP Version 2 0 IMPORTANT This checklist outlines proper printhead troubleshooting procedures All Xerox service employees and any other service personnel on any job involving a printhead replacement should perform it Service person name Service Company Phone Number Date of printhead replacement Printer serial number Defective Printhead serial number OUT Request ID number Troubleshooting Summary Follow the checklist below and fill in spaces as they apply as you complete the troubleshooting procedures Incorrect Colors Incorrect colors such as reds printing orange IS NOT A VALID REASON for replacing the printhead Color issues are correctable by either purging old ink out the printhead or using alternate Color Corrections at the print driver Check List Value What to look for Items to or Complete Result Step Do you suspect 1a Did the customer state that they have used generic ink in this 1 or have YES printhead YES NO evidence of use NO 1b Did you observe generic sticks or related packaging at the site of generic ink YES NO non Xerox Circle 4 Are there generic ink sticks in the ink loader ink oe YES NO 1d Does the service history indicate possible use of generic ink YES NO Indicate brands and lot codes of generic ink if used If you answered YES to any of the above be sure to document the use of non Xerox ink in the Comments section of thi
108. 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 21 Service Parts Disassembly 8 22 Transfix Load Module PL2 0 15 a Ff ON e gt Remove the Front Door page 8 4 Remove the Ink Loader page 8 7 Remove the Preheater page 8 20 Remove the Media Drive page 8 40 Remove 4 screws disconnect 2 connectors and remove the Exit Module page 8 32 Remove the Upper and Lower Duplex Guides page 8 33 Remove the Duplex Roller by removing the left KL clip on the shaft and sliding the left side bearing down the shaft toward the right Then slide the shaft toward the left to free the right end of the shaft Finally pull the shaft out towards the right side Insert a T 20 Torxbit through the slotted hole in the Transfix Load Module engage the hole on the back of the module and gently lever the module s spring cam toward the center of the printer to release unhook the spring hooks from the Transfix Load Arms Slowly relax the lever to return the spring cam to the relaxed position Caution Ensure that you lever the spring cam towards the center Applying the pressure in the wrong direction can damage the Transfix Load Module Also placing too much force in the leverage action could destroy the cam Transfix Load Module 8500 087 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly 9 Remove the clevis pins securing the Transfix Load Arms to the
109. 60 Drum Fan Did the test pass 2 Check the wiring for the problem fan Replace the Replace the Is the wiring damaged harness fan 8400 PEST Description 8500 8550 8560 PEST description 37 016 43 PEST 50 V power supply test 50 V power supply test The power For Phaser 8400 printers the 50 supply is loaded with the Head V power supply is loaded with Maintenance Deskew and the Pick the Head Maintenance clutch Clutches and then tested Check the 50 V on the Power supply Or ensure that the cables are not plugged into any of the clutches The expected power from the supply is not being drawn This error may be caused by a power supply that is faulty or shorted by some other 50 V device Check the 50 V on the Power supply Or ensure that the cables are not plugged into the clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 39 Error Messages and Codes 3 40 50V Power Supply Fault Troubleshooting Procedure Step Questions and Actions Yes No 1 Check for a short in the Electronics Module GotoStep2 Goto Step 2 NOTE Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge NOTE It is possible that the power supply is not shorted but instead is out of spec and can lead to an error condition 1 Measure the 50 V power supply output The test point is located on the power control board below the main board RAM
110. 7 to 52 10 Unregulated 11 to 16 5 11 to 16 5 Negative 15 Volts 11 Unregulated 15 11 to 17 11 to 17 Volts 12 AC Volts 120 Volts 90 to 140 90 to 140 AC Volts 240 Volts 180 to 275 180 to 275 This test drives the Process Drive to move the Wiper Blade a short distance in each direction to verify the home position Wiper Alignment Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 The engage wiper 50 to 400 Reports the distance from position min wipe home to the tilt engage position 1 Upper hard stop 2000 to Reports the distance from wiper position 5000 wipe to home to the upper min hard stop Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 49 General Troubleshooting This test drives the process motor a short distance in each direction to verify that the dmfix drive unit was in its home position Drum Maint Transfix Home Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 DM Initial FE Peak Reports the height of the initial pm motor counts peak when starting rotation of the dm drive gear 1 DM Initial FE Peak Reports the time since the Time sec start of CCW motion until the peak was detected 2 TF Initial FE Peak Reports the height of the initial pm motor counts peak when starting rotation of the tf drive gear 3 TF Initial FE Peak Reports t
111. 8550 8560 Color Printer Service Manual 3 9 Error Messages and Codes 3 0XX 6x Errors IPC Program Faults There is a communication problem between the engine and PostScript regions a Reset NVRAM and then retest b Replace the EEPROM chip 4 0XX 4x Errors Process Control System Fault 4 017 47 This fault code indicates a problem with the process control system The ambient temperature is considered too cold to warm up the printer less than 10 C 4 018 48 This fault code indicates a problem with the process control system The Printhead temperature dropped below the head cleaning needed threshold 4 020 41 This fault code indicates a problem with the process control system Declared when the printer is booted in FTTR Fast Time to Ready mode and the head wiper contact flag is set in NVRAM The printer cannot run in FTTR mode with the head wiper in contact because it would be unwise to separate the two when the printer is cold could tear wiper Service requested that this be a device fault in order to alert the service person to this condition 4 021 42 This fault code indicates a problem with the process control system Declared when the printer is booted in FTTR mode and the Drum is dirty Cleaning the Drum when very cold could increase the chance of gluing media to the Drum surface around the stripper fingers Service requested that this be a device fault in order to alert the service person to this condition Trou
112. A s8500 022 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 21 Theory of Operation 1 0 Board All sensor and switch readings are input into the I O Board The I O Board translates these states into encoded information that it sends over a serial data bus I O Board data cable to the Electronics Module The Electronics Module has no direct connection to sensors switches or solenoids In order to activate a clutch or solenoid the Electronics Module sends a command to the I O Board which processes the command and activates the appropriate device Sensors Sensors throughout all the major subsystems provide indicators of vital print operations The following graphic identifies the location of the printer s sensors Ink Low Strip Sensor Paper Exit Sensor Exit Door Sensor Ink Out Drum Temperature Sensor Preheater Drum Sensor Position Encoder Deskew Sensor _ii 9S Front Door Media Width Sensor Sensor P Paper Tray Empty Size Sensor Sensor Also in S Trays 3 amp 4 Pick Sensor 525 sheet Tray Lift Sensor Feeder Also in Trays 3 amp 4 8500 023 2 22 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Process Theory of Operation Once the printer processes an image and creates a printing bitmap the print cycle begins Sensors maintain correct operating temperatures for the Printhead and Drum Sensors also monitor ink levels
113. C Serial port settings are 19 2 kbaud 8 bits no parity 1 stop bit and software control 2 Turn off the printer 3 Remove the rear panel to access the main board 4 8400 only Connect the serial cable with adapter to the 5 pin connector labeled SERO located above the RAM DIMM connectors Pin 1 is the top pin The label THIS SIDE UP of the serial port adapter should face towards the main board s round back up battery 8500 8550 8560 only Connect the serial cable with adapter to the service only port located above the USB cable port The label THIS SIDE UP on the serial adapter should face the rear of the printer 5 Start up a terminal program such as in window s HyperTerminal usually located in Start gt Programs gt Accessories gt Communications gt Hyper Terminal Ensure the serial port settings usually COM1 is correct 6 Turn on the printer The trace should appear in the terminal dialog window Examine the trace to troubleshoot the problem If necessary save the trace file to capture the text Obtaining a Back Channel Trace with USB to Serial Adapter Many Laptops or PC s do not include serial ports An alternate method of communicating with the printer is available by using a USB to Serial Port Adapter Use these steps to capture a back channel trace using a USB to Serial adapter cable Note These instructions were developed using a Belkin USB to Serial Adapter P N F5U109 and Windows XP Other
114. Color Printer Service Manual Theory of Operation Configuration Card Personality Parameters Configuration Card Shadowed Personality Parameters Attribute Parameter Size bytes N A version not version of the layout of 4 parameter personality parameters NEST Base Printer Name 48 NEST SysAdmin Contact 128 truncated from 256 NEST Printer Location 128 truncated from 256 NEST Asset Identifier 128 truncated from 256 IP Host Name 64 IP Domain Name 256 IP Network Mask 4 IP IP Address 4 IP Default Gateway 4 IP BOOTP DHCP 1 IP DDNS 1 IP SMTP Server 256 IP IP Source 1 IP TCP IP 1 IP AutolP 1 IP DHCP Vendor Class ID 48 DNS RESOLVER Primary Name Server IP Address 4 DNS RESOLVER Secondary Name Server IP 4 Address DNS RESOLVER MulticastDNS 1 NBNS WINS Enable 1 NBNS WINS WINS Note Type 1 NBNS WINS Primary WINS Server 4 NBNS WINS Secondary WINS Server 4 Ethernet Speed 1 HTTP On 1 HTTP Information Forwarding 1 HTTP SMTP Server Automatic 1 HTTP Legal Settings 1 HTTP Admin_Password 11 HTTP Admin_Username 11 HTTP KeyUser_Password 11 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 35 Theory of Operation Configuration Card Shadowed Personality Parameters Continued Attribute Parameter Size bytes HTTP KeyUser_Username
115. Device Fault Codes Move Head to the Move XA to Left Standby position Side Hard Stop 80xx Wiper 7007 7006 7008 8005 6000 8021 Pump Not Inited 8055 8007 8008 8009 ek 7009 Wiper Alignment 7 og the 7002 PM stalled Move XA tn E a we n f Axis in order 70xx Headtilt Hard Stop 6000 to release the 7006 Headtilt Solenoid Jog the X 6000 HeadTilt 7014 Head Not Restrained Axis in N Arms 31001 Media Path order to Move XA to Tilt position homeDmfix 5001 Ya Home Timer release the 6000 again 5004 YA General Motion Error HeadTilt 4025 6000 XA Error Arms Move Head to the 4025 PM Init Failed homeDmfix Home Print position 4024 Wiper Alignment Failed 7006 7010 Others Thermal faults ECM Faults HC PM faults oiling drum San SEW E Move Head to the PARK position Rehome XA 6000 7007 7008 8005 8055 8007 8008 8009 7014 After the printer is warm the head will tilt to the print position and Oil Drum 4 times Warmup will be responsible for moving the head to the print position after the wipe and purge are performed 8500 138 4 54 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Unplanned Shutdown If the printer was not shutdown by the power switch the last time it was turned off or it was shutdown with ink on the drum As soon as the printer has warmed up the media path motor moves the wiper to the bottom o
116. F2Q The Front Door open flag unexpectedly tripped during a pick from Tray 1 F2R The Front Door open flag unexpectedly tripped while duplexing F2S Front Door sensor unexpectedly actuated while staging for transfix F2T The Front Door open flag unexpectedly tripped during transfix F2V The Front Door open flag unexpectedly tripped during Drum oiling F2W The Front Door open flag unexpectedly tripped while imaging during a print job F2X Front Door sensor unexpectedly actuated during exit 1 Ensure the media is supported 2 Ensure ground integrity of the printer see page 4 65 3 Run the diagnostic Sensors test to test the door sensor 4 Check that the doors and covers are properly closed and seated 5 Run the Door Sensor test G2M Tray 2 removed during pick from Tray 2 H2N Tray 3 was removed during pick from Tray 3 J2M Tray 4 was removed during pick from Tray 4 J2P Tray 4 Media Present Sensor event pick from Tray 4 M2C Media Drive had an unexpected event during mechanical recovery M4A Media Drive stalled during an abnormal printer shutdown M4B Media Drive stalled during a normal printer shutdown M4C Media Drive stalled during mechanical recovery M4D Media Drive stalled during printer warm up M4E Media Drive stalled while the printer was in its ready state M4F Media Drive stalled while the printer was in a fault state M4G Media Drive stalled during an auto Drum maintenance cycle M4H Media Drive stalled during Printhead maintenance M4
117. HP Color Bands 8400 only Manuf Banding 8400 only Head Roll 8400 only Head Height 8400 only X Dot Position 8400 only Y Dot Position 8400 only Chase Pages Oil Bar Chase Purge Efficiency Phaser 8400 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations In this chapter m Printer Component Homing Positions and Indicators m Jet Substitution Mode m Jet Substitution Mode Chapter 6 Adjustments and Calibrations Adjustments Wiper Alignment Procedure 1 Remove the printer covers using the procedures that begin on page 8 4 2 Remove the left head maintenance drive gear by removing the e clip from the drive shaft Left Idler Gear Left Drive Gear 6 2 Phaser 84000 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations 3 Rotate the left and right idler gears until the Wiper is all the way to the bottom and the gears cannot be rotated further Rotating the left and right gears together ensures that the wiper stays parallel and does not pop out of the belts AAA A ARAA Wiper assembly at bottom Wiper skewed when lowering of travel Wiper not skewed Rotate left and right idler gears to lower wiper AMY lt gt i K s8500 060 4 Replace the left drive gear and the e clip Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 3 Adjustments and Calibrations Printer Component Homing Positions
118. IMM SDRAM memory modules 128 to 256 MB Phaser 8500 8550 8560 printers support SIMMs instead of DIMMs Supported sizes are 128 256 and 512 MB Printers ship with a minimum of 128 MB and support a maximum of 1024 MB Hard Drive Support A hard drive IDE cable plugs into the main board from the hard drive board A separate power cable must plug into the power control board from the hard drive board to provide signals and power for the hard drive board Input Output Ports In the Phaser 8400 the main board provides support for Ethernet not supported on the B and BD printer configurations Parallel and USB 2 0 external I O interfaces For the 8500 8550 8560 the main board provides support for Ethernet all printer configurations and USB 2 0 external I O interfaces The 8500 8550 8560 configurations do not include parallel interfaces Configuration Card The Configuration Card is a thumbnail sized device that plugs into the side of the Electronics Module This device stores printer information and interacts with the printer s NVRAM chip The Configuration Card supports the transfer of printer model and network configuration information from a failed printer to a replacement printer When replacing the electronics module you must transfer the Configuration Card to the replacement electronics module Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 19 Theory of Operation 2 20 Information stored on the Configuration Card incl
119. J Media Drive stalled during a Printhead purge M4K Media Drive stalled during an oil transfix roller cycle Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued M4L M4M M4N M4P M40 M4R M4S Media Drive stalled while the printer was in standby mode Media Drive stalled while the printer picked from Tray 2 Media Drive stalled while the printer picked from Tray 3 Media Drive stalled while the printer picked from Tray 4 Media Drive stalled while the printer picked from Tray 1 Media Drive stalled while the printer duplexed the print Media Drive stalled while the printer staged the print for transfix M4T Media Drive stalled during transfix 1 Verify the media in the tray is supported by the printer 2 Inspect the paper path for obstructions 3 Run the Paper Drive Power test 4 Run the Media Path Motor and Shafts test 5 Replace the media path drive assembly N2T Y Axis Motor event during transfix Tray 1 only probably a multi pick 1 Verify the media in the tray is supported by the printer 2 Try heavier media 3 Inspect Tray 1 Separator Pad Replace if necessary 4 Send a snippet to turn off the multi pick detection code 5 Run the Y Axis Motor test replace if necessary 6 Run the Voltages test replace the power supply if necessary N2W Y Axis Motor event during imaging Probably a software fault Ensure
120. NER ga e oy ey ee al If YES replace the wiper assembly Repeat the checklist stating at Step 6 Step Visually check Is there any damage or separation on the wiper blade If YES replace 9a the Wiper the wiper assembly Assembly blade Is it OK Step Check the Check the purge pump performance 9b purge YES 9a Empty the waste tray performance of NO 9b Select Eliminate Light Stripes Basic from the printer front the purge panel and run one cleaning cycle system Circle 9c Remove the waste tray and examine how much ink was purged ee A single purge should resemble the illustration Is the purge mass noticeably less than what is pictured If YES inspect the purge hoses for pinches splits or tears Phaser 8400 8500 8550 8560 Color Printer Service Manual A 15 Reference Step Print Service e If NO go to Step 12 11 Test 2 Weak YES e If YES do the following and Missing NO e Check the exit area of the paper path for debris that could be Jets scraping ink off the drum and may mimic a weak or missing jet Are there weak Circle e Select Eliminate Light Stripes Basic from the printer front or missing mae panel up to 3 times as needed to recover a weak or missing jet jet s e Select Eliminate Light Stripes Advanced from the printer front panel up to 2 times as needed to recover a weak or missing jet e Select Jet Substitution to substitute a working jet for the missing jet However if any of the following cr
121. On site Printhead Troubleshooting Checklist 8500 8550 8560 2 0 eee A 13 Index Xvi Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information In this chapter Printer Introduction and Overview Printer Configurations Control Panel Configuration Parts of the Printer Routine Maintenance Items and Consumables Printer Specifications Chapter General Information Printer Introduction and Overview The Phaser 8400 8500 8550 8560 Color Printer Service Manual is the primary document used for repairing maintaining and troubleshooting the printer To ensure understanding of this product complete the Phaser 8400 8500 8550 8560 Service Training and self study guide 8500 002 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information Printer Configurations The Configuration Card holds configuration information that enables or disables built in features as described in the following tables Phaser 8400 Printer Configurations Features 8400B 8400BD 8400N 8400DP 8400DX Maximum Print Speed 24 24 24 24 24 Memory 128 MB 256 MB 128MB 256 MB 256MB Hard Drive No No Optional Optional Standard PostScript Fonts 137 137 137 137 137 PCL Fonts 81 81 81 81 81 Japanese Fonts No No Optional Optional Optional Job Pipelining No Yes No Yes Yes Automatic 2 Sided No Standard No Standard Standard Printing 100 Sheet Tray 1 Standar
122. Questions and Actions Yes No 3 1 Clean the Stripper Blade it may be Complete Go to Step 4 contaminated with ink 2 Run Remove Print Smears Did this correct the problem 4 1 Check for ink on the Transfix Roller Complete Go to Step 5 2 Run Remove Print Smears Did this correct the problem 5 1 Test system thermal characteristics using Complete Go to Step 6 Service Diagnostics Verify temperatures are within the normal operating range 2 Inspect the Drum Temperature Sensor Clean or replace the sensor if necessary Did this correct the problem 6 1 Check the feed rollers An accumulation Complete of paper dust and oil can produce dark rectangular marks on transparency film 2 Run Remove Print Smears 3 Replace the rollers if necessary Did this correct the problem 5 16 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Fuzzy Text Text appears indistinct and difficult to read There are three typical reasons for fuzzy text as called out in this illustration 1 Top left image displays a Y axis Drum rotation problem 2 Lower left image displays the wrong Drum temperature problem 3 Lower right image displays an X axis movement problem Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Drum
123. Remove the preheater and check for and remove any small paper scraps that may be present 2 Check for excessive media skews 3 Check for ink shards on top of the preheater next to the flag see page 8 20 4 Using diagnostics run the media drive path test If the test fails replace the preheater assembly 5 Check the paper eject path for obstructions Ensure no small pieces of paper are trapped around the paper release blade 6 Ensure that the transfix roller is rotating freely replace if necessary 7 Test the sensors in the paper path Look for damaged or non operating sensor flags 8 Check the stripper solenoid is functioning properly by running the stripper solenoid test and the stripper contact test replace if necessary 9 Check the stripper blade for damage replace the stripper carriage if necessary 10 Check for ink shards on top of the preheater next to the flag see page 8 20 Checking the Process and Media Path Drive 1 Determine if the process motor runs If it does not rotate go to Step 2 If it does rotate go to Step 4 2 Measure to determine if 50 VDC is being supplied to the motor If power is applied go to Step 3 If it is not inspect the process motor s wiring harness If the harness is functional then troubleshoot the Electronics Module Refer back to the topic Measuring AC Power Supply Voltages on page 4 64 3 Disconnect the motor s wiring harness Measure the resistance of the
124. Rotate the gears to lower the Wiper all the way down Caution To prevent damage to the ink jets do not to place your fingers on the faceplate of the Printhead 4 While pulling back slightly on the Printhead to keep it away from the Drum unlock push down the Right and Left Printhead Restraint arms then slowly allow the spring loaded Printhead to tilt forward 8 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly 5 On the left side pull the X Axis Bias Spring Hook out slightly and shift to the side rotate down Allow the hook to rest against the detents in the frame Purge Pump Bias Spring Hook Q A y A ANN ANNI AN 6 Disconnect the air hose from the Purge Pump 8500 074 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 11 Service Parts Disassembly 7 Remove Left and Right Printhead Restraints First remove the screw then pull inward towards the Printhead then lift up and slightly toward the rear to remove Printhead Restraint When reassembling torque to 6 in Ibs 1 N m Printhead Restraint 8500 075 Note Adjust Printhead position as required to remove the right restraint 8 Remove the Roll Block on the left end of the Printhead shaft Caution The Roll Block may be hot if the printer was just shut down Printhead Shaft AYS Y Lo 2 Roll Block 8500 076 8 12 Phaser 8400 8500 8550 8560 Color Printer Se
125. S sees 5 c40 5440 hooee gine heuea bonged aadh dosed ache ooedee ead eaten 5 40 Primary Solid Fills VOK ccc essence celenaih ats ag bubs iaai a Aid eG die AEs be due Re eee 5 40 Head to Drum Gap 8400 Only n n 2 decbory eh sie bees Sdeodie ened idee en eae as 5 41 Black Red Green Blue Cyan Magenta and Yellow Solid Fills 0 0 cc cece eee eee 5 42 Manuf Skew Margins 62 6440 60045 ps044 dade leds bred bods Mena Ahaa nihegeote eeededen 5 43 Cleaning P gen wcccides wid eased Oo ree E a A ea EE sar dee Mes AE OS dash ebeheods bed 5 44 Other Test and Specialty Prints 10 0 e ene e teenies 5 44 6 Adjustments and Calibrations ACJUSUMG M esi Preah s acne a a a tae eau E ENE NEEN bene vat wach an etek en 6 2 Wiper Alignment Procedure 0 0 ccc etn t eee e tenet nee eens 6 2 Printer Component Homing Positions and Indicators 0 0 0 ccc cece eee ee eee eens 6 4 Wiper Assembly POSITIONS saas 0 0 cite teen a teen n ees 6 4 Homing the Head Tilt Gear cence nent enn e eee teens 6 5 Homing the Process Drive Train 6 ninri ia nett nee ene t OA a E 6 8 Timing the Drum Maintenance Camshaft 1 0 0 0 0 ccc cece eee een ete teens 6 9 Jet Substitution Mode 2 0 0 ee ene nee eeaeee 6 12 Enabling Jet Substitution Mode 8400 0 c cece ects 6 12 Enabling Jet Substitution Mode 8500 8550 8560 0 0 c eects 6 13 Disabling Jet Substitution Mode 8400 0 cece ccc e
126. Service Manual Parts Lists Phaser Color Printing Media Continued Description Part Number Phaser Premium Cover Paper Letter 100 Sheets 016182300 Phaser Premium Cover Paper A4 100 Sheets 016182400 Phaser Professional Solid Ink Transparency Letter 50 Sheets 103R01039 Phaser Professional Solid Ink Transparency A4 50 Sheets 103R01040 Phaser Professional Solid Ink Business Cards Letter 10 103R01041 sheet 25 sheets Phaser Professional Solid Ink Business Cards A4 10 sheet 103R01042 25 Sheets Phaser Color Printing Labels Letter 30 Sheet 100 Sheets 016181200 Phaser Color Printing Labels Letter 6 Sheet 100 Sheets 016181300 Phaser Color Printing Labels A4 14 Sheet 100 Sheets 016181400 Phaser Color Printing Labels A4 8 Sheet 100 Sheets 016181500 Phaser Premium Postcards Letter 4 Sheet 100 Sheets 103R01016 Phaser Premium Postcards A4 4 Sheet 100 Sheets 103R01017 Phaser Trifold Brochures Letter 150 Sheets 103R01018 Phaser Trifold Brochures A4 150 Sheets 103R01019 Phaser Weatherproof Paper Letter 150 Sheets 103R01020 Phaser Weatherproof Paper A4 150 Sheets 103R01021 Supplies Startup Kit Standard Size Media 097803180 Supplies Startup Kit Metric Size Media 097803181 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 19 Parts Lists 9 20 Phaser 8400 8500 8550 8560 Color Printer Service Manual Wiring Diagrams In this chapter Main
127. Standard Standard Standard Standard Ethernet Connection Yes Yes Yes Yes Yes The following features are included with the Phaser 8500 8550 printers with a hard drive proof print saved print secure print personal print and font storage Phaser 8560 Printer Configurations Phaser Features 8560N 8560DN 8560DT 8560DX Maximum Print Speed 30 ppm 30 ppm 30 ppm 30ppm Memory 256 MB 256 MB 512 MB 512 MB Hard Drive Optional Optional Optional Standard PostScript Fonts 137 137 137 137 PCL Fonts 81 81 81 81 Job Pipelining No No Yes Yes Automatic 2 Sided No Yes Yes Yes Printing 100 Sheet Tray 1 Standard Standard Standard Standard 525 Sheet Tray 2 Standard Standard Standard Standard 525 Sheet Feeder Tray 3 No No Yes Yes 525 Sheet Feeder Tray 4 No No No Yes USB Connection Standard Standard Standard Standard Ethernet Connection Yes Yes Yes Yes The following features are included with the Phaser 8560 printers with a hard drive proof print saved print secure print personal print and font storage 1 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual Control Panel Configuration LED Indicators General Information The Control Panel consists of one tricolor LED a display window and six functional buttons These buttons navigate the menu system perform functions and select modes of operation for the printer Green Ready to Print Flashing Gr
128. Stripes from the Control Panel Phaser 8400 8500 8550 8560 Color Printer Service Manual Cleaning and Maintenance Ink Smears Oil Spots or Random Ink Streaks Problem type Solution Ink smears on the front Select the automated procedure Remove Print back or edges of apage Smears from the Control Panel Check the maintenance kit for ink and paper dust build up on the wiper blade Oil Drum fluid on top Select the automated procedure Remove Print edge of print Smears from the Control Panel Media Jams Note Refer to the jam codes in Jam Codes on page 3 48 Problem type Solution Tray 1 MPT jams Clean the Pick Roller Follow the Pick Roller Cleaning Method on page 7 3 Front Door jams Clean the transport rollers Exit jams Clean the Exit Rollers and Stripper Blade Tray 2 4 jams Clean the appropriate tray feed roller Duplex path jam Clean the Preheater Duplex and Exit Rollers Double picks Clean the Pick Rollers and Separator Pad with alcohol Clean pick pad with clear packaging tape using the procedure Pick Roller Cleaning Method on page 7 3 Pick Roller Cleaning Method Tray 1 Tray 1 pick roller can be cleaned with an alcohol moistened swab 1 Open the Front Door 2 Rotate the roller and clean it with an alcohol moistened swab 3 Rotate the roller so that the flat side is facing down 4 Close the Front Door Phaser 8400 8500 8550 8560 Color
129. Temperature Sensor m Y Axis Encoder a X Axis Motor m Printhead Nui ill nny 32424 081 Fuzzy Text Troubleshooting Procedure Step Questions and Actions Yes No 1 Try printing using a smoother higher quality Complete Go to Step 2 paper Some recycled brands are too rough Watermarked or 3 hole punched paper may also cause this problem Did this correct the problem 2 Try using a higher quality print mode Complete Go to Step 3 Did this correct the problem 3 This problem can occur after Printhead Complete Go to Step 4 replacement Check the Roll Block alignment Is the Roll Block positioned to match the label on the left frame Correct if necessary Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 17 Print Quality Troubleshooting Fuzzy Text Troubleshooting Procedure Step Questions and Actions Yes No 4 1 Test the Drum Temperature Sensor with Complete Go to Step 5 Service Diagnostics 2 Check that the Drum Termperature Sensor is clean and properly positioned Did this correct the problem 5 1 Test the Y Axis Encoder Go to Step 6 Clean the 2 Run the Service Diagnostics Y axis encoder or Encoder test replace the Drum Is the Y axis encoder working properly nee Assembly 6 Check X Axis motion See White Stripes Complete Go to Step 7 Pinstripes on page 5 30 for troubleshooti
130. The Preheater Lift Solenoid is now visible on the top of the Transfix Load Module 5 Disconnect the solenoid harness 6 Remove 1 screw holding the solenoid to the Transfix Load Module A s8500 134 Replacement Note Align the hole on Transfix Load Module Install and torque the screw to 15 in Ibs Reconnect the harness 8 42 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Process Drive PL4 0 14 Caution Replacement drives come with two pins to hold the gears in position Use either the pins that come with replacement drives or a paper clip bent into a U shape to hold the gears in their proper position during removal and replacement If the Process Drive is incorrectly installed the printer could be damaged See Homing the Process Drive Train on page 6 8 Torque the Process Drive screws to 12 in Ibs Irreversible damage can result if these screws are over tightened 1 Remove the Right Side Cover page 8 5 2 Disconnect the drum heater harness from the Drum Heater Relay Board and free other wiring harnesses from the gearbox cable restraint 3 Pin the gears in position to maintain correct alignment on replacement Process Drive Motor and Gearbox Holes in process drive frame aligns with holes in gears Hole in gear aligns with arrow on Hole in gear frame aligns with arrow on frame 4 Remove 3 screws and remove the Process Drive 5 Disconnect the harnes
131. USB to Serial adapters are available However software installation procedures may vary by brand Xerox is not responsible for any changes made to your Laptop or PC setup to make the adapter software function properly 1 Load the software from the CD and reboot the PC Follow the instructions included with your adapter to install the necessary software 2 Connect the USB to Serial adapter to an available USB port on your PC Attach the port adapter to the 9 pin Serial cable 012 1535 00 and the diagnostic pig tail 012 1543 00 and plug it into the printer s service port 3 Configure the USB port for diagnostics For Windows XP go to My Computer gt Control Panel gt System select the Hardware tab and then select Device Manager Click on the next to Ports COM amp LPT then right click on the USB to Serial Port device and select Properties Make a note of the port number usually COM3 or COM4 Note Check the USB to Serial adapter instructions for acceptable ports Some adapters may require that the adapter use COM3 or COM4 4 Click on the Port Settings tab Set Bits per second to 19200 and set Flow control to Hardware then click OK 5 Set up a Hyper Terminal port on the PC Click Start gt Programs gt Accessories gt Communications gt Hyper Terminal Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting 6 Name the new connection with the model number of the p
132. Wiring Diagram Right Side Wiring Diagram Left Side Wiring Diagram Inside Front Wiring Diagram Inside Top Wiring Diagram Inside Top Printhead Wiring Diagram Chapter 10 Main Wiring Diagram Printhead Driver ECB JETO JETI JET2 CLK ADCTX ADCRX 12 V regulated 3 3 V Gnd 9 Spares Vss amp Vpp Vss Vpp J210 8400 Onl J630 8400 Only J670 Wave Amp ECB VssD VppD J800 Gnd sense wave amp enable 50 V 12 V unregulated Gnd 6 Tray 3 HCF Pick sense opto Transport motor Media Tray sense ECB Width sense 3 switch Length sense 2 switch Elevator plate motor Mode Switch Parallel 10 100T J200 J600 J400 JR810 3130 Main Processor ECB Printhead tilt solenoid Main tray elevator plate motor Main tray pick clutch MPT solenoid Deskew clutch 8 HCF connector J400 Main ECB J120 HCF_RD HCF_TD HCF_CLK 50V 43 3V Gnd 3 generates 24 V PWM J820 Tray 4 HCF J930 Electronics Module 40 connector IDE isso Hard Drive g0 J860 ECB 2 5 Hard Drive Purge pump Media path motor 7 2 34 with encoder 2 2 2 3 2 M path motor fan early 8400 only Preheater Lift 3 Solenoid 8500 8550 2 Drum temp thermistor 2 Strip solenoid 2 DMU life i Button Strip sense opto Exit bin full sense opto Heat maintenance clutch Media Tray sense ECB Width sense 3 switch
133. XEROX Service Manual 701P27910 Phaser 8400 8500 8950 8560 Color Printer XEROX Service Manual 701P27910 Phasere8400 8500 8550 8560 Color Printer Warning The following servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so First Printing January 2007 Prepared By Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville OR 97070 Copyright 2007 Xerox Corporation All Rights Reserved Unpublished rights reserved under the copyright laws of the United States Contents of this publication may not be reproduced in any form without permission of Xerox Corporation Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs which are displayed on the screen such as styles templates icons screen displays looks etc Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale These materials may not be distributed copied or otherwise reproduced without prior written consent from Xerox Corporation XEROX The Document Company
134. able Parts Example Print Drum Temperature Sensor X Axis Motor e onijkimnopaqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 038 Poor Small Text Resolution Troubleshooting Procedure Step Questions and Actions Yes No 1 Try using a higher quality print mode Complete Go to Step 2 Did this correct the problem 2 1 Test the Drum Temperature Sensor with Complete Go to Step 3 Service Diagnostics 2 Check that the Drum Termperature Sensor is clean and properly positioned Did this correct the problem 3 Check that the X Axis drive system is Complete Replace the correctly assembled and lubricated see X X Axis Motor Axis Motor PL4 0 12 on page 8 44 for more information Did this correct the problem 5 22 Phaser 8400 8500 8550 8560 Color Printer Service Manual Vertical Lines Appear Wavy Print Quality Troubleshooting Straight vertical lines appear to be wavy and ill formed This problem is likely caused by too much oil on the Drum Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Drum Temperature Sensor a X Axis Motor a Y Axis Encoder Drum Maintenance Pivot Plate Drum Maintenance Camshaft abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxy
135. ace the Did the test pass Purge Pump 2 Check the Purge Pump wiring Replace the defective wiring or Is the wiring damaged the Purge Pump 8500 8550 8400 8560 PEST Description 37 024 42 37 027 45 Drum Heater Relay Board disconnect Both Drum heater relay coils are not drawing the expected power 37 025 43 37 028 46 Drum heater relay A disconnect The Drum heater A coil is not drawing the expected power from the supply 37 026 44 37 029 47 Drum heater relay B disconnect The Drum heater B coil is not drawing the expected power from the supply Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 43 Error Messages and Codes Troubleshooting Procedures for Drum Heater Relay Board Step Questions and Actions Yes No 1 Run the Drum Heater Relay test Replace the Go to Step 2 Did the test pass Electronics Module 2 Check the wiring for damage Replace the Drum Heater Relay Board 8500 8550 8400 8560 8560 PEST Description 37 027 45 37 030 48 X Axis Motor disconnect The X Axis motor is not drawing the expected power 37 028 46 37 031 40 X Axis Motor disconnect The X Axis motor first phase is not drawing the expected power 37 029 47 37 032 41 X Axis Motor short The X Axis motor is drawing too much power 37 030 48 37 033 42 X Axis Motor disconnect The X Axis motor second phase is not drawing the expected power 37 031 40 37 034 43 X Axis Motor short The X Axis motor is drawing too muc
136. ace the pivot arm w2D W2E W2F W2L w2M W2N W2P w2a W2R wav w2w Ww2s W2T W2x Tray 3 media size sensor unexpectedly activated during warm up Tray 3 media size sensor unexpectedly activated during printer ready Tray 3 media size sensor unexpectedly activated while printer in fault state Tray 3 media size sensor unexpectedly activated while printer in standby Tray 3 media size sensor unexpectedly activated while picking from Tray 2 Tray 3 media size sensor unexpectedly activated while picking from Tray 3 Tray 3 media size sensor unexpectedly activated while picking from Tray 4 Tray 3 media size sensor unexpectedly activated while picking from Tray 1 Tray 3 media size sensor unexpectedly activated while duplexing Tray 3 media size sensor unexpectedly activated while print Drum maintenance cycle being performed Tray 3 media size sensor unexpectedly activated during printer imaging Tray 3 media size sensor unexpectedly activated while paper staged for print Tray 3 media size sensor unexpectedly activated while transfixing the print Tray 3 media size sensor unexpectedly activated event while exiting print 1 Ensure ground integrity of the printer see page 4 65 2 Ensure the paper guides are correctly set 3 Run the Monitor Sensors test to test the media size sensor 4 Replace the 525 Sheet Feeder W4N W4P W4S Tray 3 motor stall during pick from Tray 3 Tray 3 motor stall during pick from Tray 4 Tr
137. act of a repeating image defect reveals which imaging component is causing the defect Transfix Roller defects show up as light spots in solid fill areas Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print a Transfix Roller Drum Assembly ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 045 Repeating Defects Troubleshooting Procedure Step Questions and Actions Yes No 1 Repeating defects that occur every 11 6 cm Complete Go to Step 2 4 58 in and do not move across the X Axis are caused by the Transfix Roller Clean or replace the Transfix Roller Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 29 Print Quality Troubleshooting Repeating Defects Troubleshooting Procedure Step Questions and Actions Yes No 2 Asingle repeating defect that has a different Complete Replace the Y position on each page but the same X Drum position on each page is probably due to a Assembly defect on the Drum Clean the Drum Did this correct the problem White Stripes Pinstripes This print quality problem has a series of regularly spaced white stripes approximately 6 mm 25 in apart If the X Axis Motor does not move the Pri
138. ada Regulations This Class B digital apparatus comply with Canadian ICES 003 Cet appareil num rique de la classe B est conforme a la norme NMB 003 du Canada Phaser 8400 8500 8550 8560 Color Printer Service Manual European Union The CE mark applied to this product symbolizes Xerox s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated m January 1 1995 Low Voltage Directive 73 23 EEC as amended by 93 68 EEC m January 1 1996 Electromagnetic Compatibility Directive 89 336 EEC m March 9 1999 Radio amp Telecommunications Terminal Equipment Directive 1999 5 EC This product if used properly in accordance with the user s instructions is neither dangerous for the consumer nor for the environment To ensure compliance with European Union regulations use shielded interface cables A signed copy of the Declaration of Conformity for this product can be obtained from Xerox Phaser 8400 8500 8550 8560 Color Printer Service Manual Manual Organization The Phaser 8400 8500 8550 8560 Color Printer Service Manual is the primary document used for repairing maintaining and troubleshooting the printer Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options This manual describes specifications theory and the diagnosis and repair of problems occurring in the print engine and attac
139. agement of the stripper sol and the point when the blade begins to withdraw from the drum see R2 Releasing Period sec 0 to 001 0 5 to 75 Reports the time between the disengagement of the stripper sol and the point when the reaction of the drum to the withdrawal of the blade fades back into the ripple see R2 Releasing Amplitude mpts 45 to 0 10 to 1 Reports the magnitude of the reaction of the drum to the blade withdrawal see R3 This test uses the drum servo error signal to indicate when the drum is contacted by the roller blade Drum Maintenance Contact Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Initial Contact Reports the distance the pm Position pm motor counts motor was moved raising the dm unit before a Y Axis reaction was detected Shows that the dm is raising provides blade drum gap information Phaser 8400 8500 8550 8560 Color Printer Service Manual Check Motors Menu General Troubleshooting This test turns on the Y Axis motor and runs it very slowly for one revolution Y Axis Motor Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Motor fe ripple 0 08 to 0 60 07 to 7 Reports variation of the motor ticks following error 1 Motor fe average 0 5 to 0 7 0 to 8 Reports the motor following ticks error average value
140. ailed list of shadowed personality parameters Power Control Board The power control board distributes drive voltages to operate the printer s various motors solenoids and clutches The power control board also provides the interface that returns information from the printer s sensors to the main board The sensors track mechanical and thermal functions such as the position and temperature of the Printhead The power control board also generates regulated 12 V and 5 V from unregulated 15 V power Power Supply There are no field adjustments necessary on the power supply In general the power supply has two main sections the AC section and the DC section In the AC section power routes to 10 triacs Under main board logic control the triacs supply AC power to the 10 heaters in the printer Two fuses provide current protection to the triacs Fuse F2 and F3 protect the power supply from a shorted triac from a defective heater If the F2 or F3 fuses blow it is best to replace the Electronics Module and of course the defective heater rather than the fuse With the fuse replaced but the triac shorted AC power may be applied to the heater However each time the main board turns on a triac to activate a heater it is turned on for only a fraction of a second The main board must constantly re address each heater it wants to control If the print engine firmware should fail the heaters would automatically shut off Therm
141. aintenance Drive Continued General Troubleshooting Time sec Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 4 Roller Average 50 to 1600 05 to 05 Reports the average period of Period sec the Y Axis following error ripple during the Roll With Both Loaded interval This variation would be due to the dmu roller rolling along the drum surface 5 Roller Revs 3 to 40 Reports the number of Y Axis following error ripple peaks during the Roll With Both Loaded interval 6 Roller Disengaged 0 001 to 05 to 0 5 Reports the time from the Time sec 0 05 unload roller command to the engine until the drum indicates no further roller contact 7 Blade loaded 160 to 800 to Reports the average Y Axis average Y Axis 50 100 following error during the Roll following error With Blade Loaded interval mpts 8 Blade loaded Y 0 001 to 115to0900 Reports the difference Axis following error 0 50 between the max and the min ripple mpts Y Axis following error during the Roll With Blade Loaded interval 9 Blade Disengaged 0 05 to 0 05 Reports the time from the unload blade command to the engine until the drum indicates no further blade contact This test drives the Printhead tilt mechanism through one cycle to determine if it is controllable and operating as expected Tilt Drive Typical Typical Value Value 8500 R Defi
142. al faults 3 26 wiper media path 3 21 x axis fault 3 14 y axis sub system 3 13 ethernet address configuration card 2 20 exit module all series parts 9 9 assembly parts 9 9 sensor assembly parts 9 15 exit rollers 2 5 2 27 2 30 exit rollers parts 9 9 exiting 2 27 F fan drum 2 16 drum cooling parts 9 11 drum diagnostics 5 39 drum disassembly 8 27 electronics module parts 9 11 media path motor 4 7 paper path parts 9 11 temperature error 3 26 fan electronics 3 26 fans menu check menu 4 6 fault codes 3 7 fault history hidden service menu 4 2 field replaceable units 8 2 front door assembly stay and retainer 9 5 hinge pin parts 9 5 removal 8 4 tray 1 assembly 8 4 function menu service diagnostics 4 9 functional specification 1 12 fuzzy text 5 17 G ghosting 5 20 ground connection integrity 4 65 ground integrity 4 65 grounding 4 65 guidelines energy 4 3 Phaser 8400 8500 8550 8560 Color Printer Service Manual H hard drive 1 8 parts list all series 9 13 POST error 3 6 replacement note 8 46 replacement procedure 8 52 support 2 19 upgrade kit parts 9 16 head tilt gear homing 6 5 heater harness 8 13 heaters ink reservoir 2 8 hidden service menu 4 5 home position 6 4 1 0 board faults 3 9 imaging components disassembly 8 8 incomplete image 5 26 indicators LED 1 5 ink jet damage 8 10 ink loader faults 3 23 function 2 3 theory 2 6 ink load
143. al fuses also protect the printer A thermal fuse opens in the unlikely event of a runaway heater following a hardware failure The Drum and the Preheater thermal fuses are located on the Preheater Additional thermal fuses are located on the Printhead and on the ink melting elements Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation The DC power supply generates 3 3 V 15 V and 50 V These voltages provide direct or regulated voltage values to various circuits in the printer The power control board regulates 15 V to 12 and other voltages The main board also has regulators providing 5 V 2 5 V and 1 8 V The power supply outputs 3 3 V in ENERGY STAR mode Fuse F1 provides protection for the switching power supply in the DC section Warning Do not touch the power supply AC line voltages are present The power switch does not disconnect power from the printer The power switch signals the supply and the printer logic to begin a shutdown sequence LAC Line EUA ve Line i S1 Gnd Ref Th Neutral AC Neutral D I fad qi od fr rl e nj inf Jn nj je Je uj jy k ik kl kl Js fs mj ft 4 13 e g 1 H H 1 ays 3 _ H AMi i AV AY H 1 l 1 H e A A c 1 0 Lf AMi H Lo 4 V7 4 a AM ontro Interface
144. al possible causes of streaks running the length of a print Initial Actions m Check the media used is supported by this printer m Check that the exit path is clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade Drum Maintenance Kit m Preheater m Electronics Module Drum Assembly ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 035 Streaks or Lines Down the Print Troubleshooting Procedure Step Questions and Actions Yes No 1 Check for and remove any media jammed Complete Go to Step 2 paper or debris found in the exit path Did this correct the problem 2 Clean the Drum Maintenance Kit wiper blade Complete Go to Step 3 or replace the kit Did this correct the problem 3 1 Check the exit area exit frame Preheater Complete Go to Step 4 Drum Maintenance Kit Printhead and Stripper Blade for anything touching the Drum 2 Reseat any component interfering or touching the Drum 3 Clean the Stripper Blade Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 11 Print Quality Troubleshooting Streaks or Lines Down the Print Troubleshooting Procedure Continued Step Questions and Actions Yes No 4 lf there are streaks on the front side only of Complete Go to Step 5 a 2 sided print the P
145. all connectors to the feeder Complete Go to Step 2 2 Remove the feeder and inspect the connector 3 Replace any damaged connectors either on the feeder or engine 4 Reseat and reconnect the feeder Did this correct the problem 2 Inspect the Pick Rollers in the feeder Replace the Go to Step 3 tray s Pick Are the rollers damaged dirty or not Assembly moving freely 3 TRun the Tray 3 4 Pick Clutch test Goto Step 4 Replace the Does the clutch operate correctly feeder 4 Run the Tray 3 4 Lift Motor test Goto Step 5 Replace the Does the motor operate correctly feeder 5 Check the feeder wiring to the Electronics Replace the Replace the Module J390 wiring and go feeder Is the wiring defective to Step 3 1 0XX 6x Errors 525 Sheet Feeder Program Faults 1 Reseat the printer on the feeder 2 Ensure ground integrity see Ensuring Ground Integrity on page 4 65 3 Reset NVRAM 4 Replace the feeder 3 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 2 0XX 4x Errors 1 0 Circuit Board Fault 2 001 47 The print engine cannot detect the presence of the I O Board Troubleshooting Procedure for 1 0 Board Step Questions or Actions Yes No 1 Areall I O Board connections properly Goto Step 3 Goto Step 2 seated 2 Reseat the connections and power Onthe Go to Step 3 Complete printer Does the error persist 3 Test the wiring from I O board J840 to
146. alue reflects the effort needed to rotate the pick shaft and compress the lift spring A higher value of R3 could show higher cam bearing friction and or lift plate spring strength Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 19 General Troubleshooting 4 20 Tray 1 Pick Shaft Continued R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Contact average fe 120 to 2000 Reports the average MP fe while the pick roller is contacting the separator pad This value should reflect the coefficient of friction between the separator pad and the pick roller This value may be effected by contamination or glazing Pushdown MP fe max 750 to 2000 Reports the peak MP fe during the interval when the pick cams are depressing the lift plate A higher value here could indicate issues with the cam surfaces or the spring compression force Final average MP fe mpts 900 to 1500 Reports the average MP fe following the re latching of the missing tooth gear This value should be the same as RO if the missing tooth gear successfully relatched Test is the same for each pick shaft although for Tray 2 the Media Path Drive motor is used and for the 525 sheet feeders the corresponding pick transport motor is used Test determines if the shaft can be driven by the clutch if the nudger rollers are being driven and
147. alve 37022 4x Purge Motor J280 37032 4x Y Motor J790 37062 4x Head VSS J390 37034 4x MP Motor 37021 4x MT Elevator 37013 4x Electric Fan Channel Connected to Ground Strap s8500 127 10 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Left Side Wiring Diagram Continued The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel 37034 3x MP Motor 37015 4x MP Fan 8400 Only p 370xx 4x Preheater NY Lift Solenoid 8500 8550 Only T a l lt gt Vas 37017 4x Deskew Clutch SoS yy ows it 8400 Only L VES 2 ray J Y AN DN Z aR S R sawon X G iS 37018 4x Pick Clutch 37019 4x Pick Solenoid 58500 128 Phaser 8400 8500 8550 8560 Color Printer Service Manual 10 7 Inside Front Wiring Diagram The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel 37036 4x Process Motor 37008 4x Preheat Power AC Connector Zhi a a a gt Dlr ia ny A H PA E E AAN p7 E N al 2 TA wN Lx e a Sy TA Jee A z eS K CoO aee SY Paper Jam aj Paper Open Front Cover J860 13131 41 Sensor Flag i s8500 129 10 8 Phaser 8400 8500 85
148. and DX 069E00380 8550 Configuration Card DN DT and DX 069E00560 8560 11 Cable Flex Wave Amp Drive 1 174448680 8400 117E29790 8500 8550 8560 12 Cable Right Side Power Control 1 117E29820 13 1 0 Board 1 671529100 8400 960K22331 8550 8550 14 Cable Combined Right Ink Loader 1 174451180 8400 Data Preheater AC 117E29810 8500 8550 8560 15 Cable 1 0 Board Data 1 117E29830 16 Cable Right Umbilical 1 117E28790 17 Drum Heater Relay Board 1 960K35170 18 Cable Front Door 1 117E28780 19 Cable Control Panel 1 117E35230 8500 8550 8560 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 13 Parts Lists PL 6 0 Sensors and Flags Actuators 8500 122 9 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts List 6 0 Sensors and Flags Actuators Parts Lists No Name Description Qty Part Number 1 Drum Temperature Sensor 1 130K75210 2 Optical Sensor Generic Snap In 1 130E11530 3 Safety Interlock Switch Mech 1 110E20390 4 Exit Module Sensor Assembly 1 130K75220 5 Paper Present Flag 1 130E11550 6 Exit Flag 1 386732680 7 Sensor Assembly Paper Tray 1 130K75230 8 Waste Tray Detect Sensor 1 130E12620 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 15 Xerox Supplies Kits Description Part Number Mechanical Kit Hardware Nut Plate 2 ea 6mm press n
149. and Indicators After servicing the printer manually set the following assemblies to their home position before powering on the printer If the assemblies are not home gears in the Process Drive can grind or the printer can generate errors m Printhead tilted forward and disengaged from tilt gear m Head Tilt Gear disengaged from Process Drive train arrows on left frame point to each other Wiper Blade bottom of travel Process Drive holes on Transfix Camshaft and Drum Maintenance Camshaft line up with marks on frame large gears within assembly line up with holes in assembly housing Wiper Assembly Positions When the Wiper Assembly is homed the Wiper Blade should be moved all the way to the bottom of the printer When the Wiper Blade is at the bottom you can easily remove the Waste Tray See the Wiper Alignment Procedure on page 6 2 6 4 Phaser 84000 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations Homing the Head Tilt Gear The Printhead Is Not in the Printer If the Printhead is removed manually rotate the Head Tilt Gear located on the inside of the left frame to its disengaged position 2 da t N of Printhead ORS a Tilt gear disengaged coon f O OOS a AR Foe oY K s8500 061 Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 5 Adjustments and Calibrations The Printhead Is in the Printer 1 Remove the Drum Maintenance Kit
150. and that it is supported by the printer 2 Use a less glossy media 3 If the Drum maintenance unit is near the end of its life replace it 4 Clean and inspect the exit rollers 5 Ensure the Process Drive is correctly homed 6 Run the Paper Path Drive test 7 Replace the Lower Exit Guide D2D D2M D2N D2P D2Q D2R D2T Exit flag unexpected event during warm up The exit flag actuated unexpectedly when paper picked from Tray 2 The exit flag actuated unexpectedly when paper picked from Tray 3 The exit flag actuated unexpectedly when paper picked from Tray 4 The exit flag actuated unexpectedly when paper picked from Tray 1 The exit flag actuated unexpectedly when duplexing The exit flag actuated unexpectedly when transfixing 1 Ensure ground integrity of the printer see page 4 65 2 Run the Sensors test to test the exit sensor 3 Run the Paper Lead Edge Times test 4 Replace problem component D2X The exit flag actuated unexpectedly exit 1 Ensure the media is not too thick and that it is supported by the printer 2 Use a less glossy media 3 If the Drum Maintenance Kit is near the end of its life replace it 4 Clean and inspect the exit rollers 5 Check the exit flag for proper installation or damage replace if necessary 6 Run the diagnostic Paper Path Drive test 7 Replace problem component D3C D3M D3N D3P D3Q D3R Exit flag time out during mechanical recovery Exit flag timed
151. anel display shows the warm up progress the Ready LED flashes When warm up completes the Ready LED displays solid The temperature of the printhead drum and paper preheater are allowed to stabilize at their operating temperatures and ink is melted if needed The printhead is homed to the print position for printing A cleaning page is printed at this time if a purge was performed A start page is printed if enabled The Control Panel displays a message that the printer is initializing and then ready The print engine is initialized and is ready to print Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 55 General Troubleshooting 4 56 Miscellaneous Electrical Troubleshooting The Electronics Module contains the power supply image processor board and the power control board If a component of the Electronics Module fails and service is necessary the entire Electronics Module is replaced as a unit No individual board troubleshooting is required The printer contains many self test routines to aid in diagnosing problems Note If the printer encounters certain fault conditions the printer may reboot up to three times before displaying an error code This is an attempt to correct the problem and reduce the number of unnecessary service calls Following the suggested debug procedures the specified sequence generally provides better test coverage than performing tests in a different order Error Message D
152. ang free 10 Relieve tension on the Y Axis Belt by pulling the end of the spring arm toward the front of the printer using your fingers See page 8 8 11 Slide the belt off the pulley 12 Unplug the Drum heater cable from the Drum Heater Relay Board and free the cable from the retaining hook 13 Unplug the Drum encoder cable connector from the Power Control Left Cable and free the cable from the retaining hook 14 Unplug the Drum Temperature Sensor connector from the I O Board Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 27 Service Parts Disassembly 15 Remove the Exit Module page 8 32 Exit Module Assembly Media Release J850 Blade Assembly Transfix Load Arm Sy eA N 7 o Q D QZ DNS i WS WO A f 110 Connector J250 ZE Not Shown m ad A o ip gt ie N AN AYE Ai Y a A Kp Y LAA 0 A of Drum Encoder Cable Power Control Left Cable 8500 091 Drum Heater Relay Board Caution The Drum Temperature Sensor harness is routed through the Exit Module Use care during removal to avoid damaging the sensor 16 Remove the clevis pins securing the Transfix Load Arms to the chassis and remove the Transfix Load Arms and the Stripper Carriage Assembly See the figure on page 8 23 17 Remove 3 left handed screws 8500 8550 8560 and washers from the right side of the Drum Assembly Note that one of the screws has no washer The 8400 uses 3 right han
153. are seated correctly in their corresponding gear detent slots Inspect the perimeter of the cam lobes for surface defects and check to see that the angular orientations of the cams match Inspect the transfix load arm return springs Verify that the maintenance kit returns home between prints Inspect the cam shaft surfaces for damage If all of these items are working correctly replace the process drive module Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 39 Print Quality Troubleshooting YMCKRGB Solid Fills These seven prints show uniformity of fill If colors are uneven or wrong see Color is Uneven or Wrong on page 5 9 7 8500 054 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 Enhanced or High Resolution Photo mode Typically wrinkling appears in the secondary colors See the blue and green solid fills in the illustration to the right Causes Weak jets or uneven Drum heating may cause uneven fills To solve wrinkling try different print media Replace the maintenance kit to correct streaking Check the Drum Temperature Sensor for debris build up on the sensor Check to see if the sensor is in
154. ated The first step is to generate prints using printable pages embedded in the printer on paper from the approved media list The paper should be from an unopened ream that has been acclimated to room temperature See the approved media list from Xerox Supplies on page 9 16 for media that has been tested and approved for use in this printer If the print quality defect is still present when printing on approved media from an unopened ream of paper then media software applications and environmental conditions need to be researched When analyzing a print quality defect first determine if the defect occurs m inallcolors m in only one color if itis repeating or random The visible surfaces of all rollers should be inspected for obvious defects Diagnosing Print Quality Problems 5 2 The Troubleshooting Print Quality page provides a good overview of the most common print quality problems To print the Troubleshooting Print Quality page follow these steps 1 From the Control Panel scroll to Troubleshooting then press OK 2 Scroll to Print Quality Problems then press OK 3 Scroll to Troubleshooting Print Quality Page then press OK The Troubleshooting Print Quality page includes instructions for printing the Eliminate Light Stripes test print These instructions are also provided on the next page of this manual The Eliminate Light Stripes test print indicates individual weak or missing jets or an obstruction in the
155. ates the strip solenoid lever which in turn rotates the Stripper Carriage until it hits the transfix ground pins This action causes the stripper blade to drop onto the deadband of the Drum After the Transfix Roller and the stripper engage the Drum rotates to advance the media and transfix the image The stripper blade catches the leading edge of the sheet of media and separates it from the Drum After the leading edge is beyond the stripper blade the Stripper Solenoid de energizes When the solenoid is de energized the solenoid return spring provides a force to move the solenoid plunger out of the solenoid coil which rotates the Stripper Carriage back to its ready position Once the entire image is transferred the Drum stops rotating and the Process Drive lifts the Transfix Roller The Media Drive now rotates the Exit Rollers in the correct direction to pull the media out However the Deskew Clutch is de energized so the deskew rollers are not driven during transfix The Exit Rollers deposit the media into the Output Tray ending the print cycle Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 27 Theory of Operation 4 Transfer Roller Transfix Load Arm A ooN Module O Transfix lt oad Spring Transfix am Drum Process Drive ENE T Transfix Roller Gear Swing Arm Gear i s8500 026 2 28 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Strip Solenoid
156. ating Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information Media and Tray Specifications Paper Size Paper Type Paper Weight Media Type 2 Sided Duplex Single sided Only Any Tray Tray 1 Only Letter 8 5 x Plain Paper 60 120 g m 16 32 Ib Bond 11 in or or B ne A4 210 x Letterhead 121 220 g m 32 59 Ib Bond 297 mm Transparency Phaser Professional Solid Ink l Transparencies Card Stock 100 120 g m 37 44 Ib Cover 121 220 g m 44 80 Ib Cover Labels Phaser Color Printing Labels l l Special Phaser Professional Solid Ink l l Business Cards Phaser Professional Solid Ink High Resolution Photo Paper Phaser Premium Postcards Phaser Weatherproof Paper l l Phaser Trifold Brochures Legal 8 5 x 60 120 g m 16 32 Ib Bond 14 in iat 60 120 g m 16 32 Ib Bond l l x 10 5 in or 2 29_ AB 148 x 121 220 g m 32 59 Ib Bond 210 mm Statement 5 5 60 120 g m 16 32 Ib Bond x 8 5 in US Folio 8 5 x 60 120 g m 16 32 Ib Bond 13 in A6 105 x 60 120 g m 16 32 Ib Bond 148 mm B5 ISO 176 x 60 120 g m 16 32 Ib Bond 250 mm B5 JIS 182 x 60 120 g m 16 32 Ib Bond 257 mm Index Cards 3 x 5 in Phaser 8400 8500 8550 8560 Color Printer Service Manual 1 13 General Information 2 55 a zak ops Er g2 i i i zo 2 Paper Size Paper Type Paper Weight M
157. ation obstructions or damage broken gear or belt Look for ink in the Wiper Belt channels 2 Ensure the wiper system is properly aligned see Wiper Alignment Procedure on page 6 2 Did this correct the problem Complete Go to Step 8 8 Run the Head Maintenance Clutch test Did the test pass Go to Step 9 Replace the Head Maintenance Clutch 9 isthe head lock mechanism on the right end of the Exit Module functioning properly Go to Step 10 Replace the Exit Module 10 Are there obstructions or spilled ink on the Wiper Blade the Head Tilt Gear drive path or under the Printhead Is the Waste Tray overfilled Clean the inside of the printer and retest 8 0XX 6x Errors Program Faults 1 Reset NVRAM and then retest 2 Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 3 22 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 9 OXX xx Errors Ink Loader Faults 9 000 44 Ink Loader device fault 9 005 49 The cyan ink melt heater is On but ink is not dripping 9 006 41 The magenta ink melt heater is On but ink is not dripping 9 007 42 The yellow ink melt heater is On but ink is not dripping 9 008 43 The black ink melt heater is On but ink is not dripping 9 015 4x through 9 018 8500 8550 8560 only When the Ink Loader door is opened to clear an ink jam the following codes are recorded
158. average effort required to rotate the deskew shaft in the CCW direction at a constant velocity An unusual value could indicate a difference in the composition and or number of the rollers the nip pressure or out of range mechanical dimensions due to wear or contamination such as paper dust increasing the effective diameter of a roller 4 CCW On fe ripple 115 to 360 0 to 2 0 Reports the variation of effort required to rotate the deskew shaft in the CCW direction at a constant velocity A larger value could indicate particles in the gears or non uniform contamination of a roller causing a lump 5 CCW Off fe settling 0 010 to Oto 5 Reports the time it takes the time sec 0 20 MP motor servo system to settle down after the sudden release of the deskew shaft load A larger value can indicate a slow to release or dragging clutch 6 Time to CW On 0 010 to 0 to 05 Reports a time that indicates peak fe sec 0 06 how long it takes the MP motor servo system to react to the sudden addition of the deskew shaft load Larger values may indicate a slipping or slow to engage clutch 7 CW On peak fe 950 to 7 0 to Reports the peak effort 450 2 0 required to accelerate the deskew shaft load A smaller value could indicate a slipping clutch 4 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Deskew Shaft Continued General Troubleshooting R Defin
159. ay 3 motor stall during pick from Tray 3 1 Ensure ground integrity of the printer see page 4 65 2 Ensure the paper guides are correctly set 3 Run the Monitor Sensors test to test the media size sensor 4 Replace the 525 Sheet Feeder X2A X2B X2C X2D X2E Tray 3 pick flag triggered unexpectedly during abnormal shutdown Tray 3 pick flag triggered unexpectedly on power up following normal shutdown Tray 3 pick flag triggered unexpectedly during mechanical recovery Tray 3 pick flag triggered unexpectedly during warm up Tray 3 pick flag triggered unexpectedly during printer ready Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 59 Error Messages and Codes Jam Code Troubleshooting Procedures Continued X2F X2L X2M X2N X2P X20 X2R X28 X2V X2W X2X Tray 3 pick flag triggered unexpectedly while printer was in a fault state Tray 3 pick flag triggered unexpectedly while printer in standby Tray 3 pick flag triggered unexpectedly while picking from Tray 2 Tray 3 pick flag triggered unexpectedly while picking from Tray 3 Tray 3 pick flag triggered unexpectedly while picking from Tray 4 Tray 3 pick flag triggered unexpectedly while picking from Tray 1 Tray 3 pick flag triggered unexpectedly while duplexing Tray 3 pick flag triggered unexpectedly while transfixing Tray 3 pick flag triggered unexpectedly while print Drum maintenance cycle was being performed Tray 3 pick flag triggered u
160. b ABCDEFGHIJKLMNOPQRSTUV abcdefghiikimnopqrstuvwxvzab 8500 034 Print Too Light or Too Dark Troubleshooting Procedure Step Questions and Actions Yes No 1 Check that the paper type settings match the driver and application settings being used especially if printing on transparency Did this correct the problem Complete Go to Step 2 Adjust the print mode or Color settings Did this correct the problem Complete Go to Step 3 Insert new ink and print a solid fill test print Run the test print until the affected color returns to normal The ink may be discolored due to age or lack of use over an extended period of time Did this correct the problem Complete Go to Step 4 If the problem is occurring for only one color purge the ink up to 10 times to clear the ink or until discoloration is cleared Did this correct the problem Complete Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 7 Print Quality Troubleshooting Blank Prints The printer processes a sheet of paper but no image is printed on it Note Blank sheets accompanying multi picks or chase pages following a jam are a part of normal operation Initial Actions m Check the media used is supported by this printer m Check the media settings are correct at the Control Panel Troubleshooting Reference Applicable Parts Example Print m Electronics Module a Printhead Wave Am
161. bbles that may be obstructing the Printhead nozzles The Drum Assembly and Transfix System Form the key portion of where imaging takes place The image is first printed as a mirror image on the rotating Drum A sheet of warmed media feeds from the Preheater and passes between the Drum and the Transfix Roller The Process Drive gear train then loads the Transfix Module and presses the media to the Drum to adhere the image as the Drum spins in the transfix direction The Electronics System includes the Electronics Module also known as the E can which contains the main board the image processor board the power control board and the power supply board Distributed in the print engine are the Wave Amplifier I O board and Drum Heater Relay Board Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 3 Theory of Operation Process Drive 2 4 A small DC servomotor powers the Process Drive gearbox to rotate the gears to specific positions during the printing process The Process Drive is able to actuate each camshaft system independently through the use of the swing arm in the gear train The rotational direction of the motor controls the operation of the transfix and drum maintenance system When the process motor rotates in one direction the swing gear engages the lower gears When the motor rotates in the opposite direction the upper gears are engaged Since the system is open loop special attention to the home position of
162. blade If YES replace 9 the Wiper the wiper assembly Assembly blade Is it OK Step Check the Check the purge pump performance 10 purge YES 10a Empty the waste tray performance of NO 10b Select Eliminate Light Stripes from the printer front panel and the purge run one cleaning cycle system Circle 10c Remove the waste tray and examine how much ink was purged one A single purge should resemble the illustration Is the purge mass noticeably less than what is pictured If YES inspect the purge hoses for kinks splits or tears Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference Step Print Service If NO go to Step 12 11 Test 1 Weak YES If YES do the following and Missing NO e Check the exit area of the paper path for debris that could be Jets scraping ink off the drum and may mimic a weak or missing jet Are there weak Circle e Select Eliminate Light Stripes from the printer front panel up to or missing a 3 times as needed to recover a weak or missing jet jet s e Perform the JetFix technique by downloading the appropriate snippet such as 8400_jetfix_c ps for a missing cyan jet to the printer The snippets are available on the Customer Support Resources website in the Phaser 8400 web pages Refer to Service Bulletin 640 e If the jet is still missing replace the printhead The repair is complete Step Is the customer If YES print 10 solid fill pages of c
163. bleshooting Procedure for Media Drive Step Questions and Actions Yes No 1 Run the Media Path Motor test Replace the Go to Step 2 Did the test pass Electronics Module 2 Check the wiring for damage Replace the Media Drive Assembly 8500 8550 8400 8560 PEST Description 37 036 45 37 039 48 Process motor disconnect The Process Drive is not drawing the expected power 37 037 46 37 040 40 Process motor short The Process Drive is drawing too much power Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 45 Error Messages and Codes Troubleshooting Procedure for Process Drive Step Questions and Actions Yes No 1 Do the Process Drive gears Transfix Goto Step 2 Look for drag Camshaft and Drum Maintenance Camshaft in the rollers rotate freely or replace the Process Drive 2 Run the Process Motor test Replace the Go to Step 3 Did the test pass Electronics Module 3 Check the wiring for damage Replace the Process Drive 37 038 47 37 039 48 37 040 40 37 041 41 37 042 42 37 043 43 37 044 44 37 045 45 37 046 46 37 047 47 37 048 48 37 049 40 37 050 41 37 051 42 37 052 43 37 053 44 37 054 45 37 055 46 3 46 8400 PEST Description The power supply did not reset properly Reset may be disconnected Power supply 5 volt over limit Power supply 5 volt under limit Power supply 1 8 volt over limit Power supply 1 8 v
164. bleshooting Procedure for Process Control System Step Questions and Actions Yes No 1 1 Verify the temperature of the room where Complete Go to Step 2 the printer is located see Environmental Specifications on page 1 12 2 Is the room temperature too cold 3 Ensure the printer is acclimated to the room temperature Did this correct the problem 2 Run the Monitor Heaters tests with all Replace the Go to Step 3 heaters ON Electronics Are the heaters operating correctly and Module within specification 3 Inspect the harness to the failed heater Replace the Replace the Is the harness damaged harness problem component 3 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 4 024 42 This fault code indicates a problem with the wiper The wiper is not aligned properly and engaged the headtilt while in the waste lock position Troubleshooting Procedure for 4 024 Error Code Step Questions and Actions Yes No 1 Ensure the Process Drive is correctly homed Isthe problem Go to Step 2 as described in Homing the Process Drive fixed Train on page 6 8 2 Run the Check Wiper Alignment test Perform the Go to Step 3 Did the test fail Wiper Alignment Procedure and test again Go to Step 3 if the test fails again 3 Run the Wiper Drive test Goto Step 4 Goto Step 6 Did the test fail 4 Inspect the wiper drive and wiper lock Goto Step 5 Replace th
165. bly PL1 0 1 1 Open the Front Door by pulling out on the handle to the right side of the door 8500 065 2 Remove the right and left stay retainers from the Front Door 3 Open the plug cover and disconnect the plug from the right side of Front Door 4 Release the harness from cable retainer on the right side of Front Door 5 Carefully remove the Front Door by releasing the left hinge pin from the frame and sliding the assembly to the right Stay Retainer Stay Retainer 8500 066 Note Do not lose the hinge pins or stay retainers for the Front Door 8 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Control Panel Cover PL1 0 5 1 Open the Exit Cover Exit Cover Control Panel Cover Control Panel See a s8500 067 2 Using either your fingers or a small flathead screwdriver loosen the Control Panel Cover on the left side and then slide it forward while lifting up to remove it from the printer Control Panel PL1 0 6 1 Remove the Control Panel Cover page 8 5 2 Disconnect the two wiring harness connectors and one ribbon cable connector from the back of the Control Panel 3 Remove the Control Panel Right Side Cover PL1 0 10 Open the Exit Cover Remove the Control Panel Cover page 8 5 Open the Front Door Remove the rear screw Pull forward on the latching tab located by the power plug to release it
166. c Mode See Service Diagnostics Mode Menu on page 4 5 for a complete explanation of each function Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Menu Item Description Reset NVRAM Provides access to reset the printer back to its factory default settings and erase all network settings If possible print the Configuration Page before resetting NVRAM Power Saver Timeout Selects the Power Saver Timeout the amount of time the printer must be idle before changing to Power Saver low energy consumption mode per ENERGY STAR 256 guidelines Reset Printer Resets all items in the Printer Controls menu to their default values Head Adjust This is for manufacturing or engineering use only Adjust X Axis scale This is for manufacturing or engineering use only Drift Compensation This is for manufacturing or engineering use only Head to Drum Adjust This is for manufacturing or engineering use only Wiper adjust 8500 Adjusts the tension on the wiper blade for engineering use only Purge adjust 8500 When replacing a purge pump different than the manufactured pump you may need to adjust the amount of pressure in the pump using this menu item Reset Ink Loader 8500 Resets the ink loader ink stick count Service Usage Profile Prints pages with detailed printer usage information Print OCR Usage Profile Prints usi
167. cellaneous Electrical Troubleshooting on page 4 56 See also Verifying Power Supply Operation on page 4 64 Boot loader memory test failure Ensure the printers RAM chips are properly seated and that the correct RAM type for this printer is installed CPU bridge and or PCI bus is not communicating Reboot the printer if the error still occurs replace the Electronics Module ROM not responding Reboot the printer if the error still occurs replace the Electronics Module PE LED PS LED Off or 1 Off or 1 Blink and Blink and then off then off On Solid On Solid dimly dimly Off PS and Control Panel 1 2 sec blink 1 Rapid blinking 2 Rapid blinking 3 Rapid blinking Printer hangs during code initialization 1 Unplug all cables from the Electronics Module 2 Plug in the power cable 3 Power on the Electronics Module system 4 If the problem still occurs reseat the RAM DIMMs 5 Replace the Electronics Module For disassembly see Electronics Module PL5 0 5 on page 8 46 For replacement go to the Parts List on page 9 3 Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 3 Error Messages and Codes POST Error Reporting POST checks the communication paths within the Electronics Module and to other various printer components POST testing initializes the Control Panel and in most cases if an error occurs a text message is displayed on the Control Panel along with
168. ces sharing the printer s AC circuit shared such as a laser printer a coffee maker or a space heater may be placing heavy intermittent demand on the AC circuit This sudden inductive demand creates momentary AC voltage sag that causes the PEST test to fail Verify the AC power source prior to troubleshooting these errors For wiring diagrams to aid in diagnosing PEST faults see Wiring Diagrams on page 10 1 37 001 46 37 002 47 37 03 48 37 004 40 37 005 41 37 006 42 37 008 44 37 009 45 37 010 46 37 011 44 8400 8500 8550 8560 PEST Description Generic PEST error Something went wrong during the PEST process PEST Error Printhead Left jetstack disconnect The left jetstack is not drawing the expected power from the supply PEST Printhead Right jetstack disconnect The right jetstack is not drawing the expected power from the supply PEST Printhead Reservoir 0 disconnect Reservoir 0 is not drawing the expected power from the supply PEST Printhead Reservoir 1 disconnect Reservoir 1 is not drawing the expected power from the supply PEST Drum disconnect The Drum heater is not drawing the expected power from the supply PEST Preheater disconnect The Preheater is not drawing the expected power from the supply 8400 PEST Description 8500 8550 8560 PEST Description Inkmelt 0 Yellow disconnect All ink melters are disconnected All The inkmelt heater is not ink melters are n
169. ch 4 10 purge vent solenoid 4 12 strip solenoid 4 12 tray 1 pick solenoid 4 11 tray 2 tray 3 tray 4 pick clutch 4 11 check drive menu 4 31 drum maintenance drive 4 34 paper path drive 4 32 tilt drive 4 35 transfix drive slow and transfix drive fast 4 34 tray 2 tray 3 tray 4 lift plate drive 4 36 wiper drive 4 31 x axis drive 4 33 check drum menu 4 37 drum maintenance contact 4 42 stripper contact 4 41 y axis belt slip 4 40 y axis belt tension 4 40 y axis drive 4 39 y axis encoder 4 37 y axis geometry 4 38 check misc menu 4 46 drum maint transfix home 4 50 paper path status 4 46 purge pump 4 47 temperature status 4 47 voltages 4 49 wiper alignment 4 49 check motors menu 4 43 media path motor 4 44 process motor 4 44 tray 2 tray 3 tray 4 lift motor 4 45 tray 3 and tray 4 pick feed motor 4 45 x axis motor 4 43 y axis motor 4 43 check paper path menu duplex paper drive power 4 27 duplex paper lead edge times 4 28 duplex paper sensor bounce times 4 30 duplex paper trail edge times 4 29 paper drive power 4 22 paper lead edge times 4 22 paper sensor bounce times 4 26 paper trail edge times 4 24 tray 1 pick shaft 4 18 tray 2 tray 3 and tray 4 pick shaft 4 20 wiper shaft 4 16 check shafts menu 4 13 deskew shaft 4 13 cleaning ink smears 7 3 light stripes or missing colors 7 2 media jams 7 3 cleaning cycle 2 33 cleaning page 2 14 2 33 5 44 cleaning procedures 7
170. ck the preheater exit flag for debris 7 Remove the paper preheater and ensure that the exit flag does not interfere with the assembly Replace the Paper Preheater if all else checks out P4A Process motor stalled on abnormal shutdown P4B Process motor stalled on power up following a normal printer shutdown P4C Process motor stalled during mechanical recovery P4D Process motor stalled during an printer warm up P4E Process motor stalled while the printer was in its ready state P4F Process motor stalled while the printer was in a fault state 3 56 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued P4G P4H P4J P4K P4L P4S PAT P4V P4W P4X Process motor stalled while the printer performed an auto Drum maintenance cycle Process motor stalled while the printer performed Printhead maintenance Process motor stalled while the printer performed Printhead purge Process motor stalled while the printer performed an oil transfix roller cycle Process motor stalled while the printer was in standby mode Process motor stalled while the printer staged for transfix Process motor stalled while the printer transfixed the print Process motor stalled while the printer performed a print Drum maintenance cycle Process motor stalled while the printer imaged the Drum Process motor stalled while the print exited the printer 1 Ensure the media i
171. cks 108R00608 8400 108R00672 8500 8550 108R00727 8560 Rainbow Pack 108R00612 8400 058K00220 8560 Genuine Xerox Metered Solid Ink Cyan 6 sticks 108R00707 8550 108R00687 8560 Genuine Xerox Metered Solid Ink Magenta 108R00708 8550 6 sticks 108R00688 8560 Genuine Xerox Metered Solid Ink Yellow 6 sticks 108R00709 8550 108R00689 8560 Genuine Xerox Metered Solid Ink Black 6 sticks 108R00706 8550 108R00690 8560 Genuine Xerox Solid Ink Cyan 1 stick 108R00687 8500 8550 Genuine Xerox Solid Ink Magenta 1 stick 108R00688 8500 8550 Genuine Xerox Solid Ink Yellow 1 stick 108R00689 8500 8550 Genuine Xerox Solid Ink Black 1 stick 108R00690 8500 8550 KS Sy a Ca Software and Documentation Description 8400 8500 8550 8560 Setup Guide poster 001153600 001167300 Quick Reference Guide 71086500 721P58550 World Kit 061449300 650K24290 650K27770 Printer Installer and Utilities CD ROM 063344900 N A N A User Documentation CD ROM 063345000 N A N A Software and Documentation CD ROM N A 063347500 Phaser Color Printing Media Description Part Number Phaser Premium Color Printing Paper 24 Ib Letter 016136800 500 Sheets Phaser Premium Color Printing Paper 24 Ib A4 500 Sheets 016136900 9 18 Phaser 8400 8500 8550 8560 Color Printer
172. cle was being performed Tray 4 media size sensor unexpectedly activated while printer imaging Tray 4 media size sensor unexpectedly activated while exiting print 1 Ensure ground integrity of the printer see page 4 65 2 Ensure the paper guides are correctly set 3 Run the Monitor Sensors test to test the media size sensor 4 Replace the Tray 4 525 Sheet Feeder 5 Replace the pivot arm Z2A Z2B Z2C Z2D Z2E Z2F Z2L Tray 4 pick flag triggered unexpectedly during abnormal shutdown Tray 4 pick flag triggered unexpectedly during normal shutdown Tray 4 Pick flag triggered unexpectedly during mechanical recovery Tray 4 pick flag triggered unexpectedly during warm up Tray 4 pick flag triggered unexpectedly while printer ready Tray 4 pick flag triggered unexpectedly while printer in fault state Tray 4 pick flag triggered unexpectedly while printer in standby Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 61 Error Messages and Codes Jam Code Troubleshooting Procedures Continued Z2M Z2N Z2P Z20 Z2R 228 Z2T Z2V Z2W Z2Z Tray 4 pick flag triggered unexpectedly while pick from Tray 2 Tray 4 pick flag triggered unexpectedly while pick from Tray 4 Tray 4 pick flag triggered unexpectedly while pick from Tray 4 Tray 4 pick flag triggered unexpectedly while pick from Tray 1 Tray 4 pick flag triggered unexpectedly while duplexing Tray 4 pick flag triggered unexpectedly while paper staged for
173. cs to run the Head Replace the Go to Step 7 Maintenance Wiper Clutch test Head Did the test fail Maintenance Clutch 7 Use Service Diagnostics to run the Wiper Inspect the Replace the Drive test maintenance Exit Module Did the test fail drive system replace any defective parts 3 18 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 7 010 43 The Printhead is stuck in the tilted position or is not able to tilt forward to the print position due to problems 7 011 44 This is a soft fault and will not halt the printer 7 012 45 The Drum transfix is not in home position after the return home motion has been completed 7 014 47 The Printhead is not locked in the head tilt restraint spring 7 015 48 The head tilt restraint spring is out of place Troubleshooting Procedure for 7 010 to 7 015 Error Code Step Questions and Actions Yes No 1 Reboot the printer Complete Go to Step 2 Did this correct the problem 2 Do the Printhead Restraints rotate Goto Step 3 Repair or correctly replace the Printhead Restraints 3 1 Has ink spilled ink around the Printhead Clean the Go to Step 5 that prevents the Printhead from moving Printhead to its center position You should be able area to push the Printhead right to left 4 Is the Printhead stuck to the Wiper Blade Start the Go to Step 4 printer in diagnostics mode and run idiags test Exercise Heater toggle Pr
174. current error occurred Troubleshooting Procedure for X Axis Motor Step Questions and Actions Yes No 1 1 Inspect the Printhead power cable and Goto Step 2 Goto Step 3 heater wiring 2 Verify the Printhead travels smoothly from left to right 3 Ensure the Printhead does not bind due to ink spills Is Printhead movement restricted 2 Clear the obstruction restricting Printhead Complete Go to Step 3 movement Did this correct the problem 3 Inspect the X Axis Motor harness Replace the Go to Step 4 Is the wiring damaged harness 4 Use Service Diagnostics to test the X Axis Replace the X Replace the drive Axis Motor Electronics Did the test fail Module 6 0XX 6x Errors Program Faults 6 001 64 6 002 65 allowed 6 008 62 6 011 65 6 013 67 6 017 62 The X Axis task received an unexpected message Attempt to home the X Axis from a state where homing is not Attempt to use the X Axis drive without initializing it Attempt to service the X Axis while not in the appropriate state Unknown X Axis program fault An attempt was made to drive the X Axis using the wrong server 6 018 63 6 019 64 6 023 68 6 025 66 6 032 68 6 033 60 An attempt was made to move with the X Axis uninitialized An attempt was made to move the X Axis from a homeless state Could not allocate memory for X Axis home parameters An attempt was made to home with the X Axis uninitialized Could
175. d Standard Standard Standard Standard 525 Sheet Tray 2 Standard Standard Standard Standard Standard 525 Sheet Feeder Tray 3 Optional Optional Optional Optional Standard 525 Sheet Feeder Tray 4 Optional Optional Optional Optional Optional USB Parallel Connection Standard Standard Standard Standard Standard Ethernet Connection No No Standard Standard Standard Japanese fonts are provided for applicable countries per special licensing requirements The following features are not included in this configuration proof print saved print secure print and collation Phaser 8400 8500 8550 8560 Color Printer Service Manual 1 3 General Information Phaser 8500 8550 Printer Configurations Phaser Features 8500N 8500DN 8550DP 8550DT 8550DX Maximum Print Speed 24ppm 24ppm 30ppm 30ppm 30ppm Memory 128MB 128MB 256 MB 256 MB 512 MB Hard Drive Optional Optional Optional Optional Standard PostScript Fonts 137 137 137 137 137 PCL Fonts 81 81 81 81 81 Job Pipelining No No Yes Yes Yes Automatic 2 Sided No Yes Yes Yes Yes Printing 100 Sheet Tray 1 Standard Standard Standard Standard Standard 525 Sheet Tray 2 Standard Standard Standard Standard Standard 525 Sheet Feeder Tray 3 No No No Yes Yes 525 Sheet Feeder Tray 4 No No No No Yes USB Connection Standard
176. d Power Time sec power on that the peak power occurred 9 110 V Coil Initial Reports the average power Average Power following power on watts Check Shafts Menu Runs the Media Path Drive train and engages the Deskew Clutch on the fly then disengages the clutch The test is repeated in both directions to determine clutch characteristics steady state drive requirements bearing status etc Deskew Shaft Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Time to CCW On 0 01 to 01 to 04 Reports how long it takes the peak fe sec 0 04 MP motor servo system to react to the sudden addition of the deskew shaft load Larger values may show a slipping slow to engage clutch 1 CCW On peak fe 540 to 750 2 0to 8 0 Reports peak effort needed to accelerate the deskew shaft load A smaller value could indicate a slipping clutch 2 CCW On fe settling 0 017 to Oto 2 Reports the time it takes the time sec 0 21 MP motor servo system to settle down after the sudden addition of the deskew shaft load A longer time could indicate a looseness in the deskew shaft assembly or a slipping clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 13 General Troubleshooting Deskew Shaft Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 3 CCW On average fe 250 to 600 1 0to2 5 Reports the
177. d Arms Note Ensure that you lever the spring cam towards the center Applying the pressure in the wrong direction can damage the Transfix Load Module see the figure on page 8 22 Insert a T 20 Torxbit through the right side slotted hole in the Transfix Load Module engage the hole on the back of the module and lever the module s spring cam toward the center of the printer while connecting the spring hooks to the Transfix Load Arms Repeat for the other side Pull the lower end of the Y Axis spring arm toward the front of the printer and install the Y Axis Belt first on the motor pulley and then on the Drum pulley It is not necessary to align the belt on the Drum pulley Ensure that the grooves of the belt align in the grooves of the motor pulley and that the cross ribs are away from the pulleys Reposition the Media Drive Assembly insert the 3 screws and torque the screws to 12 in Ibs Connect the Media Drive Fan and Media Drive motor harnesses Bend the cable retainer as required to hold the fan cable Connect the Drum heater harness to the Drum Heater Relay Board Connect the Drum encoder harness to the Power Control Left Cable Connect the Drum Temperature Sensor harness to the I O Board Caution 20 21 22 23 24 25 The Drum Temperature Sensor harness is routed through the Exit Module Use care during removal to avoid damaging the sensor Connect the Exit Module Cable to the I O Board Ensure that t
178. d J870 and one on the left 4 Remove the 4 screws holding the Exit Module to the printer chassis and remove the Exit Module Note You may need to remove the Media Drive to access the screw 8500 132 Replacement Note Seat the Exit Module on the chassis Torque the 4 screws to 15 in lbs After installing the Exit Module perform the Wiper Alignment page 6 2 The printer may report error 7 009 4x if the Wiper Assembly is misaligned 8 32 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Inner Simplex Guide PL3 0 1 1 Open the Front Door to access the guide 2 Using a small flatblade screwdriver pry inward on one retainer to remove it from the mounting post then remove the other retainer 3 Slide the guide down and forward to remove Replacement Note The fingers on the Inner Simplex Guide go over the segmented roller First snap the left retainer into place then the right Lower Inner Duplex Guide PL3 0 2 1 Open the Front Door 2 Pull out on the tabs at the bottom of the guide and let the guide swing free 3 Pry inward toward the center of the printer on the right upper retainer until it is free of the mounting boss and remove the guide Lower Exit Guide Assembly with Strip Flag PL3 0 3 1 Open the Exit Cover 2 Lift upward on the center of the guide then flex the left retainer inward to remove it 3 Remove the right retai
179. d eee oe ea Sha waa ene baw E a anes 8 44 Head Tilt Gear PLA 9 sua asoa Stree hence d doen Ghee enced E a a EEN A Pe E eta 8 45 Phaser 8400 8500 8550 8560 Color Printer Service Manual XV Contents EIGGUO MCS 2 faucet tity E wet ve sia E tore E Wea teen eka ane E E matin tanntee anes E 8 46 Electronics Module PL5 0 5 22 teen ttt eee eee ees 8 46 Wave Amplifier PL5 0 4 0 0 0 ccc cece ereere 8 47 V O Bard PL5 0 13 rosaces ceca wee ae hae dea ed epee GU eae ee diene Mareeba bee 8 48 Drum Heater Relay Board PL5 0 17 2 2 ect et eee teens 8 49 NVRAM PL5 0 9 acre euaissi a Eaa a iaa a ip ac a POE E te ahaa cece 8 50 DIMM Memory PL5 0 8 0 0 ce enn ee eeaeee aara 8 51 Hard Driv PLS O T sicsc cinch pen aeee eee a die pee Sayeed Meee ead eed dace ee Be ed 8 52 9 Parts Lists Serial Number Formati isenip bth deena hee paiva de ead nai ade Bade i a a a Mat lao bate eh eed 9 2 Using the Parte List lt cc2 occa t eee NEREAREN ARAE EE NEARER Paleed adeeb acl eae dene ees 9 3 PETO COVENS cio eae cclsioodos ooiivechad ee aa oondpored rei Mad Mae pobbeo aidan gad aden 9 4 PL 2 0 IMAGING sareen toe AE ERRAR RIE EEE eee de eed dee bode hea ewe Pek eae Ree ee wooed 9 6 PLESO Paper Patt iccii eu mies beet hoki daa kaw E h dece hts ea bend hae EA bak 9 8 PL 4 0 Motors Gears Solenoids Clutches and Fans 0 00 ect eee eee e eee 9 10 PE 5 0 Circuit BOATA Sis cacica nde cee ioira eae iaa ae iara ada E i labled a aA POE a Wipe
180. d of the shaft Move the Take Away Roller shaft to the left side to release it from the right side frame rotate the shaft forward and remove it to the right NO of WD Note Pressure from the idler rollers makes it difficult to move the Take Away Roller shaft to the right during removal KL Clip 8500 100 Replacement Note First remove the tray Next rotate the Pick Roller Shaft until the clutch seats Working upwards rotate the Take Away Roller and Duplex Roller until all shafts seat properly Check that the Media Drive is correctly positioned on the side frame Install and torque the 6 screws to 12 in lbs Finally check that all rollers rotate freely 8 36 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Pick Assembly PL3 0 10 Note Replace the Retard Roller at the same time you replace the Pick Assembly 1 Remove Tray 2 from the printer 2 Reach into the tray cavity and release the orange colored catch holding the Pick Roller in place The catch is located on the ceiling of the tray cavity about 1 4 of the way across the unit from the right side and about 12 5 cm 5 inches back When you pull forward on the catch the roller will swing down s8500 101 3 Pull down to remove the roller Replacement Note Insert the replacement with the metal shaft at the top and toward the left the grey rollers should face you Position the roller back about 5 cm
181. da aah nye ehiaeabes 5 20 Poor Small Text ReSOlUtiON 0 0 eee een n eee t tenn nee e tenes 5 22 Vertical Lines Appear Wavy isc ccceatereeonnec oe ceedonaed i kia baad ead Enea ened ead d 5 23 Qil Streaks on Print f 20 ani esas ee se gues eee ew eee kee Pe oe aes ese wees aed bo 5 24 Incomplete Image Transfer to Paper 0 ete tne e ene e an ees 5 26 Ink Smears on First Printed Side of Auto Duplex Print 0 0 ccc cece cece ee eee eee ees 5 28 Repeating Detects On Print 22s ie04 4 pies peed deeded Pade de Meda doe ee oad 5 29 White Stripes Pinstripes 0 0 0000 e eee eee eee 5 30 WINK IM Giscie as 2 coda garcia Aso tle oe cand ga GMa bet pond dQ a nh dash acm layne bei a ra n 5 31 Image Is Offset or Cut Off 0 cence een n ened eee teen ene eenes 5 33 Poor Ink Adhesion Poor Image Durability 2 0 ccc ccc eet tenes 5 33 Analyzing Service Test Prints 0 0 ccc cee ene nen n nent eee n ne eee teen ene es 5 34 Weak MISSINGUGt so saws peed E hea hea tee bh lean dene eee Dee eek 5 34 X Axis Motion 8400 Only 2 0 eee nent teen nent een n eens 5 35 Color Bands RGBK Dither 0 0 00 cece eee eee bene e een e ne 5 36 REVISE TO ets aoe TPES ENET EEE ENERE E aoe dpe es AER ESETE dead a ed are ea wee 5 37 Big Bands OHP ci s 2cden 4 eka dando alae sot Sa been ya takai ployee a daa eatin dice Maleate de ke con a eo 5 38 Gray Fill Dot Size Uniformity 0 cence eee n ene e nee es 5 39 YMCKRGB Solid Fill
182. dards These standards are designed to mitigate interference caused or received by this product in a typical office environment United States FCC Regulations The Phaser 8400 8500 8550 8560 complies with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy If it is not installed and used in accordance with these instructions it may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiver device being interfered with m Increase the separation between the printer and the receiver m Connect the equipment into an outlet on a circuit different from that which the receiver is connected Consult the dealer or an experienced radio television technician for help Any changes or modifications not expressly approved by Xerox could void the user s authority to operate the equipment To ensure compliance with Part 15 of the FCC rules use shielded interface cables Can
183. de Drum Thermistor Step Questions and Actions Yes No 1 Using Service Diagnostics run the Drum Goto Step 2 Replace the Temperature Sensor test Drum Did the test pass Temperature Sensor 2 Inspect the sensor wiring harness Replace the Replace the Is the wiring free from defects Is the wiring Drum sensor correctly routed through the pass thru and Temperature harness not pinched against the Drum Sensor 13 072 48 The Preheater got too hot 13 074 41 The Preheater took too long to reach its setpoint 13 131 44 The Preheater thermistor circuit is open 13 133 46 The Preheater thermistor circuit is shorted 13 135 48 The Preheater thermistor returned a bad reading or the reading was corrupted by ESD Troubleshooting Procedure for 13 072 to 13 135 Error Code Preheater Step Questions and Actions Yes No 1 Check that the ambient room temperature is Advise Go to Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Run the Preheater test Replace the Go to Step 3 Did the test pass 1 0 Board 3 Check the wiring from the Preheater Replace the Replace the Is the wiring connected and intact Preheater harness 13 136 49 The Printhead left jetstack heater is too hot 13 138 42 The Printhead left jetstack heater took too long to reach its setpoint 13 195 45 The Printhead left jetstack thermistor circuit is open 13
184. ded screws 18 Remove 3 screws and washers from the left side of the Drum Assembly 8 28 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly 19 Remove the Drum Assembly from the chassis by lifting it straight up as shown in the following figure Note You will need to temporarily remove 3 screws of the Media Drive motor PL 4 8 and pull the motor out of the way before you can lift the Drum and pulley from the chassis Yellow Left Hand Threaded Screws ium e i g g ad 58500 096 Caution Never rest the Drum on its pulley Let the pulley hang over the edge of a surface and place the Drum on its feet Replacement Caution The Drum Temperature Sensor harness is routed through the Exit Module Use care during removal to avoid damaging the sensor Note To help seat the Drum properly follow steps 2 6 in order when installing the screws to secure the Drum Assembly to the chassis 1 Gently seat the Drum Assembly into the chassis 2 Align the screw holes in the left and right sides of the Drum Assembly to the holes in the chassis sides 3 Install one silver screw at the rear position of the left side of the chassis to hold the left side of the Drum Assembly and torque the screw to 25 in Ibs 4 Install the remaining two silver screws into the bottom and front chassis locations to the left side of the Drum Assembly 5 Install one yellow reverse threaded screw at t
185. drawing the Clutch is not drawing the expected expected power power 37 019 46 Tray 1 Pick Solenoid Main Tray Pick Clutch Disconnect Disconnect The tray 1 Pick The Main Tray Pick Clutch is not Solenoid is not drawing the drawing the expected power expected power 37 020 47 Strip Solenoid disconnect The Tray 1 Pick Solenoid Disconnect strip solenoid is not drawing the The Tray 1 Pick Solenoid is not expected power drawing the expected power 37 021 48 Strip Solenoid disconnect The Phaser 8400 8500 8550 8560 Color Printer Service Manual Strip Solenoid is not drawing the expected power from the supply 3 41 Error Messages and Codes 8400 PEST Description 8500 8550 8560 PEST description 37 022 40 Preheat Solenoid Disconnect The Preheat Solenoid is not drawing the expected power from the supply 37 023 41 Head Tilt Solenoid Disconnect The Head Tilt Solenoid is not drawing the expected power from the supply Solenoid or Clutch Troubleshooting Procedure Step Questions and Actions Yes No 1 Run the appropriate diagnostic test Goto Step 3 Goto Step 2 37 017 44 Head Maintenance Clutch 37 018 45 Deskew Clutch m 37 019 46 8500 8550 8560 Main tray pick Clutch m 37 019 46 8400 Pick Solenoid m 37 020 47 8500 8550 8560 Multipurpose Pick Solenoid m 37 020 47 8400 Strip Solenoid m 37 021 48 8500 8550 8560 Strip Solenoid m 37 022 40 8400 Preheat Solenoid a 37 023 41 8500 8
186. e system Look for ink in the belts problem Is the wipe system operating correctly component 5 Inspect the Head Maintenance Clutch Clean the Go to Step 6 Is there any oil or contamination interior of the system and replace clutch if necessary 6 Run the Head Maintenance Clutch test Replace inthis Replace the Is the Head Maintenance Clutch operating correctly order m Exit Module Media Drive Wiper Blade Head Maintenance Clutch 4 025 46 This fault code indicates a problem with the process control system Cannot successfully home the transfix mechanism Troubleshooting Procedure for 4 025 Error Code Step Questions and Actions Yes No 1 1 Check for obstructions around the Complete Go to Step 2 Printhead Look for ink shards in gears of the tilt drive 2 If the Printhead is obstructed remove any obstruction from the system and reboot Did this fix the problem 2 Check the Printhead harness routing Re route all Go to Step 3 Is the wiring blocking the Printhead wiring to the Printhead Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 11 Error Messages and Codes 3 12 Troubleshooting Procedure for 4 025 Error Code Continued Step Questions and Actions Yes No 3 Remove the Waste Tray and Printhead and Clean any ink Goto Step 4 look for ink build up or debris Is there ink build up anywhere in the which may be printer restricting movement of the drive train or Print
187. e 1 386739380 8400 137E24130 8500 8550 8560 16 Drum Maintenance Pivot Plate 1 020K15100 Assembly 17 Preheater and Deskew Assembly 1 119641980 8400 126E02721 8500 8550 8560 18 Transfix Arm Assembly 1 401101280 8400 059K50011 8500 8550 8560 19 X Axis Bias Spring Hook 1 019E75180 20 X Axis Roll Adjuster Spring 1 809E69940 21 X Axis Bias Spring 1 809E69930 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 7 Parts Lists PL 3 0 Paper Path 8500 119 9 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts List 3 0 Paper Path Parts Lists No Name Description Qty Part Number 1 Inner Simplex Guide 1 351111480 8400 032E29480 8500 8550 8560 2 Lower Inner Duplex Guide 1 038K16870 3 Lower Exit Guide Assembly with Strip 1 038K17800 Flag 4 Outer Duplex Paper Guide with Sensors 1 032K04640 Safety Interlocks 5 Upper Duplex Guide with Solenoid 1 351113280 8400 032K04630 8500 8550 8560 6 Exit Roller 1 059E05610 7 Take Away Roller 1 022E32420 8 Duplex Roller 1 022E32410 9 Separator Pad Kit 1 650429300 8400 604K31140 8500 8550 8560 10 Pick Assembly and Retard Roller Kit 1 650429200 8400 604K42200 8500 8550 8560 11 Main Tray Tray 2 1 650433200 8400 050E23080 8500 8550 8560 12 525 Sheet Feeder and Tray 1 059K58610 8400 525 Sheet Feeder a
188. e 25 to 75 2 0 to 12 Reports the ripple in the Sin Sun Sum units Sum amplitude values Excludes the neighborhood of the Home notch a distance of 50 samples from the Home notch min location 3 Max Position 140000to 24000 to Reports the max variation in Ripple mpts 275000 52000 the reported delta position between samples over the revolution 4 Sin max delta 3 105 3 105 Reports the max value of the position diference between the rotation position of any adjacent sin sum peaks 5 Home Notch Depth 0 to 13 68 to 80 Reports the ratio between the Ratio none notch bottom amplitude and the max amplitude value as reflected in the Sin Sum data 6 Home Notch Width 50 to 90 720 to 960 Reports the width of the Home sec notch at 99 full depth as reflected in the Sin Sum data 7 Home Notch 250 to 550 35 to 65 Reports the ratio of the Home Symmetry none notch width sections as bisected by a vertical from the notch min as reflected in the Sin Sum data 8 CosineSum Data 90000to 125000to Reports average of the max Offset cosine sum 450000 200000 and min Cosine Sum average units amplitude values 9 Cosine Sum Data 300000 to 300000 to Reports difference between the Amplitude cosine 500000 500000 max and min Cosine Sum sum units average amplitude values Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 37 General Troubleshooting Rotates the drum at a cons
189. e 8 4 Control Panel Cover PL1 0 5 0 eee e eee eee 8 5 Control Panel PL1 0 6 i jue 252 ces terre aoe a a wld ee a a en A R A i 8 5 Right Side Cover PL1 0 10 0 0 cece ccc eeeeeeees 8 5 LeftSide Gover PL1 0 9 022 0002 seca deca Yas POR iae a Hebe aE idee bebe E A 8 6 Exit Cover PITO oe ca bson anit teh aid enderra hs aha aah aati chia Pbawie PEE wage ea aaa 8 6 IK Eader PIOB esa pa gn eo a poe e eaae a E ETE EE es OR ESEE ach Mego nace wes Pee agen a ho 8 7 IMAGING 4 3 3 35 hd asses codon dee us tee aoe nd Gen waa dual eed Deon dees dees seh dw eew tamed 4Seeas 8 8 Y Axis Belt Y Axis Tension Spring and Y Axis Motor 0 0 0 coc eee eens 8 8 Printhead Right and Left Printhead Restraints 20 0 ccc cece cee cee ene nee 8 10 Head Tilt Solenoid PL4 0 12 0 0 00 cece ttt ett tet t tet neeenes 8 15 X Axis Bias o pring PL2 0 19 y 0ccieen chat ide ceaernvidGvaerdeeamaues vixen saad i 8 16 Wiper Assembly PL2 0 17 n nonan eee eee e eee e eee eee 8 17 Stripper Carriage PL2 0 12 and Transfix Roller PL2 0 13 00 cece cece e eee ee eee ee 8 19 Pr heater PIA OIT io ninen anne e a a a e a aa A E Ra a Beton teat agen acetate E 8 20 Duplex Roller PES 0 8 2202 6 cvew2aketdaeeelaeenit domed eed dhe ed Ghee dared a oaw ed dhe a 8 21 Transfix Load Module PL2 0 15 2 2 2 0 eee e eee eee 8 22 Transfix Camshaft PL2 0 10 2 eee eee eee eee 8 25 Drum Maintenance Camshaft PL2 0 11
190. e IS Wait Timeout Requires Page Description Language NetWare Network Configuration Job Pipelining IPX Frame Type Duplex Configuration Optional Lower Tray s Hard Drive Page 1 of 2 8400DX only with stored jobs present A 2 Phaser 8400 8500 8550 8560 Color Printer Service Manual Paper Source 2 Sided Printing Tray 1 Setup Tray 2 Paper Type Tray 3 Paper Type Printer Setup gt Tray 4 Paper Type continued Load Paper Timeout Cleaning Page Source Paper Handling Setup gt Reset Paper Handling Setup PostScript Setup gt PCL Setup gt Printer Controls Startup Page Power Saver Timeout Date and Time Intelligent Ready Metric Defaults Reset Printer Controls Troubleshooting 3 Reference PostScript Error Info Print Quality Mode TekColor Correction Image Smoothing Reset PostScript Setup Font Number Pitch Point Size Symbol Set Orientation Form Length Line Termination Draft Mode Reset PCL Setup Front Panel Setup gt Front Panel Language Front Panel Brightness Front Panel Contrast Accessible Front Panel Reset Front Panel Setup Help Guide amp Paper Tips Page Online Jam Prevention Guide Paper Jams gt Paper Path Test Print Quality Problems gt Service Tools gt amp Printer Status Page Engine Error History Jam History Diagnos
191. e exiting print 1 Verify the paper loaded in Tray 4 is the correct size and type 2 Inspect clean the pick roller assembly Replace if necessary 3 Run the Tray 4 Pick Shaft test 4 Replace the Tray 4 525 Sheet Feeder 3 62 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting In this chapter Service Diagnostics Service Diagnostics Mode Menu Check Menu Definition Tables Electronics Troubleshooting Ensuring Ground Integrity Paper Path and Media Based Problems Operating System and Application Problems Chapter General Troubleshooting Introduction Hidden Service Menu 4 2 This chapter covers the general start up Power On Self Test POST and power supply operations of the printer to aid in troubleshooting problems not associated with a Control Panel error message or error code For troubleshooting problems associated with an error code or Control Panel error message notes on how to use the troubleshooting procedure tables and how to use service diagnostics see Chapter 3 Error Messages and Codes on page 3 1 The Printer Status page also contains useful troubleshooting information This page provides general printer information life information for all consumables printhead cleaning and power cycles and jam and error code information Troubleshooting procedures will isolate a problem to a specific component or subassembly in some cases including the wiring harnes
192. e has the ZIF connector lock the connection If the cable is not inserted incorrectly it can short out the Wave Amp 3 Insert the ribbon cable fully and squarely into the flex connector 4 Connect the data cable connector and heater harness connector Note The Printhead heater cable not only needs to be routed through the cable restraint but also needs to be clear of the Printhead to prevent interference which would result in errors 7009 and 4025 fault codes Caution Before reinstalling the Printhead move the wiper all the way down 5 Lower the Printhead into its mounts The Printhead should be tilted forward in the print position Note Remove any paper placed between the faceplate of the Printhead and the Drum during disassembly 6 Route the air hose through the frame and connect it to the purge pump Check that the hose is routed clear of the Left Printhead Restraint 7 Install the Roll Block on the left end of the Printhead shaft Position the Roll Block as shown on the label on the left side of the frame 8 Install the Left and Right Printhead Restraints Tighten the screws to 6 in lb to avoid stripping the chassis threads Caution Ensure that the tilt spring on the left restraint is properly positioned in the notch on the back of the Printhead and does not pinch the air hose 9 Set the X Axis Hook and spring on the end of the left Printhead shaft Ensure that the point of the hook is centered in the shaft and t
193. e list and select OK Note Phaser 8500 8550 8560 printers include diagnostic tools for network connections Use the menu path Troubleshooting gt Network Problems gt Network gt Diagnostics To troubleshoot network problems select the standard Network Log Pages or Network Diagnostics Network Diagnostics take about 60 seconds to test the network connection for basic communication problems such as collisions wrong ethernet speeds possible missing hubs when not using crossover cable and inappropriate IP settings for the network type detected or server 5 The page should now print Note To print the Connection Setup Page or Configuration Page select the Printer Setup Menu Obtaining Serial Back Channel Trace In rare cases the printer may exit unusual behavior that is difficult to troubleshoot In such cases if feasible it can be useful to obtain a Back Channel Trace from the printer s on board serial port The Back Channel Trace lists step by step what the printer is doing up to the point that an error occurs The trace may offer clues to help troubleshoot the problem You will need the following Computer with a serial port m Null modem serial cable Serial cable adapter part number 600T80374 Same adapter used to run PC based diagnostic on other Phaser printers Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 73 General Troubleshooting 4 74 To obtain a trace 1 Connect the serial cable to your P
194. e of printer Margin tolerance is the margin 2 See the Media Margin Specification in the Appendix Note Measurements for skew and margin for Sides 1 and 2 may not match Check The media must be supported for the tray The side and rear guides must be adjusted to the size of the paper to ensure correct deskewing If you have skew on simplex prints in Trays 2 3 or 4 check for a worn take away roller or pick roller in Tray 1 check for a worn pick roller This test print uses the tray selected in Paper Source on the Paper Handling Menu Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 43 Print Quality Troubleshooting 5 44 If yo u have skew on duplex prints check for a worn duplex roller an verify that the front door is completely closed and latched on both the left and right side flag Cleaning Page s lf the lead edge margins are outside of tolerance check the preheater This page is automatically printed following a purge It is used to flush the jet nozzles of any possible contamination or color mixed jets It can also be printed on its own An ocassional stripe or series of short stripes on this page is normal 8500 058 Other Test and Specialty Prints The following prints are used by Manufacturing and Engineering for development and test Manuf Five Duplex GSF Drum Seal 8400 only is not supported for this printer Manuf Paper Path Manuf X Axis Scanner 8400 only O
195. e version of driver the installation and the settings of the customer s computer e If test computer is unsuccessful continue with debug 2 Customer network or printer s Ethernet port not properly configured a Please see Testing Communications Ports on page 4 71 for procedures related to communication problems 3 Disconnect the printer from its network and see if the behavior continues 4 Printer internal settings corrupted a On the Control Panel use the Hidden Service Menu to reset NVRAM b Perform full test of printer Printer Resets Unexpectedly 1 Transient on AC line tripped reset circuitry in printer a Cycle power to ensure printer initializes during stable AC power 2 Check if non Xerox third party RAM DIMM is installed Non compliant RAM can cause erratic printer behavior 3 Internal fault a Record any error codes and report to Xerox Office Group If the printer detects an error the printer will attempt to reboot and re initialize up to three times to correct the problem After the third cycle of rebooting an error code displays on the LCD and flashes on the PS and PE indicators 4 Disconnect the printer from its network for a few hours if necessary to see if the behavior continures Printer Fails to Enter Energy Star Mode 1 Model not certified as an Energy Star model a Use the Control Panel to enable Energy Star mode Printer Setup gt Printer Control gt Select Power Saver Timeou
196. ead Restraints should be torqued to 6 in Ibs Irreversible damage can result from over tightening the screws into plastic parts m Always use the correct type and size screw coarse thread brass colored screws into plastic and fine thread silver colored screws into metal m Using the wrong screw can damage tapped holes This applies to the yellow reverse threaded screws on the Drum m Do not use excessive force to remove or install either a screw or a printer part If using a power driver to install a screw into plastic start the screw by hand m If you strip out threads in the plastic chassis a silver blue tinted thread repair screw included in the hardware kit can be used to correct the problem E If you remove a silver blue tinted thread repair screw during disassembly replace the screw the same location or additional damage to the printer will occur Warning Unplug the AC power cord from the wall outlet before removing any printer part Notations in the Disassembly Text m The notation item X points to a numbered callout in the illustration corresponding to a part or step being performed m The notation PLX X X indicates that this component is listed in the Service Parts List Bold arrows in an illustration show direction of movement when removing or replacing a component Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 3 Service Parts Disassembly Covers Front Door Tray 1 Assem
197. ed media 2 Reduce the amount of media in the tray and reposition the guides to fit firmly against the media 3 Inspect and or clean the pick roller assembly 4 Run the Tray 3 Pick Shaft test 5 Ensure ground integrity of the printer see page 4 65 6 Push up on the nudger roller until it is captured by the actuator arm 7 Run the Pick Clutch test replace the pick clutch 8 Run the Media Path Drive test 9 Replace the pick roller assembly 10 Replace the Tray 3 525 sheet feeder Y2D Y2E Y2F Y2L Y2M Y2N Y2P Y2Q Y2R Y2S Y2T Y2V Y2W Y2X Tray 4 media size sensor unexpectedly activated during warm up Tray 4 media size sensor unexpectedly activated during printer ready Tray 4 media size sensor unexpectedly activated while printer in fault state Tray 4 media size sensor unexpectedly activated while printer in standby Tray 4 media size sensor unexpectedly activated while picking from Tray 2 Tray 4 media size sensor unexpectedly activated while picking from Tray 3 Tray 4 media size sensor unexpectedly activated while picking from Tray 4 Tray 4 media size sensor unexpectedly activated while picking from Tray 1 Tray 4 media size sensor unexpectedly activated while duplexing Tray 4 media size sensor unexpectedly activated while paper staged for print Tray 4 media size sensor unexpectedly activated while transfixing the print Tray 4 media size sensor unexpectedly activated while the printer Drum maintenance cy
198. ed with 120 VAC shut off printer power and disconnect the power cord before starting this procedure Remove the Right Side Cover page 8 5 Disconnect all connections to the board Remove 2 screws securing the board to the chassis Remove the Drum Heater Relay Board A ON a Drum Heater Relay Board k Replacement Note Ensure that no wires are routed behind the Drum Heater Relay Board during reinstallation Install and torque the 2 screws to 12 in Ibs Reconnect all connections Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 49 Service Parts Disassembly NVRAM PL5 0 9 Caution Some semiconductor components such as the NVRAM chip are vulnerable to damage by Electrostatic Discharge ESD Note Observe the orientation of the NVRAM chip before removing it 1 Remove the Back Cover from the Electronics Module Note On 8400 models the NVRAM chip is located at U850 On 8500 8550 8560 models NVRAM is located at U840 2 Remove the old NVRAM chip from itis socket in the Electronics Module NVRAM Chip O c Og Z MN S7 N s8500 114 3 Insert the new NVRAM chip into the socket Ensure that the notch on the chip is on the left side 4 Download the snippet titled setsn ps from the Support web site Edit the snippet to include the printer serial number using a text editor 6 Download the edited file to the printer usin
199. edia Type 5 cR 3 Custom NOTE Print custom size media from Tray 1 only Maximum 216 mm wide x 355 mm long 8 5 in wide x 14 in long Minimum 75 mm wide x 127 mm long 3 in wide x 5 in long Minimum 139 7 mm wide x 210 mm long 5 5 in wide x 8 3 in long Envelopes Any Tray 10 Commercial 4 12 x 9 5 in DL 110 x 220 mm l l C5 162 x 229 mm l l Tray 1 Only 5 1 2 Baronial 4 375 x 5 75 in l l 6 3 4 3 625 x 6 5 in l l Monarch 3 87 x 7 5 in l l Brochure 6 x 9 in l l l l l l l l A7 5 25 x 7 25 in Choukei 3 Gou 120 x 235 mm Choukei 4 Gou 90 x 205 mm NOTE Some wrinkling and embossing may occur when printing envelopes See Printing on the User Documentation CD ROM for information on how to minimize these occurrences NOTE 2 sided printing can only be used for paper with widths greater than 5 5 in 139 7 mm and lengths greater than 8 3 in 210 82 mm 1 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation In this chapter Main Printer Subsystems Print Process Printer Self Maintenance Configuration Card Personality Parameters Chapter Theory of Operation Main Printer Subsystems 2 2 Transfix System Ink Loader Drum Printhead Electronics Module Configuration Card Preheater Waste Tray Drum Maintenance Kit Wave Amp Wiper Assembly 8500 008 Printer Subsystem Overview The printer is made u
200. edures to check all circuits connected to the I O Board a b Turn off printer and wait 30 seconds for power supply capacitors to discharge Plug in the I O Board connectors one at a time and perform steps C and D for each connector Turn on printer and wait for the error code 34 001 43 Check that the three voltage indication LEDs inside the Electronics Module visible through the vent holes of the Electronics Module near the AC power switch are lit If the proper error code and LED doesn t appear after each I O connector is reconnected repair or replace the faulty circuit If the proper code appears repeat the procedures until all 1 O board connectors are plugged back in If repairs are made during this step plug in all connectors to printer and retest If printer is fixed reattach covers to printer and perform a full test If no defects are found in this step continue with next step 3 The proper error code is displayed repeat the following procedures to check all circuits connected to the Electronics Module a b Turn off printer and wait 30 seconds for power supply capacitors to discharge Plug in the connectors one at a time and perform steps C and D for each connector Turn on printer and wait for the error code 34 001 43 Check that the three voltage indication LEDs inside the Electronics Module visible through the vent holes of the Electronics Module near the AC power switch are lit If the p
201. eee e eee tenn e ne es 4 71 Network Proble Masa iee rnnr a E AEE A EA REE AE E E ARAE ee be ee ee as 4 73 Obtaining Serial Back Channel Trace eee cette nee eee nee n ees 4 73 Obtaining a Back Channel Trace with USB to Serial Adapter 0 00 ccc cece eee eee eee 4 74 Phaser 8400 8500 8550 8560 Color Printer Service Manual xiij Contents 5 Print Quality Troubleshooting Print Quality Problems OvervieW 0 0 0 ccc ccc ee eee eee eee nen e ene ete e ene e eens 5 2 Random Light Stripes os puai rwa canen ew cies en hades ade a Ras Oe ea ave hee oe ae 5 3 Predominate Light Stripes 0 cc en eee n nee ee eee een e beeen 5 4 SMUAQES OF SMEAS 2 eee een e nee aa Eaa ETE EA ea ek 5 5 Print Too Light or 1 00 DaKine aa Sloa Ws wt NN ade ores Wa dee dew aes aAA 5 7 Blank PIMS erri sree ool dems deena dus ook doe Hague swe duets gh ehinde Sa ee eee Senge ade 5 8 Color is Uneven or WIONG ice os ce dckie boae do eee oad sede Casa deabe ede dae Keene gas 5 9 Streaks or Lines Down the Print 0 0 ccc cc cece eee e nent e ene ees 5 11 Scratches or Marks Parallel to the Long Axis of Printing Particularly with Film 5 13 Ink on White Portion of Print 0 ent ne tenet EE AA nes 5 15 FUZZY extant esctee dine gene godde ge peandedoe geht heelh a shtdbeshehartheledacdedpeaeg a4 5 17 Poor Primary Color Fills 2 0 0 ccc ene eee nnn e nee tee nent e ean 5 18 GMOSTING Soros aes ode dena ests da ed Vedanta a e
202. een Receiving Processing Data Printing or Power Saver Mode Flashing Amber Warning w Flashing Red Error Control Panel Feature Descriptions 1 Status Indicator LED Green Ready to print Yellow Warning condition printer continues to print Red Startup sequence or error condition Blinking Printer is busy or warming up 2 Graphic display indicates status messages and menus 3 Cancel button Cancels the current print job 4 Back button Returns to the previous menu item Phaser 8400 8500 8550 8560 Color Printer Service Manual 8500 003 Up Arrow button Scrolls upward through the menus Down Arrow button Scrolls downward through the menus OK button Accepts the selected setting Help or Information button Displays a help message with information about the printer such as printer status error messages and maintenance information 1 5 General Information Menu Maps The Customer Menu Map helps you navigate the Control Panel menus The Menu Map s are provided in the Reference section of this manual see page A 2 To print the Menu Map 1 On the Control Panel select Information and then press the OK button 2 Select Menu Map and then press the OK button to print The service diagnostic menu map is detailed in Section 4 see Service Diagnostics on page 4 4 for more information Control Panel Shortcuts Mode or Menu Shortcut Service Tools Menu From any m
203. egardless of colors used 8400 8560 Extended P N 108R00603 8400 Maintenance Kit Life P N 108R00676 8550 8560 0 20 Coverage 30 000 20 100 Coverage 20 000 30 000 7 4 The image coverage is determined by counting the number of pixels imaged Phaser 8400 8500 8550 8560 Color Printer Service Manual Waste Tray Lubrication Inspection Cleaning and Maintenance A Control Panel message indicates when the maintenance kit is low Printing is still possible when the Drum Maintenance Kit is low When the message indicates the Drum Maintenance Kit is empty replace the kit to continue printing Note The Drum Maintenance Kit fluid an oil poses no known adverse health effects See the Material Safety Data Sheet at www xerox com office msds The Waste Tray collects ink that has been purged from the ink jets A Control Panel message indicates when the Waste Tray is full Empty the waste tray to continue printing Caution Never reuse waste ink in the printer it will damage the Printhead The printer is lubricated during assembly at the factory and requires no periodic lubrication Some parts require lubrication following replacement These parts are identified in the replacement procedures When lubricating during replacement use the grease approved for all Phaser printers The grease part number is 070E00890 Caution Plastic parts will deteriorate when unspecified grease and chemicals are used To a
204. elt partly on the clip and then press the center of the clip with a small needle nose plier until the belt is secured in the clip _ Belt 8500 082 Note Later versions of 8500 8550 models serial numbered WYN1xxxxx or WYP 1xxxxx use the wider style Wiper Belt and 8400 model Wiper Blade 8 18 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Stripper Carriage PL2 0 12 and Transfix Roller PL2 0 13 Caution Hold the Transfix Roller and Stripper Carriage with one hand during removal of the Transfix Roller shaft to prevent the Transfix Roller from falling and damaging the printer Also do not use the Transfix Roller Shaft Restraint as a lever to pry the shaft Doing so can bend the restraint Remove the Right Side Cover page 8 5 Disconnect P J250 from the I O Board Remove the Control Panel Cover page 8 5 Remove 2 screws securing the I O Board to the chassis slide the board towards the rear and move the board out of the way 5 Loosen 1 screw securing the Transfix Roller Shaft Restraint and remove the restraint 6 Use the end of the Transfix Roller shaft restraint to remove the shaft 7 Remove the Stripper Carriage and Transfix Roller kOnNnND 7 8500 083 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 19 Service Parts Disassembly Preheater PL2 0 17 Open the Front Door Remove the Lower Inner Duplex Guide page 8 33 Remove the Inner S
205. embly 8 8 dot size variations 5 39 drum assembly 2 3 2 16 drum assembly parts 9 7 drum cleaning 2 34 drum heater 2 16 drum maintenance 2 23 camshaft 6 8 camshaft assembly parts 9 7 definition 2 3 door part number 9 5 pivot plate 8 25 pivot plate part 9 7 removing pivot plate 8 26 theory 2 13 drum maintenance system 2 3 drum operation assembly and transfix system 2 16 drum cleaning 2 34 drum preparation 2 23 maintenance system 2 13 purge system 2 14 relation to printhead 2 10 drum preparation 2 23 duplex printing 2 30 duplex roller disassembly 8 21 parts 9 9 E electrical troubleshooting 4 56 electronics module 2 19 BIST errors 3 3 DIMM replacement 8 51 failures 4 60 1 0 board faults 3 9 interface faults 3 24 location 1 8 NVRAM replacement 8 50 overview 2 3 parts list 9 13 POST errors 3 4 replacement 8 46 theory of operation 2 19 electronics subsystem 2 3 eliminate light stripes 2 33 5 2 eliminate light stripes service menu 4 2 energy guidelines 4 3 Phaser 8400 8500 8550 8560 Color Printer Service Manual envelopes printing on 1 14 environmental specifications 1 12 error codes 525 sheet feeder faults 3 8 code version 3 33 electronics module 3 24 I O board program 3 9 1 0 circuit board 3 9 ink loader 3 23 IPC program 3 10 mechanical initialization 3 34 printhead calibration 3 32 process control system 3 10 process motor gearbox 3 15 therm
206. ens 6 13 Disabling Jet Substitution Mode 8500 8550 8560 002 cece eect eee 6 14 Resetting NVRAM e0i 0ded c ange ede So hae bene Yawae Sead cada Wha owe Ro aG aa a aed wd 6 14 xiv Phaser 8400 8500 8550 8560 Color Printer Service Manual Contents 7 Cleaning and Maintenance Service Cleaning Maintenance Procedure 0 ccc eee ee eee ene teen ene e nes 7 2 GIG AMING soot e ntact ra tens a she exes ape eden tare dunt besa an ok a apie eee Fond Riese a 7 2 Pick Roller Cleaning Method 0 ccc ccc ccc eee tee enn e een teen eet eens 7 3 MaInt NanCe o eoa heat beanies da Pb E EEE do ee bated hoe heh de Ga er eee bia bes 7 4 Drum Maintenance Kites sce diced onda dee SOW Sion Okie wal sed OM ewan Weed dae aa aaa 7 4 WS Thay snc TEENE EEE E ese AEE REEE died eade aed we aee eager wade tena eenae wes 7 5 LUDICAtON i045 ined rede eee ede OE aoe eee eee ORE ee Renee eda eee ede abe E M4 7 5 IMS POCUION 0 s dos eros arenas dea save Sad PEE auntie Antone iene mean E eens a eas meee adie ied aioe te 7 5 8 Service Parts Disassembly OVGIVIGW orice arse ache nh 8 ayesha E a AE Manas ett E Gel wink HUIS a dave E E E ae ae a Eea Pees 8 2 Standard Orientation of the Printer 0 1 eee eee eens 8 2 General Notes on Disassembly 0 ccc eect eee teen ene ete nes 8 3 GOVEIS 2 natn ents aerate eta hi etait nea hicwatanates Mant ieee ee aS thea tamed E E A 8 4 Front Door Tray 1 Assembly PL1 0 1 0 0 0 0 cette ee
207. enu press and hold the Up Arrow and then press OK Hidden Service Menu From the Service Tools menu press and hold the Up Arrow and then press the Down Arrow Service Internal Diagnostics Phaser 8400 Hold the Back and Info button at power up for about 30 seconds Phaser 8500 8550 8560 Wait until Control Panel screen turns black and then press and hold Back and Help buttons until the message Beginning Service Mode displays Set Control Panel language Press and hold the Cancel button and then press the Help button Bypass protected menus Press and hold the Cancel button and then press the Back button Jet Substitution Mode Phaser 8400 only To add Jet Substitution Mode to the Print Quality Problems menu From the Print Quality Problems menu press and hold the Up Arrow button and then press the Back button Phaser 8500 8550 8560 have Jet Substitution in the main menu system under Eliminate Light Stripes FTTR Fast Time To Ready Printer goes to the ready state without waiting for thermal temperatures to reach the proper operating values On power up when the Xerox splash screen displays press and release the Up Arrow button then press the Down Arrow button If the printer detects ink on the drum the display indicates a warming up status 1 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information Parts of the Printer This section s
208. eparator Pad 9 Replace the Pick Assembly Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued A3R Deskew Sensor time out during movement from Exit Roller to deskew roller when duplexing print 1 Ensure the media is appropriate for two sided printing Not too short not too smooth Check printer specifications 2 Inspect the condition of the exit and the duplex rollers 3 Check the Front Door for obstructions or damage replace if necessary 4 Test operation of the exit and the duplex rollers using diagnostic Duplex Paper Lead Edge Times test 5 Test the Deskew Sensor using the diagnostic Sensors test B2C Preheater exit sensor unexpected state during mechanical recovery 1 Clear jam and let printer finish mechanical recovery 2 Ensure ground integrity of the printer see page 4 65 B2F B2S Preheater exit sensor in unexpected state during fault Preheater exit Sensor in unexpected state during stage 1 Ensure ground integrity of the printer see page 4 65 2 Check the Drum Maintenance Kit NVRAM contacts during the oiling process for continuity 3 Check the Waste Tray 4 Replace the Preheater B2M B2N B2P B20 The preheat flag tripped unexpectedly while picking paper from Tray 2 The preheat flag tripped unexpectedly while picking paper from Tray 3 The preheat flag tripped unexpectedly while picking paper
209. er disassembly 8 7 ink smears 5 28 ink out sensor 2 6 input output Ports 2 19 J jam code tables 3 49 jam codes 3 48 jet nozzles 2 7 jet stack 2 8 jet substitution 2 24 6 12 L lift motor 4 8 4 45 lift motor disassembly 8 39 lower inner duplex guide parts list 9 9 removal 8 33 lubrication 7 5 M main board electronics module 2 19 main board memory 2 19 main subsystems 2 2 maintenance kit 7 4 mechanical initialization 4 52 4 54 l 3 media drive assembly parts 9 11 function 2 2 gearbox removal 8 40 theory 2 5 media path drive 2 2 media path faults 3 34 miscellaneous error codes 3 33 N NVRAM 1 8 2 19 NVRAM reset 6 14 O oil streaks 5 24 oiling cycle 2 34 outer duplex guide illustration 8 34 paper path part 9 9 removal 8 34 P paper color media 9 18 jam 2 34 main tray 9 9 media specifications 1 13 pick process 2 25 preheater 2 16 present flag 9 15 transfix and print speeds 2 31 transfixing and editing 2 27 transport system 2 2 2 5 paper path check menu 4 16 drive problems 4 32 ink residue 5 5 jams 3 34 motor jam codes 3 54 parts list 9 9 problems 3 21 scratches or marks 5 13 status 4 46 temperature problems 5 28 theory 2 26 paper pick errors 4 68 theory 2 25 parts list usage 9 2 personality parameters 2 20 2 35 PEST Error Codes 3 6 PEST error reporting 3 6 PEST tests 3 6 Phaser features l 4 8400 serie
210. er supply Reports max and min values Control Panel Monitors Control Panel buttons and Buttons reports button presses Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Service Diagnostics Menu Map Continued Menu Description Exercise Menu Functions for causing mechanical actions which may then be observed Press a Control Panel button to stop the test Pulses the activator to cause it to generate some sound or motion Activators Menu Exercise All Cycles each of the listed activators 4 times in sequence Tray 1 Pick Solenoid Cycles the activator repeatedly Tray 2 Pick Clutch Cycles the activator repeatedly Tray 3 Pick Clutch Cycles the activator repeatedly If not installed generates an Option not detected message Tray 4 Pick Clutch Cycles the activator repeatedly If not installed generates an Option not detected message Deskew Clutch Cycles the activator repeatedly Pre heater Solenoid Cycles the Preheater Solenoid 8500 8550 8560 Strip Solenoid Cycles the activator repeatedly Tilt Solenoid 8500 Cycles the Head Tilt Solenoid 8550 8560 Head Maintenance Cycles the activator repeatedly Clutch Purge Vent Solenoid Cycles the activator repeatedly 110V 220V Drum Cycles the activator repeatedly Heater Relay s Exercise Motors Shafts Menu These functions drive the motor or shaft to ge
211. eral Troubleshooting 4 6 Service Diagnostics Menu Map Service Diagnostics Menu Map Description Displays general help text describing the general operation of the Control Panel menu system Development Menu A temporary submenu containing some development functions and access to tests still under development Return to Customer Mode Exits service diagnostics and runs through POST to Ready Check Menu Check All See the individual table descriptions Activators Menu starting on page 4 10 for all Check Shafts Menu Activator menu items Fans Menu Heaters Menu Paper Path Menu Drive Menu Drum Menu 8500 Motors Menu Misc Menu Monitor Menu Functions for monitoring mechanical measurements Sensors Monitors all mechanically activated sensors except for the Control Panel buttons Whenever a state change is detected it appears on the Control Panel Encoders Monitors each of the non temperature analog sensors Tray 1 width 495 narrow 7486 wide Y Media Path and Process motor encoders Temps Monitors each of the thermal sensors Shows the current thermal control loop setpoint first value and the current sensor temperature second value Heaters Monitors each of the heaters Shows if the heater is currently enabled first value and what percentage of maximum power is currently allocated second value Line Voltage Monitors line voltage as seen by the pow
212. es defined in the following tables check the entire system containing the problem component to ensure a problem within the system is not influencing the test results To access the Check Menus enter Service Diagnostics and go to Check Menu gt Check Activators Menu Note The Check All selection will run all check tests taking 1 5 hours to complete and is not for use by field technicians Check Activators Menu The Head Maintenance Clutch test gathers data on the performance of the Head Maintenance Clutch coil Head Maintenance Clutch R Typical Typical Value Value 8500 Definition 8400 8550 8560 Actions Peak Power watts 3 0 to 5 9 3 2to6 3 Reports the max power value Average Power 2 8 2 2t03 5 Reports the average power watts Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting The Deskew Clutch test gathers data on the performance of the Deskew Clutch coil Deskew Clutch Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Peak Power watts 2 5 to 5 3 3 0t05 8 Reports the profile max power 1 Average Power 2 2 to 5 3 1 5 to 3 0 Reports the average power watts Gathers data on the performance of the Tray 1 Pick Solenoid coil and flapper Tray 1 Pick Solenoid Typical Typical Value Value 8500 R Definition 8400 8550 8560
213. exist 13 007 68 Thermal power manager task was expecting initialization message but received other 13 008 60 Thermal power manager task received an unexpected message a Reset NVRAM and retest b Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 31 Error Messages and Codes 19 0XX xx Errors Printhead Calibration faults 19 001 46 HFD server failed due to NVRAM operation This fault only occurs when the printer is set in manufacturing mode Program fault 19 002 47 Attempted to perform a Printhead operation without the Printhead NVRAM data being loaded 19 003 48 Scale and offset error is too large The voltages measured have more than a 20 error from their expected values Something is wrong with the Electronics Module or the Wave Amplifier 19 004 40 The Printhead and the Electronics Module do not match Contact escalated Service Support Representative for information to clear fault 19 005 41 A posssible static discharge from the Pick Clutch to the Electronics Module Characterized by 19 005 41 error code displayed on the Control Panel Printer hangs while printing with the Electronics Module Fan on full m Low humidity m Occasional Jam Behind the Front Cover messages usually accompanied by error 19 005 41 in Fault History To prevent these discharges a Grounding Clip P N 650442700 was added between the
214. f its travel and the process motor moves the printhead to the print position a chase page is sent through the paper path to clean ink from the drum Temperature Below Purge Threshold If the Printhead ink reservoirs or jetstack temperature are below purge threshold the printer performs a Printhead cleaniong cycle 1 2 10 1i 12 13 14 The printer waits for the printhead to reach its purge temperature The printer moves the wiper to the bottom of its travel and tilts the printhead forward to its print position to check the ink levels If the ink level is low ink is melted into the appropriated reservoirs The printhead tilts to the standby position and moves the wiper assembly to the purge position in front of the printhead faceplate The purge pump begins the pressure purge after about 2 seconds the purge pump solenoid opens The printhead tilts forward against the wiper assembly wipe position and the purge and wipe cycle begins The Control Panel indicates the printer is performing the cleaning process The printhead is moved left to the tilt zone where the printhead can tilt back without interference and the media path motor moves the wiper to the bottom of its travel to engage the printhead tilt cam The process motor rotates the printhead tilt gears which tilt in order to move the printhead to the forward print position After the print engine is in a known valid state the Control P
215. f printer and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge Phaser 8400 8500 8550 8560 Color Printer Service Manual C General Troubleshooting Unplug power cord and remove printer s covers Caution Use caution around motors pulleys and live AC connections when working with the printer covers off a 2 f g 9 or H BH HH 8 8 H E Unplug the following Electronics Module connections This step removes all other circuits so the Electronics Module can be tested alone Power Control to I O board J800 Power Control right J400 Preheater solenoid interconnect cable Printhead tilt gear solenoid interconnect cable Printhead data J130 Waveamp signal J790 Power Control left J390 Y Axis motor J280 Plug in power cord and turn on power to the printer If the PE and PS indicators do not flash momentarily the short is inside the Electronics Module Replace the Electronics Module and retest the printer If PE and PS indicators flash continue with debug Plug in all cables removed during service Trace through all service steps performed to reattach any cables that were unplugged during debugging Attach printer covers Perform full test of printer 4 Short circuit on 3 3 V power supply within the I O board a e REQURIED Follow all procedures from Step 3
216. fe ripple Reports amount of variation of ticks the motor following error Motor fe average ticks Reports the motor following error average value average watts 2 Motor drive voltage Reports amount of variation of ripple volts the motor drive voltage 3 Motor drive voltage Reports the motor drive volts voltage average value 4 Motor drive power Reports amount of variation of ripple watts the motor drive power 5 Motor drive power Reports motor drive power average value Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 45 General Troubleshooting Check Misc Menu This test looks at the paper path sensors to identify if anything would prevent a page from printing The Control Panel will display messages indicating if anything unexpected is found for RO upper paper path R1 tray 1 R2 tray 2 R3 tray 3 and R4 tray 4 The display is a string of 0 s and 1 s one digit for each sensor state and is listed below from most significant bit to least significant bit 1 an item that needs to be corrected 0 normal Paper Path Status Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Upper Paper Path 6 31 Not used always 0 0 5 Front door open 0 4 Top door open 0 3 Paper at deskew sensor 0 2 Paper at preheat exit sensor 0 1 Paper at strip senso
217. following order a Transfix Roller Transfix Camshaft Transfix Load Arms a Transfix Load Module 5 32 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Image Is Offset or Cut Off 1 Print an information page internal page embedded in the printer 2 Verify that the tray guides are adjusted correctly 3 Ensure that the paper size settings for the driver and printer match the paper loaded in the tray 4 Check the application for the correct image sizing and orientation Poor Ink Adhesion Poor Image Durability Follow these steps if the ink is flaking off the print after the print is complete 1 If a specialty coated paper is being used for example glossy media try a different paper Xerox transparency film provides the best ink adhesion versus off the shelf transparency film 2 Verify the Preheater temperature using diagnostics 3 The Drum is too cold or too hot Verify the Drum temperature using diagnostics Ensure that the Drum Temperature Sensor is properly positioned and has no contamination between it and the Drum surface Image durability is almost always an issue with the paper being used It is never an issue with the printers Printhead Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 33 Print Quality Troubleshooting Analyzing Service Test Prints 5 34 Weak Missing Jet This section shows how to select and analyze all test prints sto
218. from Tray 4 The preheat flag tripped unexpectedly while picking paper from Tray 1 1 Test the preheat flag using the diagnostic Sensors test 2 Ensure ground integrity of the printer see page 4 65 B3M B3N B3P B30 B3S B3T The preheat flag timed out waiting for the paper picked from Tray 2 The preheat flag timed out waiting for the paper picked from Tray 3 The preheat flag timed out waiting for the paper picked from Tray 4 The preheat flag timed out waiting for the paper picked from Tray 1 Preheater sensor timed out during stage Preheater exit sensor timed out during transfix 1 Verify the media is appropriate for the tray 2 Check for paper path obstructions ensure the preheater plate moves freely 3 Replace the Tray 1 Separator Pad Assembly 4 Run diagnostics to test the preheat flag 5 Ensure the deskew rollers are in good condition 6 Run the Deskew Clutch test 7 Run the Paper Path Drive test 8 Replace the preheater then retest C2C c2D C2E Strip flag unexpected event during mechanical recovery Strip flag unexpected state during warm up Strip flag unexpected event during printer ready Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 51 Error Messages and Codes 3 52 Jam Code Troubleshooting Procedures Continued C2F C2K c2M C2N c2P C20 C2R C2T Strip flag unexpected event during fault Strip flag unexpected event during transfix roller oiling The strip flag act
219. g an FTP program oa 8 50 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly DIMM Memory PL5 0 8 Caution Some semiconductor components such as memory are vulnerable to damage by Electrostatic Discharge ESD Review the Electrostatic Discharge ESD Precautions on page 1 v before continuing with this procedure Note Observe the orientation of the memory devices before removing them Notice that the DIMM boards are inverted to each other 1 Remove the Back Cover from the Electronics Module 2 Pull the connector release tabs away from the DIMM s to release The 8400 models include a clip that secures the DIMM s in place For 8500 8550 8560 DIMM s the top DIMM swings down and the bottom DIMM swings up in the removal position while they clip in place in the flat position 3 Remove the old DIMM chips from their sockets in the Electronics Module 8500 85008560 8500 115 4 Insert the new DIMM chips into the sockets 5 Swing the DIMM chips to their secure position against the electronics module and snap them into their respective connectors Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 51 Service Parts Disassembly Hard Drive PL5 0 7 Caution Some semiconductor components such as the NVRAM chip are vulnerable to damage by Electrostatic Discharge ESD 1 Remove the Back Cover from the Electronics Module 2 D
220. g the Process Drive engage the Drum Maintenance Pivot Plate to the Drum Maintenance Camshaft by pushing the Drum Maintenance Kit to the left toward front of printer while seating the drive M D Holes in process drive frame aligns with holes in gears Hole in gear aligns with arrow on Hole in gear frame aligns with y arrow on frame s8500 064 When correctly homed slightly rotating the Drum Maintenance Camshaft in either direction should result in a proportional movement of the Drum Maintenance Kit with no delays or lags 6 8 Phaser 84000 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations Timing the Drum Maintenance Camshaft Caution Use either the pins that come with replacement Process Drives or a paper clip bent into a U shape to hold the gears in their proper position during removal and replacement If the Process Drive is incorrectly installed the printer could be damaged See Homing the Process Drive Train on page 6 8 The Process Drive screws are torqued to 12 in lbs Irreversible damage to the chassis mounting bosses or the threads can result if screws are over tightened After replacing the Process Drive Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft or any component requiring removal of the Process Drive the printer may experience Front Cover jams from Tray 2 The jam occurs with paper in the Preheater and C3T jam errors strip flag timeout during transfix
221. gear drive train homing 6 8 purge pump 8 11 purge system 2 3 2 14 purging 2 33 R random light stripes 5 3 remove print smears 2 34 roll block 8 12 routine maintenance items 1 9 S scratches 5 13 self maintenance functions 2 33 self maintenance cycles 2 33 sensors 2 22 service diagnostics 4 4 service menu hidden 4 2 silicone oil 2 13 six jet interlace 2 24 smudges or smears 5 5 specifications electrical 1 12 environmental 1 12 functional 1 12 media and tray 1 13 physical dimensions 1 10 specifications printer 1 10 status indicator LED 1 5 streaks 5 11 supplies Xerox 9 16 T test prints 5 34 tilt cam 2 10 2 11 tilt gear 2 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual transfix roller 2 16 2 27 transfix speeds 2 31 transfix system 2 3 2 16 transfixing 2 27 troubleshooting jam codes 3 49 U uneven color 5 9 W waste ink 2 14 waste tray 7 5 wavy vertical lines 5 23 wiper alignment procedure 6 2 wiper assembly lock 8 10 wiper faults 3 21 wiping 2 33 wiring inside front 10 8 inside top 10 9 left side 10 6 main wiring 10 2 printhead 10 10 right side 10 4 wrinkling 5 31 X x axis bias spring hook 8 11 x axis faults 3 14 3 15 x axis system 2 9 Y y axis belt disassembly 8 8 y axis faults 3 13 l 5 Index Notes Reference Description
222. git To be rolled when a major product change occurs Initiated with a change request SSSSS Five digit numeric serial number Serial Number Example RPC453072 4 Revision level 53072 Serial number 9 2 Phaser 8400 8500 8550 8560 Color Printer Service Manual Using the Parts List Parts Lists 1 No The callout number from the exploded part diagram 2 Part Number The material part number used to order specific parts 3 Qty This number represents the parts per printer not the number of parts supplied in the actual part order 4 Name Description Details the name of the part to be ordered and the number of parts supplied per order 5 Parts identified throughout this manual are referenced PL For example PL3 1 10 means the part is item 10 of Parts List 3 1 6 A black triangle preceding a number followed by a parenthetical statement in an illustrated parts list means the item is a parent assembly made up of the individual parts called out in parentheses 7 The notation with X Y following a part name indicates an assembly that is made up of components X through Y For example 1 with 2 4 means part 1 consists of part 2 part 3 and part 4 8 An asterisk following a part name indicates the page contains a note about this part 9 The notation NS next to a part indicates that particular part is not spared but contained in a kit or major assembly 10 The notation J1 lt gt J2 and P2 is
223. gnostics without a Reboot This method of entering diagnostics is to allow customers to be diverted to Service Diagnostics in order to perform some tests 1 Display the Hidden Service Menu as described in Hidden Service Menu on page 4 2 2 Scroll down to Enter Diagnostics and press the OK button Entering Service Diagnostics by a Reboot 8400 1 Turn the printer power Off 2 Press and hold the Back and Help buttons 3 Turn the power On and hold the Back and Help buttons for approximately 30 seconds until the Control Panel indicates Diagnostic Menu Entering Service Diagnostics by a Reboot 8500 8550 8560 1 Turn the printer power On 2 Wait for the Xerox logo to begin moving across the display 3 Before the logo is centered on the display stops moving press and hold the Back and Help buttons on the Control Panel 4 Hold both buttons until the display reads Beginning Service Mode Initialization Release the buttons and the printer reboots into service mode with the Service Diagnostics menu displayed 4 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Service Diagnostic Control Panel Button Descriptions Button Function Back Returns to the prior higher level menu structure if available Cancels the display of test results on the Control Panel If help text is displayed on the Control Panel pressing BACK will restore the current menu item and remove the help
224. ground integrity of the printer see page 4 65 N4A N4B N4C N4D NFE N4F N4G N4H N4J N4K N4L N4S N4T N4V N4W Y Axis Motor stalled on power up following an abnormal printer shutdown Y Axis Motor stalled on power up following a normal printer shutdown Y Axis Motor stalled during mechanical recovery Y Axis Motor stalled during an printer warm up Y Axis Motor stalled while the printer was in its ready state Y Axis Motor stalled while the printer was in a fault state Y Axis Motor stalled during an auto Drum maintenance cycle Y Axis Motor stalled while the printer performed Printhead maintenance Y Axis Motor stalled while the printer performed Printhead purge Y Axis Motor stalled while the printer performed an oil transfix roller cycle Y Axis Motor stalled while the printer was in standby mode Y Axis Motor stalled while the printer staged for transfix Y Axis Motor stalled while the printer transfixed the print Y Axis Motor stalled during a Drum maintenance cycle Y Axis Motor stalled while the printer imaged the Drum Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 55 Error Messages and Codes Jam Code Troubleshooting Procedures Continued N4X Y Axis Motor stalled while the print exited the printer 1 Check the media generally label trifold or envelopes cause this error 2 Try running fewer sheets through the tray 3 Ensure the Process Drive is correctly aligned refer to Homing the Process
225. h power Troubleshooting Procedure for X Axis Motor Step Questions and Actions Yes No 1 Run the X Axis Drive test Replace the Go to Step 2 Did the test pass Electronics Module 2 Check the X Axis Motor wiring Replace the X Axis Motor 8500 8550 8400 8560 PEST Description 37 032 41 37 035 44 Y Axis Motor disconnect The Y Axis motor is not drawing the expected power 37 033 42 37 036 45 Y Axis Motor short The Y Axis motor is drawing too much power 3 44 Phaser 8400 8500 8550 8560 Color Printer Service Manual Troubleshooting Procedure for Y Axis Motor Error Messages and Codes Step Questions and Actions Yes No 1 1 Remove any obstructions interfering with Drum rotation 2 Inspect the Drum and ensure the Drum rotates smoothly if not replace the Drum Assembly and retest Did this correct the problem Complete Go to Step 2 2 Disconnect the Y Axis Belt Does the Y Axis Motor shaft rotate smoothly Goto Step 3 Replace the Y Axis Motor 3 1 Reconnect the Y Axis Belt 2 Run the Y Axis Motor test Did the test pass Replace the Go to Step 4 Electronics Module 4 Check the wiring for damage Replace the Y Axis motor 8500 8550 8400 8560 PEST Description 37 034 43 37 037 46 Media Drive motor disconnect The Media Drive is not drawing the expected power 37 035 44 37 038 47 Media Drive motor short The Media Drive is drawing too much power Trou
226. haft to the right and make sure the bearing slides over to the gear Move the shaft down and slightly to the right and then up and to the left to remove it Transfix Camshaft 0 Drum Maintenance Camshaft PL2 0 11 Caution Do not attempt to remove the Drum Maintenance Camshaft until the bushing is completely disengaged from the right ground plane 1 Remove the Drum Maintenance Pivot Plate page 8 26 2 Remove the Process Drive page 8 43 3 Slide the shaft to the right free the bushing and remove the shaft to the right 4 Carefully pry the bushing out of the right ground plane 5 Rotate the left end of the shaft slightly toward the rear of the printer lift the shaft through the slot and pull it out to the right through the large hole DN aaa DE f D SAA ES 5 H Ar T i qal Be tow f a Z E bos DA Z SEF Drum Maintenance Camshaft Bushing 8500 094 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 25 Service Parts Disassembly Drum Maintenance Pivot Plate PL2 0 16 Remove the Drum Maintenance Kit Remove the Right Side Cover page 8 5 Remove the Left Side Cover page 8 5 Remove the grounding clip on the right end of the Pivot Plate Shaft Remove the KL clip on the right end of the Pivot Plate Shaft Remove the Pivot Plate Shaft Disconnect the connector from the I O Board black white OnNoOahtWD Feed
227. he Drum heater and encoder harnesses are dressed correctly and secured by the retainer hook at the Process Drive Reinstall the Drum Fan and secure it with 3 screws Torque the top screw into the Labyrinth Seal to 20 in lbs and the other two screws into the chassis to 12 in Ibs Pass the Stripper Blade Solenoid harness through the right side of the chassis and seat the Lower Inner Duplex Guide on the four mounting pins on the chassis Install the Ink Loader page 8 7 Reinstall all covers and doors Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Purge Pump PL2 0 7 1 Remove the Left Side Cover page 8 6 2 Disconnect the air hose from the Purge Pump 3 Disconnect the harness from the Purge Pump 4 Remove 3 screws to remove the Purge Pump j l 8500 097 Replacement Note Screws in plastic are torqued to 12 in Ibs metal to 15 in Ibs unless otherwise specified Irreversible damage can result from over tightening screws into plastic parts Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 31 Service Parts Disassembly Paper Path Exit Module PL3 0 13 Caution The Drum Temperature Sensor harness is routed through the Exit Module Use care during removal to avoid damaging the sensor 1 Remove the Exit Cover page 8 6 2 Remove 3 screws securing the Media Drive and let the motor hang 3 Disconnect 3 connectors two on the right I O Board J680 an
228. he buckle for the deskew process Pick Roller drive to disengage when the door is opened and closed Pivoting separator pad to prevent it from binding Drive Gear Cam ane Roller a Spring Loaded Lift Plate Separator Pad 8500 024 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 25 Theory of Operation Paper Pick for Trays 2 4 2 26 Note Trays 3 and 4 are 525 Sheet Feeders For Trays 2 through 4 the paper pick process is different than the pick process used by Tray 1 To pick a sheet of paper the Media Path Drive starts and the pick clutch engages which turns the Pick Roller and the Nudger Roller The Nudger Roller advances one sheet of paper forward into the pick nip The Retard Roller prevents two sheets from advancing The sheet of paper continues past the Take Away Roller until the sheet completes the deskew process When using the optional 525 sheet feeder paper is pre picked from the tray and staged in the paper path while the printer is printing previous pages The deskew process uses a reverse buckle deskew for all three paper paths The paper is driven against the non rotating rollers which are reversing during simplex causing a buckle in the paper ensuring the leading edge is straighten to prevent skewing The deskew rollers do not reverse during duplex printing Strip Sensor Exit Sensor reheat Ex Deskew Sensort___ Zy Take Away Roller e Pick Roller T Rol
229. he customer is manually duplexing check that the customer is selecting the second side in the print driver m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade m Preheater ABCDEFGHIJKLMNOPQRSTUV abcdefghijklinhopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab 8500 044 Ink Smears on First Printed Side of Duplex Print Troubleshooting Procedure Step Questions and Actions Yes No 1 Clean or replace the Stripper Blade Complete Go to Step 2 Did this correct the problem 2 1 Check the duplex paper path for Complete Go to Step 3 obstructions contamination or damage 2 Clean or replace defective parts Did this correct the problem 3 Run Remove Print Smears Complete Go to Step 4 Did this correct the problem 5 28 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Ink Smears on First Printed Side of Duplex Print Troubleshooting Procedure Step Questions and Actions Yes No 4 Test the Preheater temperature Replace in the following order Does the Preheater operate within the Preheater normal operating range Replace the Electronics Module Preheater if necessary Did this correct the problem Repeating Defects on Print The distance between each artif
230. he rear position of the right side chassis to hold the right side of the Drum Assembly and torque to 25 in Ibs 6 Install the remaining two yellow reverse threaded screws into the bottom location without a washer and the front location with a washer on the right side of the Drum Assembly 7 Spread apart the chassis handles near the left and right labyrinth seals to ensure the bearing is properly sealed Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 29 Service Parts Disassembly 8 30 10 11 12 13 14 15 16 17 18 19 Align the clevis on the Transfix Load Arms with the holes in the mounting ears on the Drum The Transfix Load Arms point in the opposite direction from the Drum Thermistor Ensure that the cam followers on the Transfix Load Arms are under the Transfix Cams Insert the clevis pins through the clevis and the mounting ears on the Drum pins are inserted from the outside Ensure that the o rings are mounted on the inside end of each clevis pin Align the Exit Module to the chassis and route the Drum Temperature Sensor harness through the opening in the Exit Module that the other cables pass through Seat the Exit Module on the two front locating pins and then on the rear locating pins Insert and torque the four screws securing the Exit Module to 15 in lbs Apply a small quantity of Rheolube 768 grease P N 070E00890 to the spring hook s groove of the Transfix Loa
231. he rest of the hook floats freely 8 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly 10 After completing the installation print the Light Stripes Page and check for jets in service mode If necessary use the Control Panel to reset the jet substitution mode Head Tilt Solenoid PL4 0 12 Note Be careful not to lose the restraining spring from the unit Remove the Printhead page 8 10 Lower the Wiper Blade to its lowest position From the left side disconnect the Head Tilt Solenoid P J208 Remove 1 screw from the Head Tilt Solenoid then swing the unit out to the left until the solenoid is free from the chassis A Q Na P J208 8560 108 Replacement Note To ensure proper operation of the Printhead observe the following order when reinstalling the Head Tilt Solenoid Insert the plastic end of Head Tilt Solenoid into the chassis swing to the right and replace the screw in the chassis Torque to 12 in lbs Next from the right side of the chassis use a screwdriver from the right side of the chassis to turn the lower screw of the Process Drive clockwise until you hear the Head Tilt Solenoid snap into place Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 15 Service Parts Disassembly X Axis Bias Spring PL2 0 19 Caution The spring is in close proximity to the Drum Use care not to damage the Drum with the removal tools or the spring 1 Re
232. he time since the Time sec start of CW motion until the peak was detected 4 50 Phaser 8400 8500 8550 8560 Color Printer Service Manual Electronics Troubleshooting General Troubleshooting Printer 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 last power down condition and where the printer has last determined the printhead is positioned this is stored in non volatile RAM The Electronics Troubleshooting Checklist is the primary reference for troubleshooting power up problems i 2 Power cord is plugged in and the power switch is turned on 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 high voltage DC supplies causing a blink effect on the Control Panel LEDs BIST test flashes the PE LED very briefly at a fast rate until the end of the next test The Boot loader performs CPU initialization and RAM test It then sends the boot loader version to the serial port Power On Self Test POST initializes the Control Panel The Control Panel LED turns red green orange and then off The Control Panel LCD then goes black and then clear The POST version displays on the LCD and waits two seconds During this time the operator can
233. he word command and click OK to launch the MS DOS command prompt 5 At the prompt type in the command ipconfig and press Enter to display the computer s IP address subnet mask and gateway 6 On the Control Panel print the Configuration Page and use this page to verify that TCP IP is enabled and to determine the current TCP IP values Note To enable communication between the computer and printer both must be configured for the same TCP IP network 7 Using the printer Control Panel disable DHCP BOOTP and AutolP so that the printer can be configured manually 8 Select an IP address for the printer that matches the computer except for the last field which must be unique 9 Edit the printer s gateway and subnet mask to match the computer 10 At the MS DOS command prompt type ping followed by a space and the printer s IP address Then press Enter If the number of packets sent and received match the PING was successful and the Ethernet port is functional If the request times out and fails to reply either the cable or the port is defective Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 71 General Troubleshooting Ethernet Port Verification for Default Assigned IP Address 169 254 xxx xxx An alternate method is required to test the Ethernet port when the PC s IP address falls within the range 169 254 xxx xxx PCs that have not been configured for a specific network default to a LOCAL LINK
234. head 4 1 Check the Process Drive for damage Replace the Go to Step 5 2 Ensure the gears are correctly aligned Process Drive see Homing the Process Drive Train on page 6 8 Is the Process Drive damaged 5 Check the nose cone alignment on the X Correct Go to Step 6 Axis Motor alignment of Is the nose cone misaligned with the the nose cone Printhead shaft 6 1 Check the X Axis Motor connector for Replace the X Go to Step 7 damage Axis Motor 2 Run the X Axis Motor test to check the X Axis Motor current Did the test fail 7 Run the Tilt Drive test Replace the Did the test fail Process Drive 4 0XX 6x Errors Process Control Software Fault 1 Reset NVRAM and then retest 2 Ensure ground integrity see Ensuring Ground Integrity on page 4 65 3 Replace the EEPROM chip 4 Reboot the printer Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 5 OXX 4x Errors Y Axis Sub System Fault 5 001 41 The Drum turned one full revolution without seeing the Drum home sensor activate 5 002 42 The Y Axis encoder is not working properly or the Drum has stalled 5 003 43 There is a general problem with the Y Axis sub system 5 004 44 Y Axis fault_general fail problem with Drum motion sub system Troubleshooting Procedure for Y Axis Sub System Step Questions and Actions Yes No 1 From the Service Diagnostic Monitor Menu GotoStep2
235. head X Axis Nose X Axis Shaft Cone Motor Gear X Axis Shaft Tension Spring S amp i E Drum s8500 014 X Axis or lateral movement of the Printhead is accomplished using a stepper motor driving a fine thread screw system The Printhead mounted to the X Axis shaft moves laterally across the surface of the drum To find the Printhead home position the X Axis system drives the Printhead in an open loop The Printhead is driven against the left printer frame for a few seconds and then reversed a set distance A tension spring links to the Printhead s left shaft and provides a preloaded tension to allow the Printhead to move smoothly Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 9 Theory of Operation Printhead Tilt The Printhead is able to rotate into four basic positions 1 Printhead lock ship position 19 5 degrees The Printhead restraint pins are resting against the right and left locks In this position the Printhead tilt arm follower is free of the tilt cam and the head is secured for shipping 2 Wipe position 12 degrees The Printhead tilt arm follower is engaged with the tilt cam and the head overload spring contact is engaged with the overload spring plate to provide the correct force for the wiper 3 Standby position 20 9 degrees Allows the wiper to clear the Printhead in order to be in the start wipe Printhead position and also al
236. hed options Also included are detailed replacement procedures parts lists and wiring diagrams The Phaser 8400 8500 8550 8560 Color Printer Service Manual contains these sections Introductory Safety and Regulatory Information This section contains important safety information and regulatory requirements Section 1 General Information This section contains an overview of the printer s operation configuration specifications and consumables Section 2 Theory of Operation This section contains detailed functional information on print engine components Section 3 Error Codes and Messages This section provides detailed troubleshooting procedures for error messages and codes generated by resident diagnostics Section 4 General Troubleshooting Troubleshooting discussions cover the operation of Power On Self Test POST Service Diagnostics In addition this section includes troubleshooting methods for situations where no error indicator is available Section 5 Print Quality Troubleshooting This section focuses on techniques to correct image quality problems associated with printer output Section 6 Adjustments and Calibrations This section provides procedures for the adjustment of print engine components Section 7 Cleaning and Maintenance This section provides periodic cleaning procedures for the printer Section 8 Service Parts Disassembly This section contains removal procedures for spare parts listed
237. hows the main external components of the printer including interfaces the electronics module and the internal sensors Front View 1 Optional 525 Sheet Feeder Tray 4 2 Optional 525 Sheet Feeder Tray 3 3 Tray 2 4 100 Sheet Tray 1 MPT 5 Control Panel 6 Exit Cover release 7 Front Door release T 11 8 Exit Cover 9 Ink Loader top cover 10 Legal A4 output tray extension 7 J 42 11 Interface cover 12 Side Door 8500 004 1 Maintenance kit 2 Waste Tray 3 Power Cord connection 4 Power switch 5 Parallel connection 8400 series only 6 USB connection 7 Configuration Card 8 Ethernet 10 100 Base T connection Phaser 8400 8500 8550 8560 Color Printer Service Manual 1 7 General Information Rear View The rear view consists of the printer s main electronics and power supply which are enclosed in a metal case called the Electronics Module The rear panel allows access to the Electronics Module RAM and NVRAM The printer s Hard Drive is also mounted on the rear panel When installing a new electronic module in the printer the following components need to be transferred from the old board se 9 o a DE gt BFE 8500 006 1 Hard Drive optional 3 Configuration Card Installed from the side under the interface cover 2 Memory RAM DIMM 1 and DIMM 2 4 NVRAM Configuration
238. i an ra from Process i oF Se Motor Stall YES Move Head to the Hom ene Y i Standby position 60 lt m 1 i 7007 7008 8005 8055 8007 i i 7006 8008 8009 l I i ARMS and restrain Move XA to Left headagain Move XA to Left Side Hard Stop 8035 7009 Side Hard Stop 6000 Jog the X ese nesses 6000 Axis in ge Pec cccccccccccccccces order to z is the X Device Fault Codes E isin Move XA to Tilt Move XA to Tilt PET Position Position FAU 80xx Wiper order to i 6000 Arms 7002 PM stalled A release the 6000 i Eo 70xx Headtilt Head Tilt i 7014 Head Not Restrained Arms Move Head to the i h Dmfi 31001 Media Path Home Print M x 5001 YA Home Timer position 1 Move Head to the 4025 mte 3 vA Aai Stall PARK position 7010 7006 4025 PM ae Failed e 7007 7008 8005 8055 8007 v 4 i 7006 8008 8009 7014 Start YA Slew i Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 53 General Troubleshooting Mechanical Initialization 8500 8550 8560 Mechanical Recovery POWER ON MECHANICAL RECOVERY Start Mechanical Recovery Start the thermals 13 xxx Values in NVRAM are used to determine if printhead and wiper have contact or if the printhead was parked on last power down If Close preheater printhead and wiper are in contact the printhead Unbind Media warm
239. imaging path that affects a vertical band down the entire page Also you may see color variation from jet to jet on the Eliminate Light Stripes test print Some variation is normal occasionally occurs and usually self corrects within a few printed pages If a print quality problem is not resolved with the information provided in the Diagnosing Print Quality Problems section see the specific problem in Analyzing Service Test Prints on page 5 34 Phaser 8400 8500 8550 8560 Color Printer Service Manual Random Light Stripes Print Quality Troubleshooting One or more color bars are missing on the test page This is likely caused by a weak or clogged Printhead jet Initial Actions m Run the Eliminate Light Stripes routine from the Control Panel m Check the exit path for debris or contamination Troubleshooting Reference Applicable Parts Example Print m Printhead a Drum Maintenenace Kit Stripper Carriage XEROX Light Stripes Test Random Light Stripes Troubleshooting Procedure Step Questions and Actions Yes No 1 On the Control Panel select the Eliminate Light Stripes function and follow the procedure on the printed pages For 8400 printers this step does not include Jet Substitution Did this correct the problem Complete Go to Step 2 It may be necessary to repeat Step 1 up to 3 times if the stripes still appear NOTE If there are discolored
240. implex Guide page 8 33 Unplug the AC and sensor flag connectors from the bottom of the Preheater A OND Note Release the lock on the back of the AC connector AC Connector Sensor Flag Connector nT 5 Slide the latches in and forward to latch in their slots Note Preheaters in 8500 8550 8560 models are more difficult to slide out than the 8400 versions because of reduced clearance with the Preheater Lift Solenoid 8 20 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly I A Mm ie N on a ss gt EL ty Ewen Ne ere 6 Slide the Preheater off the shelves and out of the printer Replacement Note The fingers on the Inner Simplex Guide go over the segmented roller First snap the left retainer into place then the right Duplex Roller PL3 0 8 Open the Front Door Remove the Outer Duplex Guide page 8 34 Remove the Upper Duplex Guide page 8 34 Remove the Lower Inner Duplex Guide page 8 33 Remove the Duplex Roller by removing the left KL clip on the shaft and sliding the left side bearing down the shaft toward the right Then slide the shaft toward the left to free the right end of the shaft Finally pull the shaft out towards the right side of the printer a ron KL Clip 5 LLY i mF Enw e 1 s8500 08
241. improper contact with the Drum See the Reverse Text test print As a last resort to fix wrinkling replace the transfix roller transfix load module and transfix load arm Primary Solid Fills 10x This item enables you to print 10 CMYK solid fill prints These prints are used to determine if the Drum or transfix roller have a defect Drum defects do not move in the X position print to print but it does move into the Y position print to print Drum defects do not repeat down the page Transfix Roller defects do not move in the X direction but these defects repeat every 4 58 in 11 63 cm down the length of the page Many Transfix Roller defects will be most visible on duplex solid fills 5 40 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Head to Drum Gap 8400 Only These prints indicate if the gap between the Printhead and the Drum is correct ll ll 8500 055 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 A difference indicates the Printhead gaps at each end of the Printhead are not equal Text Examine each end of the band of text Look for fuzziness or differences between the quality of the characters on
242. in the paper path The scratch or mark may extend into non printed areas or be more pronounced on the lower portion of the image Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade a Drum Maintenance Kit m Preheater Media Guides ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefahiikimnoparstuvwxvzab 8500 036 Scratches or Marks Troubleshooting Procedure Step Questions and Actions Yes No 1 1 Check the exit area exit frame Preheater Drum Maintenance Kit Printhead and Stripper Blade for anything touching the Drum 2 Reseat any component interfering or touching the Drum 3 Clean the Stripper Blade Did this correct the problem Complete Go to Step 2 Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 13 Print Quality Troubleshooting Scratches or Marks Troubleshooting Procedure Step Questions and Actions Yes No 2 1 Check the Drum Maintenance Kit If the Complete Go to Step 3 defect is a thin line that is glossier than the surrounding area it may be due to a defect on the maintenance kit wiper blade 2 Clean the wiper blade or replace the Drum Maintenance Kit Did this correct the problem 3 Using transparency media print
243. ing 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 Enhanced print mode s8500 051 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 Note Check that the printer is not in High Resolution Photo or Standard print mode and the Printhead drive voltage is set to the default 128 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 Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 37 Print Quality Troubleshooting 5 38 Big Bands OHP This print allows you to evaluate transparency printing It prints two transparencies from Tray 1 one with primary color fills and one with secondary color
244. ing strength Engage Time sec 0030 to 0035 0 to 05 Reports time between engagement of the stripper solenoid and initial contact between the blade and the drum May indicate the geometry of the mechanism such as parts out of tolerance mis assembled or bent causing an incorrect blade to drum gap Engaging Period sec 0 to 0 11 0 to 3 Reports time between stripper solenoid engagement and the point when the reaction of the drum to the contact of the blade fades back into the ripple noise Another indication of blade to drum interaction The profile shape R2 R2 could be a dynamic indication of the blade drum interaction as is the static value reported by RO Engaging Amplitude mpts 3 to 18 5 0 to 35 Reports the magnitude of the reaction of the drum to the contact of the blade See R2 Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 4 General Troubleshooting 4 42 Stripper Contact Continued R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Release Displacement mpts 0 75 to 2 2 4 5 to 4 5 Reports the static difference between the average ya_fe before and after the blade disengages from the drum indicating the strength of the blade drum interaction while pulling off the drum see RO Release Time sec 0 to 0 09 002 to 1 Reports the time between the diseng
245. ink sticks to load one unique color in each channel When the Printhead requires ink the melting element of the appropriate color melts the end of the ink stick The melted ink drips into the Printhead ink reservoirs Sensors in the Ink Loader alert the customer to install more ink sticks before the printer completely consumes the current sticks If the ink level sensors inside the Printhead detect that the Printhead has run out of ink but the ink low out sensors are not activated the Control Panel reports an Ink Jam error The Phaser 8400 features a single Ink Out sensor which activates when there is no ink stick in any of the four ink channels This condition activates the sensor flag The 8500 8550 8560 features an Ink Out sensor in each ink stick channel Each sensor determines if the individual channel is empty The sensors also determine the count of the ink sticks as they pass by the Ink Out sensor flag Ink Loader Door S Ink Stick q V Ink Melt Units A E Ink Low Sensor A Out Sensor Printhead T s8500 011 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Printhead The Printhead is the heart of the printer spanning nearly the length of the drum Using its 1236 jet nozzles 309 jets for each primary color with a horizontal motion of slightly less than 5 mm 0 2 inches the Printhead can print the entire image on the rotating drum The Printhead provides one size in
246. inthead heaters to soften the ink Manual separate the wiper and Printhead Set them in their home positions 5 Does the X Axis Motor drive the Printhead Go to step 6 Troubleshoot to its center position so it can tilt forward the X Axis drive 6 1 Check the Process Drive for obstructions Complete Go to Step 7 or damaged 2 Ensure the gears are correctly aligned and homed 3 Verify the process shaft and drive module shaft are at their home positions Did this correct the problem 7 Has ink spilled on the Head Tilt Gear on its Clean the Go to Step 8 drive train near left side of the Printhead gears Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 19 Error Messages and Codes Troubleshooting Procedure for 7 010 to 7 015 Error Code Continued Step Questions and Actions Yes No 8 Use Service Diagnostics to run the Head Replace the Go to Step 9 Maintenance Wiper Clutch test Head Did the test fail Maintenance Clutch 9 1 Align the Wiper Assembly page 6 2 Replace the Go to Step 10 2 Use Service Diagnostics to run the Wiper Exit Module Drive Test Did the test fail 10 1 Use Service Diagnostics to run the Load Inspect the Go to step 11 Maintenance Clutch test maintenance Did the test fail drive system replace any defective parts 11 Verify the Head Tilt Gear engages You can Go to Step 12 Set the Head manually set the Head Tilt Gear Tilt Gear Is
247. inthead is operating normally Purge Pump Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Jetstack 134 138 Reports current jetstack Temperature deg temperature If the temperature is above current threshold 120 deg the test will abort and following results will report as 0 This avoids having ink extrude out of the faceplate and onto the drum requiring both a wipe and a chase to clean up 1 Start Power watts Reports initial peak pumping power after pump power on This reflects the inrush current to the pump motor An unusual value could indicate a defective motor windings brushes etc Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 47 General Troubleshooting 4 48 Purge Pump Continued R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Initial Pumping Power watts Reports minimum pumping power after start up peak R1 This is the first value to reflect the system pressure If the volume is normal hose printhead then the drop is large and the pressure rises slowly If the volume is small hose pinched plugged near the pump then the drop is minimal and the pressure rises quickly Max Pressure Pumping Power Reports average pumping power just before maximum pressure is reached May indicate the efficiency of the pump leaks and or the setting of the pressure
248. inthead ink data partition in NVRAM 34 003 45 An error occurred while attempting read write access to the Printhead data partition in NVRAM 34 004 46 An error occurred while accessing the Printhead NVRAM hardware for the purpose of initialization The Printhead cable may be unplugged Troubleshooting Procedure for Printhead NVRAM Step Questions and Actions Yes No 1 Check and reseat all wiring to the Printhead Complete Replace in Did this correct the problem this order m Printhead m Electronics Module Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 35 Error Messages and Codes 36 000 40 Errors Drum Maintenance Faults Troubleshooting Procedure for Drum Maintenance Step Questions and Actions Yes No 1 Ensure ground integrity see Ensuring Complete Go to Step 2 Ground Integrity on page 4 65 Did this correct the problem 2 Ensure the Process Drive system is Complete Go to Step 3 correctly homed as described in Homing the Process Drive Train on page 6 8 3 1 Check the Drum Maintenance Pivot Plate Complete Go to Step 4 for cracks 2 Check the Drum Maintenance Camshaft rollers for damage or improper movement 3 If the Drum Maintenance Pivot Plate or cam rollers are faulty replace Did this correct the problem 4 Use Service Diagnostics to run the Drum If either test fails replace the Maintenance Transfix Home test Process Drive Use Service Diagno
249. isconnect the 2 connectors from inside the Electronics Module 3 Pull out and replace the entire unit including chassis holder hard drive and board 8500 116 4 Reattach the 2 connectors to the replacement Hard Drive 5 Replace the Back Cover 8 52 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists In this chapter m Serial Number Format m Using the Parts List m Xerox Supplies Chapter QO Parts Lists Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available It is important when ordering parts to include the following information Component s part number m Product type or model number m Serial number of the printer Serial numbering Particular fields in the serial number indicate the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows The text S N followed by the serial number in the barcode The barcode does not include a field identifier The nine digit serial number is based on the following format PPPRSSSSS PPP Three digit alphanumeric product code Product Model Product Code 8400 B BD N DP DX RPC 8400 DPF TMV 8500 N DN WYN 8550 DP CT DX WYP 8550 DPF L91 8560 N DP DT DX FBT R Single digit numeric revision di
250. isplayed on Control Panel LCD Printer has detected a fault condition See Fault Code Error Message Troubleshooting on page 3 7 for definitions and solutions Blank Display and the PS and PE LEDs Are Flashing an Error Code Printer has detected a fault condition but can t display a message on the LCD Some portion of the chain of devices used to drive the LCD may be defective since an error message is not displayed See Fault Code Error Message Troubleshooting on page 3 7 for definitions and solutions Printer Fails Power Up PS PE and 3 3 V LEDs Do Not Illuminate Printer is not receiving proper AC Caution Use caution with hazardous voltages when diagnosing AC problems The 3 3 V LED is located inside the Electronics Module and must be observed through the vent holes close to the AC power switch see the illustration on page 4 64 1 Inspect the power cord a Verify AC outlet voltage and current capacities are within specifications b If necessary move the printer to a different outlet and retest 2 Transient on AC line tripped protective circuitry in printer power supply Cycle power to printer to reset protective circuits in power supply 3 Short circuit on 3 3 V supply within the Electronics Module ESD damage to the printer may occur if static electricity is discharged to printer electronics a With power cord connected touch the metal Electronics Module to discharge any static electricity b Turn of
251. iteria is met you should replace the printhead instead e Ifthe customer uses the billing meters features e If three missing jets of the same color are adjacent for example cyan jets 79 80 and 81 e By the customer runs mainly in Fast Color or Standard mode as revealed on the Usage Profile page The repair is complete Step Is the customer e If YES print 10 solid fill pages of cyan If the bands vary in intensity 12 experiencing YES and or location over the 10 prints the customer is experiencing vertical bands NO stagnant ink discoloration Continue to print solid fills of the not light offending color until the output is uniform It may take as many as 60 stripes in solid Circle solid fill pages to refresh all of the ink in the printhead reservoir The color areas ane repair is now complete e If No the repair is complete Comments Xerox U S personnel please add all comments into FIST A completed checklist and sample prints must be returned with each printhead Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed troubleshooting checklist and a sample print with each returned printhead Please return the following items with the defective printhead e Service Print 1 not necessary for error code based failures not applicable for printheads replace because of an error code e This Printhead Troubleshooting Checklist filled out e Inven
252. itialize 16 3 09 01 Flutter only Soft Control Panel data path failure 16 4 10 01 Flutter then 10 blinks Hard PLD power control link down 33 1 10 02 Flutter only Soft PLD power control link invalid 33 2 mismatch error 11 01 Flutter then 11 blinks Hard EEPROM read failure 12 1 1 Check EEPROM orientation 2 Replace EEPROM 11 02 Flutter then 11 blinks Hard EEPROM write failure 12 2 1 Check EEPROM orientation 2 Replace EEPROM 11 03 Flutter then 11 blinks Hard EEPROM re read failure 12 3 1 Check EEPROM orientation 2 Replace EEPROM 11 04 Flutter then 11 blinks Hard EEPROM data failure mismatch error 12 4 1 Check EEPROM orientation 2 Replace EEPROM 12 xx Flutter only Soft Configuration card test failure 1 Check card orientation 2 Reseat then replace the configuration card NOTE Printer will work as a base model without networking without the configuration card 8400 only 13 01 Flutter then 13 blinks Hard PHY reset failure reset stuck low 2 1 13 02 Flutter then 13 blinks Hard PHY ID error mismatch error 2 2 14 xx Flutter then 14 blinks Hard USB errors N2280 netchip read write 19 1 and mismatch errors POST hard errors 15 01 Flutter then 15 blinks Hard CPU interrupt error 19 3 15 02 Flutter then 15 blinks Hard CPU interrupt error missing CPU 19 4 interrupts 15 03 Flutter then 15 blinks Hard CPU interrupt error IRQ spurious 19 5 assertion Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 5
253. ition Typical Value 8400 Typical Value 8500 8550 8560 Actions CW On fe settling time sec 0 010 to 0 20 Oto 2 Reports the time it takes the MP motor servo system to settle down after the sudden addition of the deskew shaft load A longer time could indicate a looseness in the deskew shaft assembly or a slipping clutch CW On average fe 610 to 220 3 to 1 3 Reports the average effort required to rotate the deskew shaft in the CW direction at a constant velocity An unusual value could indicate a difference in the composition and or number of the rollers the nip pressure or out of range mechanical dimensions due to wear or contamination such as paper dust increasing the effective diameter of a roller 10 CW On fe ripple 110 to 400 2 25 to 1 0 Reports the variation of effort required to rotate the deskew shaft in the CW direction at a constant velocity A larger value could indicate particles in the gears or non uniform contamination of a roller causing a lump 1 CW Off fe settling time sec 0 010 to 0 20 01 to 05 Reports the time it takes the MP motor servo system to settle down after the sudden release of the deskew shaft load A larger value could indicate a dragging or slow to release clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 15 General Troubleshooting Check Paper
254. ix process until the Strip sensor activates part way through the paper transfix motion 7 Exit Interval us Reports the interval from the time the engine software is commanded to start the transfix process until the Exit sensor activates part way through the paper transfix motion Simplex Path 8 Exited Interval us Reports the interval from the time the engine software is commanded to start the exit process until the Exit sensor deactivates Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected Paper Trail Edge Times Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Common 0 Tray Reports the tray from which the test paper was picked 1 Paper Size Reports the picked media size 4 24 Phaser 8400 8500 8550 8560 Color Printer Service Manual Paper Trail Edge Times Continued General Troubleshooting R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Tray 4 Pick 2 Tray 4 Pick Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the tray 4 pick process until the Tray 4 Pick senso
255. k drop which is used for all print quality modes Reservoir Drum 8500 012 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation 2 8 Printhead Ink Loader Level Sense Probe ame D 7 YA Purge Valve me P ES aa Yellow 8500 013 The Printhead s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array Channels formed by the stacked plates route ink past the 1236 individual piezo electric crystal driven diaphragms which force the ink in droplets out the 1236 corresponding nozzles Looking at the Printhead face the nozzles are arranged in 12 rows in color order KYKYKYCMCMCM where K black Y yellow C cyan and M magenta During the printing process the Printhead would only have to travel approximately 14 pixels horizontally to provide complete coverage However the Printhead travels much further depending on print resolution to interlace each jet with the output of neighboring jets The jet array bonds to a cast aluminum ink reservoir which supplies the molten ink to the jet array Heaters in the reservoir and the jet array maintain the ink at a printing temperature of about 60 degrees centigrade Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation X Axis Hook Print
256. king damaged a Drum Maintenance Pivot Plate Drum Maintenance Camshaft Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 25 Print Quality Troubleshooting 5 26 Incomplete Image Transfer to Paper All of the image does not transfer to the paper Media that is not smooth enough or too light can cause this problem This problem can also occur on watermarked paper or when poor Drum oiling causes an incomplete image on one side of the page Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Drum Temperature Sensor a Drum Maintenance Kit Drum Maintenance Pivot Plate Drum Maintenance Camshaft ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 043 Incomplete Image Transfer Troubleshooting Procedure Step Questions and Actions Yes No 1 Try a higher quality or heavier media type Complete Go to Step 2 Did this correct the problem 2 Try using a higher quality print mode Complete Go to Step 3 Did this correct the problem 3 Test Drum maintenance operation Complete Go to Step 4 1 Run service diagnostics to verify the Drum maintenance system is operating correctly 2 Check and if necesary replace these parts check fo
257. l pages and problem Complete Go to Step 6 6 1 Turn off the printer for at least 4 hours Complete 2 Turn on the print repeat Step 1 Did this correct the er and if necessary problem Follow the instructions on the Printhead Troubleshoot ng Checklist Predominate Light Stripes All four color bars are missing on the test page A thin stripe with no colon is likely due to foreign debris scratching ink off the Drum or the print If there are a series of regularly spaced white lines approximately 6 mm 25 in apart see White Stripes Pinstripes on page 30 Initial Actions Run the Eliminate Light Stripes routine from the Control Panel m Check the exit path for debris or contamination Troubleshooting Reference Applicable Parts Example Print a Printhead a Drum Maintenenace Kit Stripper Carriage 5 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Predominate Light Stripes Troubleshooting Procedure Step Questions and Actions Yes No 1 Clean the exit path and Stripper Blade witha Complete Go to Step 2 lint free cloth Did this correct the problem 2 Remove the Drum Maintenance Kit and wipe Complete If the problem the clear plastic wiper blade with a lint free persists cloth follow the Did this correct the problem steps for Random Light Stripes on
258. laps is normal Wrinkling may occur on the second side of a 2 sided print on the secondary colors This indicates the Preheater is too open on the duplex side of the print Note On the paper s packaging an underline under the 11 in 8 5 in x 11 in indicates the paper is long grain Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 31 Print Quality Troubleshooting Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print m Preheater a Drum Maintenance Kit Transfix Components ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 047 Wrinkling Troubleshooting Procedure Step Questions and Actions Yes No 1 Try a higher quality or heavier media type Complete Go to Step 2 from an unopened fresh ream of paper Did this correct the problem 2 Increase the margin size of the image Complete Go to Step 3 Wrinkling generally occurs in solid fills near the print s edge Did this correct the problem 3 Did the wrinkle occur printing the duplex Replace the Go to step 4 side only Preheater 4 Inspect clean or if necessary replace the Complete Go to Step 5 Drum Maintenance Kit Did this correct the problem 5 Inspect the transfix components Replace in the
259. larger value could indicate particles in the gears or non uniform contamination of a roller causing a lump 5 Off fe settling time Reports the time it takes the sec MP motor servo system to settle down after the sudden release of the Tray 2 pick shaft load A larger value could indicate a dragging or slow to release clutch 6 Time to lift plate up Reports the time between the sec activation of the Tray 2 lift motor and the detection of the raised lift plate Out of range values may indicate a problem with the lifting mechanism which could effect the following friction measurement or media left in the tray Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 21 General Troubleshooting 4 22 Tray 2 Tray 3 and Tray 4 Pick Shaft Continued Typical Typical Value Value 8400 8500 R Definition 8550 8560 Actions 7 Plate lifted average Reports the peak effort fe required to drive the pick shaft when the nudger roller is in contact with the separator pad A smaller value could indicate a Slipping clutch missing nudger assembly pressure spring or glazed dirty roller pad Test picks paper from selected tray test currently supports picking from Tray 2 only and moves it through either the simplex or duplex paper path to determine paper path power requirements Paper Drive Power Typical Typical Value Value
260. ler Retard Roller s8500 025 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Transfixing and Exiting Transfixing and exiting consists of four major functions 1 Staging the paper for rendezvous with the image on the drum and transfix roller nip 2 Loading the transfix roller and engaging the drum stripper blade assembly 3 Stripping the paper from the drum 4 Exiting the paper from the printer or exiting the paper for 2 sided duplex printing Tripping the preheat exit sensor see previous illustration sets up a series of events which take place on a predetermined schedule Paper is transported through the Preheater to thermally prepare it for transfixing The preheat sensor detects the paper s presence and accurately references the leading edge of the media with the image on the Drum Based on the timing information from the Preheater the leading edge of the media is advanced to the transfix nip Once the media is stopped in the transfix nip the Process Drive gears move to rotate the Transfix Camshaft to bring the Transfix Roller into contact with the Drum The Transfix Roller nip applies the load necessary to transfer the image to the media from the Drum At the point where the Transfix Roller loads but before the Drum begins to rotate the Stripper Solenoid engages The Stripper Solenoid positions the stripper blade The solenoid mounts on the Upper Inner Duplex guide and activ
261. les from the driver are not installed on the computer locate the driver files on the CD ROM Once the files have been located the computer installs the driver and automatically configures it to match the printers feature set 5 To test the connection click the START button Select SETTINGS and then PRINTERS 7 Locate the Phaser 8400 8500 8550 8560 Color Printer icon and display its properties 8 From the General tab click the Print Test Page button to generate the test print If the test page prints the USB port is functioning normally e gt 4 72 Phaser 8400 8500 8550 8560 Color Printer Service Manual Network Problems General Troubleshooting The printer maintains 6 logs in memory detailing network functions The logs contain TCP IP NetWare and AppleTalk initialization events The logs can also be accessed remotely via CentreWare The logs list events chronologically The log is limited in length when the log is full the printer stops recording data to the log The logs are stored on the Hard Drive so only new data is stored each time the printer s power is cycled There is a Connection Setup page Configuration page and a network reset available for troubleshooting network problems Print an Event Log or Runtime Log 1 Enter normal Customer Mode 2 From the main menu select Troubleshooting and press OK 3 Scroll and select Network Log Pages and press OK 4 Highlight the appropriate menu item from th
262. ll heaters Off Toggle Printhead Heaters Toggles Printhead heaters to opposite state Toggle Preheat Heater Toggles Preheater heater to opposite state Toggle Drum Heater Toggles drum heater Toggle Ink Melt Heaters Toggles ink melt heaters to opposite state There is a melt heater for each of the four colors Control Panel Display Exercises the Control Panel LCD LED outputs Cycle LED Cycles the LED through a red Yellow Green sequence Set display dark Sets the LCD display dark Test backlight Changes the display backlight from off to max Set display light Sets the LCD display light Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Diagnostics Menu Map Continued General Troubleshooting Menu Description Function Menu Functions for commanding more complex actions by portions of the printer mechanism Initialize Mechanism Performs a power up mechanical initialization sequence Print DMU Blot Raises the DM unit up against the Drum then does a Chase sequence The result is an oil print of the contact of the DM unit with the Drum about 2 3 of the way down the page Display Fault History Displays the contents of the Fault History NVRAM NOTE Jam History can only be accessed from customer mode There is no way to access the information Service Diagnostics Mode Access PE NVRAM Parameters Pro
263. lling Meters feature and multiple adjacent problem jets can affect the recommended solution Enabling Jet Substitution Mode 8400 6 12 To add Jet Substitution Mode to the Control Panel menu 1 Scroll to Troubleshooting and then press the OK button 2 Scroll to Print Quality Problems and then press the OK button 3 Press and hold the Up Arrow button then press the Back button The Jet Substitution Mode is now displayed on the Control Panel Phaser 84000 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations To correct print quality problems refer to the Eliminate Light Stripes test page to determine which jets are weak or missing ii 2 3 Select Jet Substitution Mode and then press the OK button Select Jet Select and then press the OK button Scroll to the color for the weak or missing jet and then press OK to select the color Use the Up Arrow and Down Arrow buttons to select the number of the weak or missing jet and then press OK to confirm the selection Select Save Change and Exit and then press OK to complete the procedure After substituting a jet print the Light Stripes Test page to verify the problem has been solved At the bottom of the page a Service Mode key summarizes the number of substituted jets for each color Note The Configuration and Printer Status pages also list jets in Service Mode substituted Enabling Jet Substitution Mode 8500 8550 8560
264. low the Printhead locks to pivot and lock or unlock the Printhead In this position the Printhead tilt arm follower is engaged at the standby position of the tilt cam 4 Print position 0 degrees The Printhead is forward and resting against the right and left head to drum buttons The head to drum buttons define the space between the jet stack and the drum The tilt cam tilts the head into the basic four positions listed above The cam has five special features and associated functions 1 The cam is combined with a missing tooth gear that allows the cam to be inactive in the print position which frees the process drive to perform other printer operations 2 The cam has a latching feature to unlatch and latch the missing tooth gear to engage the Printhead tilt drive train 3 The cam profile has a standby dwell the portion of the cam that has a constant radius that holds the Printhead back in the standby position 4 The cam profile has a wipe dwell the holds the Printhead back in the wipe position 5 The cam profile increases the power consumption at a specific phase of rotation This allows the software to identify a power consumption footprint that alerts the printer to a fault when the head is locked in error The Printhead is tilted away from the drum and locked for shipping The Printhead is locked if the head lock indicator is above the level of the output tray When the Printhead is locked in the shipping position the
265. ly into which the device will be installed Minimize body motions when handling unpacked replacement devices Motion such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro statically sensitive device m Handle IC s and EPROM s carefully to avoid bending pins m Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards PCB s Phaser 8400 8500 8550 8560 Color Printer Service Manual v Service Safety Summary General Guidelines For qualified service personnel only Refer also to the preceding Power Safety Precautions Avoid servicing alone Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present Use care when servicing with power Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is on Disconnect power before removing the power supply shield or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come into contact with dangerous voltages and currents Warning Labels Read and obey all posted warning labels Throughout the printer warning labels are displayed on potentially dangerous components As you service the printer check to make certain
266. mage to the Electronics Module did not occur due to the shorted printhead Plug in all cables removed during service Trace through all service steps performed to reattach any cables that were unplugged during debugging Attach printer covers Perform full test of printer Printer Prints and the Display is Frozen With No Errors Note Opening and closing the Front Door resets the Control Panel 1 Electrostatic Discharge a b i j If the printer is currently powered on and frozen open then close the front door of the printer and see if the LCD responds If printer appears functional after operating the door advise client that failure may have been due to an ESD event Thoroughly test printer for any other problems Skip the rest of this section if printer now appears functional otherwise continue debugging With power cord connected touch the metal Electronics Module to discharge any static electricity ESD damage to the printer may occur if static electricity is discharged to printer electronics Turn off printer and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge Unplug power cord and remove printer s covers Use caution around motors pulleys and live AC connections when working with the printer covers off Examine printer for loose grounding connections especially the
267. ment If either of the Transfix Arm assemblies are worn replace the arm If there are repeating white stripes on the print there may be a problem with the X Axis motion see White Stripes Pinstripes on page 30 5 42 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Manuf Skew Margins This print consists of an image used by manufacturing to gauge skew and margin on 2 sided prints 8400 145 s8400 201 To measure skew measure between the edge of the paper and the magenta frame should be within tolerance along the entire length of the top of the paper For example the measurement on the top left side of the sheet should be the same as the measurement on the top right side of the sheet within tolerance To calculate skew measure the margin at the leading edge of each corner then take the difference between them For example if the margin at the right leading edge corner is 5 1 mm and the margin at the left leading edge corner is 4 9 mm then the skew is 5 1 4 9 0 2 mm Skew tolerances are All sizes except envelopes and custom sizes 0 0 0 89 mm m Envelopes 0 0 1 04 mm m Custom media evaluate with the following formula Skew Spec mm 998 4 width 12 5 4 1 02 where width is in millimeters To measure margin measure from the magenta frame to the edge of the paper at the midpoint on the top and left edge margin right side of paper left sid
268. move the Printhead page 8 10 2 Using your hands a spring hook or pliers remove the X Axis Bias Spring from inside the printer cavity Ls X Axis Bias Spring E s8500 080 Replacement Note Do not rotate the spring more than 1 4 turn during installation 8 16 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Wiper Assembly PL2 0 17 Caution Place several sheets of paper between the Printhead and the Drum to protect the Drum from damage 1 Remove the Printhead page 8 10 2 Using the gears position the Wiper Blade all the way up 3 On the left side remove the KL clip and gear as shown below Wiper Clip 8500 081 4 Remove the left plastic clip from the Wiper Belt and slide the Wiper off of the belt Note For early model 8500 8550 printers insert a small flatblade screwdriver between the backside of the left wiper clip and the flat side of the belt Apply a small amount of pressure against the plastic wiper clip with the screwdriver and gently slide the Wiper off the belts Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 17 Service Parts Disassembly Replacement 1 Position the Wiper so both ends are all the way down following reassembly see Wiper Alignment Procedure on page 6 2 2 When reinstalling the belt into the wiper clip in 8500 8550 8560 models place the b
269. nce Wiper Clutch test Head Did the test fail Maintenance Clutch Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 17 Error Messages and Codes Troubleshooting Procedure for 7 008 Error Code Continued Step Questions and Actions Yes No 8 Perform the Wiper Alignment procedure Complete Go to Step 9 see Wiper Alignment Procedure on page 6 2 Did this correct the problem 9 Use Service Diagnostics to run the Wiper Inspect the Complete Drive test wiper drive Did the test fail system and replace any defective parts 7 009 42 The Printhead is tilted back but not properly restrained in the park arms Troubleshooting Procedure for 7 009 Error Code Step Questions and Actions Yes No 1 Check that the right and left Printhead Complete Go to Step 2 Restraints operate correctly and are not damaged 2 Check that the Wiper Assembly is aligned Complete Go to Step 3 correctly see Wiper Alignment Procedure on page 6 2 3 1 Check the Printhead wire routing Complete Go to Step 4 2 Remove the Printhead and clean around the Printhead tilt gears Did this correct the problem 4 Check that the Process Drive gears are Complete Go to Step 5 correctly aligned and homed see Homing the Process Drive Train on page 6 8 Did this correct the problem 5 Replace the Process Drive Complete Go to Step 6 Did this correct the problem 6 Use Service Diagnosti
270. nd Tray 050E23570 8500 8550 8560 13 Exit Module Assembly 1 441223980 8400 133K27700 8500 8550 8560 Phaser 8400 8500 8550 8560 Color Printer Service Manual 9 9 Parts Lists PL 4 0 Motors Gears Solenoids Clutches and Fans 8500 120 9 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists Parts List 4 0 Motors Gears Solenoids Clutches and Fans No Name Description Qty Part Number 1 Preheater Lift Solenoid 1 121K44430 8500 8550 8560 2 Motor Y Axis Drive 1 127K56520 3 Pick Solenoid Tray 1 1 121E20120 4 Head Tilt Solenoid 1 121K44480 8500 8550 8560 5 Gearbox Media Drive with 2 Clutches 1 401098480 8400 Solenoid 807E23090 8500 8550 8560 6 Tray Lift Motor Kit and Gear plus item 10 1 604K31810 Paper Path Cooling fan 1 119650580 8400 No longer orderable refer to service bulletin 655 8 Electronics Module System Fan 1 119642680 8400 133K25010 8500 8550 8560 9 Compound Gear Head Tilt 1 807E16060 10 Tray Lift Motor Kit and Gear plus item 6 1 604K31810 11 Electric Clutch Wiper Head Maintenance 1 033E05190 Clutch 12 X Axis Motor Assembly 1 127K53580 13 Drum Cooling Fan 1 119641780 8400 127E16010 8500 8550 8560 14 Gearbox and Motor Process Drive 1 401100080 8400 005K12670 8500 8550 8560 15 Ground Clip Pick Clutch 1 650442700 8500 8550 8560
271. ndix Reference Menu Map 8400 Main Menu ze Front Panel Buttons 9 ITF Up Arrow Walk Up Features gt Cancel Q Printer Setup gt r Troubleshooting Back NS Information Shut Down gt X Darin AION 5 prints an information page Model 5 Help Guide Printer Name 5 Configuration Page Inf tion gt Print Server 5 Paper Tips Page nformevon IP Address 5 Connection Setup Page Serial 5 Moving Guide Menu Map Activation Date Startup Page Printer Identification gt Usage Profile 5 PostScript Font List Information Pages gt PCL Font List Sample Pages gt Supplies Info gt Maintenance Kit Life F x Graphics Demonstration Total Print Count Office Demonstration 2 Sided Demonstration Print Mode Demonstration Walk Up eee a amp CMYK Sampler Pages RGB Sampler Pages Secure Print Jobs Proof Print Jobs Saved Print Jobs Walk Up Printing Select for Installation TCP IP Setup gt __ TCP IP 7 NetWare Setup gt DHCP BOOTP printer Stun Ethernet Speed AutolP Configuration Page Connection Setup Page eae dees foe Mask Network Setup gt Connection Setini Parallel Setup p Parallel Port es Port 9100 USB Setup gt Wait Timeout LPR Reset Connection Setup Page Description Language Job Pipelining SLP SSDP USB Port CentreWar
272. ner and remove the guide Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 33 Service Parts Disassembly Outer Duplex Guide With Safety Interlocks PL3 0 4 1 Remove the Control Panel page 8 5 2 Remove 4 screws and remove the guide Outer Duplex Guide Replacement Note Seat the guide on the chassis Torque the 4 screws to 12 in Ibs Upper Duplex Guide with Solenoid PL3 0 5 1 Remove the Right Side Cover page 8 5 2 Remove the Outer Duplex Guide 3 Disconnect the solenoid connector from the I O Board and release the harness from the right side frame 4 Remove the Upper Duplex Guide from the printer 8 34 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Solenoid Lever Upper Duplex Guide Hole for Solenoid Lever 8 a 4 Replacement Note Route the Stripper Solenoid harness through the right side frame when replacing the Upper Duplex Guide Also verify that the solenoid lever engages the hole in the Stripper Carriage lt 2 8500 099 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 35 Service Parts Disassembly Take Away Roller PL3 0 7 Remove the Right Side Cover page 8 5 Remove the Left Side Cover page 8 5 Remove the Media Drive page 8 40 Remove the Lower Simplex Guide page 8 33 Remove the KL clip from the right end of the shaft Remove the KL clip and bushing from the left en
273. nerate observed motion without making substantial change to the printer s state Press a Control Panel button to stop the test Exercise All Cycles each of the listed motors shafts 3 times in Sequence Process Motor Cycles the motor shaft repeatedly Y Axis Motor X Axis Motor Purge Pump Motor Drum Fan Motor Media Path Motor Fan Motor Media Path Motor amp Shafts Transfix Cam Shaft Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 7 General Troubleshooting 4 8 Service Diagnostics Menu Map Continued Menu Description Drum Maintenance Cam Shaft Deskew Shaft Wiper Shaft Tray 1 Pick Shaft Tray 2 Pick Shaft Tray 2 Lift Motor Cycles the motor shaft repeatedly Tray 3 Pick Shaft Tray 4 Pick Shaft Tray 3 Lift Motor Tray 3 Motor amp Shafts Tray 4 Pick Shaft Tray 4 Lift Motor Tray 4 Motor amp Shafts Cycles the motor shaft repeatedly If not installed generates an Option not detected message Exercise Heaters Menu Allows the heaters to forced to an ON or OFF condition or to be toggled from one condition to the other Also provide monitoring to observe the resulting heater power or temperature Monitor heaters Monitors heater power Monitor Temperatures Monitors heater temperature All Heaters On Turns all heaters On All Heaters Off Turns a
274. nexpectedly during printer imaging Tray 3 pick flag triggered unexpectedly while exiting print 1 Ensure ground integrity of the printer see page 4 65 2 Ensure the paper guides are correctly set 3 Run the Monitor Sensors test to test the media size sensor 4 Replace the 525 Sheet Feeder 5 Replace the pivot arm X3D X3E X3F X3L X3M X3N X3P X3Q X3R X3S X3T X3V X3 W 3 60 Tray 3 pick flag sensor timed out during warm up Tray 3 pick flag sensor timed out during wile printer ready Tray 3 pick flag sensor timed out while printer in fault state Tray 3 pick flag sensor timed out while printer in standby Tray 3 pick flag sensor timed out while picking from Tray 2 Tray 3 pick flag sensor timed out while picking from Tray 3 Tray 3 pick flag sensor timed out while picking from Tray 4 Tray 3 pick flag sensor timed out while picking from Tray 1 Tray 3 pick flag sensor timed out while duplexing Tray 3 pick flag sensor timed out while paper staged for print Tray 3 pick flag sensor timed out while transfixing the print Tray 3 pick flag sensor timed out while the printer Drum maintenance cycle was being performed Tray 3 pick flag sensor timed out while printer imaging Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued X3X Tray 3 pick flag sensor timed out while exiting print 1 Verify the paper loaded in Tray 3 is support
275. ng a font optimized for FAX Engine Copy Count Displays engine copy count Head Serial Number Displays the printhead serial number Head Cal Date Displays the date the printhead was calibrated Head Version Displays the printhead version Engine Firmware Version Displays the engine firmware version 2 Sided Printing Oil Chase Enables a chase page to follow a 2 sided printing job Envelope Oil Chase Enables a chase page to follow an envelope print job Center Image 8400 Centers the image by adjusting the margin not operational Exit Exits the Hidden Service Diagnostics Menu and returns to the previous menu Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 3 General Troubleshooting Service Diagnostics The printer has built in diagnostics to aid in troubleshooting Service Diagnostics provides tests for sensors motors switches clutches fans and solenoids Service Diagnostics also contains functions to report printer status and some NVRAM access Note Tests listed without a typical value range for 8400 8500 8550 8560 models indicates that no documented typical range exists Use the test to observe if the system being tested is capable of performing the desired tested action Service Diagnostics are executed through the Control Panel by a certified service technicians only Service Diagnostics are invoked one of two ways Entering Service Dia
276. ng this problem Did this correct the problem 7 Verify the Printhead is tilted forward against Complete the Drum in the proper print position Did this correct the problem Poor Primary Color Fills Primary fills appear banded and inconsistent Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Drum Temperature Sensor m Y Axis Encoder a X Axis Motor m Printhead D ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopgrstuvwxyzab ABCDEFGHIJKILMNOPQRSTL K abcdefghijkimnoparstuvwxyz s8500 039 5 18 Phaser 8400 8500 8550 8560 Color Printer Service Manual Poor Primary Fills Troubleshooting Procedure Print Quality Troubleshooting Step Questions and Actions Yes No 1 Banded and inconsistent primary fills may Complete Go to Step 2 indicate a missing weak or discolored jet 1 Print the Weak Missing Jet test print 2 If there are discolored jets print the Solid Fill test print in the affected color Did this correct the problem 2 1 Test the Y Axis Encoder Go to Step 3 Clean the 2 Run the Service Diagnostics Y axis Drum encoder Encoder test or replace the Is the Y axis encoder working properly Drum Assembly 3 If the bands are uniform or in a corduroy Goto Step 4 Replace the X pattern check X Axis motion See
277. nition 8400 8550 8560 Actions 0 Tilt Engage Cap 10 to 600 50 to 550 Reports the distance from the Position min cap Home position to the tilt cam engage point 1 Pre Standby Peak 325 to 125 to 10 Reports the distance around Location 3100 the tilt cam from the tilt engage position to the pre standby peak Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 35 General Troubleshooting 4 36 Tilt Drive Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 2 PreStandby peak 5100to 150to Reports the pm motor Magnitude pm 500 20 following error at the pre ticks standby peak location 3 Post Wipe Peak 1400 to 450 to 150 Reports the distance around Location 4150 the tilt cam from the tilt engage position to the post wipe peak 4 Post Wipe peak 4000 to 130 to 25 Reports the pm motor Magnitude pm 75 following error at the post ticks wipe peak location This test raises the lift plate to verify motion and sensor operation If the test is requested for a tray not installed an Option Not Detected message appears Tray 2 Tray 3 Tray 4 Lift Plate Drive Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Tray Configuration Reports the tray status present plate not lifted etc See Paper Path Status test for a description of the
278. nk Circle one No ink ina reservoir indicates that an ink level sensor has failed Step Has the printer If YES replace the wiper assembly Proceed to Step 9 5 had a printhead YES replaced before NO The new wiper assembly may take 6 purges to before achieving optimal for a non NXI performance Ensure the wiper assembly is correctly aligned with the related weak or Circle printhead missing jet one If the missing jet s recovers the repair is complete problem A 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference Step Is the Is the wiper assembly out of alignment not parallel with the printhead 6 Cap Wipe YES faceplate Purge assembly NO If YES perform the wiper alignment procedure as described in the correctly Phaser 8400 8500 8550 Color Printer Service Guide aligned Circle one Step Print Service Is there color mixing from one row to the next row for the same jet 7 Test Print 2 YES Note Some color mixing is normal following a purge It Weak and NO usually clears after one or two prints Missing Jets If YES replace the wiper assembly Repeat Step 6 Is severe color Circle mixing ong apparent Step Visually check Are there streaks smudges or a scum of wax in the jet area outlined in 8 the printhead YES red of the printhead faceplate Is NO Examplevof Bad Wipe Action the faceplate 2 a contaminated Circle EN aM Tale one I Wy o E
279. nk on White Portion of Print Color on the 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 Drum Maintenenace Kit may be the problem Printing on recycled or 3 hole punch paper commonly causes this problem Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade a Drum Maintenance Kit m Preheater Transfix Roller ABCDEFGHIJKLMNOPQRSTUV abcdefghijklmnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab 8500 037 Ink on White Portion of Print Troubleshooting Procedure Step Questions and Actions Yes No 1 Try printing using a smoother higher quality Complete Go to Step 2 paper Some recycled brands are too rough Watermarked or 3 hole punched paper may also cause this problem Did this correct the problem 2 Clean the Drum Maintenance Kit wiper Complete Go to Step 3 blade If necessary replace the kit Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 15 Print Quality Troubleshooting Ink on White Portion of Print Troubleshooting Procedure Continued Step
280. not find a solution to the described home motion profile Could not allocate memory for X Axis move parameters a Reset NVRAM and then retest b Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 3 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual 7 0XX 4x Errors Process Motor Gearbox Faults Error Messages and Codes 7 002 44 There is a problem with the process motor sub system The process motor stalled during operation Troubleshooting Procedure for 7 002 Error Code Step Questions and Actions Yes No 1 Verify the Process Drive system is properly Complete Go to Step 2 homed see Homing the Process Drive Train on page 6 8 Did this resolve the problem 2 Use Service Diagnostics to run the Tilt Axis GotoStep3 Goto Step 4 Drive test Did the test fail 3 1 Check for and remove any obstructions in Replace the Go to Step 4 the Process Drive Process Drive 2 Ensure the Process Drive gears are correctly aligned Are the gears damaged 4 Use Service Diagnostics to run the Process Replace the Go to Step 5 Motor test Process Drive Did the test fail 5 Use Service Diagnostics to run the Transfix Verify the Replace the Drive Slow test transfix cams Process Did the test fail are not Drive damaged Replace problem component 7 006 xx The Head Tilt Solenoid is not activating the Head Tilt Gear or the Printhead is not tilting properly T
281. ns 3 7 1 000 4x Errors 525 Sheet Feeder Faults 00 ccc cece eee eee eee eens 3 8 1 0XX 6x Errors 525 Sheet Feeder Program Faults 0 0 0 0 0c ccc nauuna nananana 3 8 2 0XX 4x Errors I O Circuit Board Fault 0 0 cc cece a 3 9 2 0XX 6x Errors I O Board Program Faults 0 0 0 ccc ccc cee cece eee n nee aee 3 9 3 0XX 6x Errors IPC Program FaultS 2 0 cc een eee cence A 3 10 4 0XX 4x Errors Process Control System Fault 0 0 0 cece 3 10 4 0XX 6x Errors Process Control Software Fault 0 0 00 c cece eee eee eens 3 12 5 0XX 4x Errors Y Axis Sub System Fault 0 0 00 e ence nnn eee 3 13 5 OXX 6x Errors Program Faults 2 eee ence een e nee nees 3 13 6 0XX 4x Errors X AxiS Fault 0 cc tenn eee teen eee n nes 3 14 6 0XX 6x Errors Program Faults 0 ce ence een e beeen ene ees 3 14 7 0XX 4x Errors Process Motor Gearbox Faults 0 00 00 cc eee eee een 3 15 7 0XX 4x Errors Printhead Tilt Faults 00 cee ence teen eee 3 16 7 0XX 6x Errors Program Faults 0 cee nee een e beeen nee 3 20 8 0XX xx Errors Wiper Media Drive Faults 00 0c ccc ee ee nee e eee nee 3 21 8 0XX 6x Errors Program Faults 2 eee eee n een e eens 3 22 9 0XX xx Errors Ink Loader Faults 00 0 cc cece ee teen nent e teen eens 3 23 9 009 44 and 9 00X 6x Errors Program Faults 0 2 cee ence nen eee 3 24 11 0XX xx Errors Electronics Module Interface Fault 0 0
282. nt Complete Go to Step 3 will have the worst ghosting Some Transfix Roller ghosting is inherent to the printer but will improve with multiple prints Does this correct the problem 5 20 Phaser 8400 8500 8550 8560 Color Printer Service Manual Ghosting Troubleshooting Procedure Continued Print Quality Troubleshooting Step Questions and Actions Yes No 3 Inspect and clean the Drum Maintenance Kit wiper blade If necessary replace the kit Did this correct the problem Complete Go to Step 4 Test Drum maintenance operation 1 Run service diagnostics to verify the Drum maintenance system is operating correctly 2 Check and if necesary replace these parts check for cracking Drum Maintenance Pivot Plate Drum Maintenance Camshaft Did this correct the problem Complete Go to Step 5 1 Test the Drum Temperature Sensor with Service Diagnostics 2 Check that the Drum Termperature Sensor is clean and properly positioned Did this correct the problem Complete Replace the Drum Temperature Sensor Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 21 Print Quality Troubleshooting Poor Small Text Resolution Small characters appear heavy and plug up Initial Actions m Check the media used is supported by this printer m Check that the paper path is clean and clear of debris Troubleshooting Reference Applic
283. nter Service Manual 4 67 General Troubleshooting Paper Path and Media Based Problems For paper path and media based problems first check the displayed error codes using the Error Code Definition Table beginning on page 3 7 to help determine where the error is occurring Run paper path diagnostics to help eliminate problems with printer components Media Based Problems 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 Control Panel Ensure the printer is operating under the right environmental conditions see Section One for more information Ensure the correct weight of paper is being used Ensure that envelopes are of an acceptable size and oriented with the flap up for Tray 1 and the flap down for Trays 2 3 and 4 Ensure that the correct media is in the correct media tray The paper guides indicate to the printer the size of media being used Ensure that the media guides in the tray are set correctly Inspect the paper for bent torn or folded corners Check to ensure no small pieces of paper are in the paper path Run the paper path status test in service diagnostics to ensure all sensors are operating correctly Try printing from a fresh unopened ream of paper Pick Errors Trays 2 3 and 4 Pick errors occur when the media in the media tray mispicks or the printer double pick
284. nthead smoothly and evenly during printing vertical lines appear on the print Initial Actions m Check the media used is supported by this printer m Check that the Printhead is free to move in the horizontal direction Troubleshooting Reference Applicable Parts Example Print ad a X Axis Motor ES COLD REDE Gi S CLIN CP SHFESE TILE abodefghijkimnoperetuwweyzak ABCDEFGHIJKLMN OP OIS TILU alkedetahiikimnoreirstiuwwvzak s8500 046 5 30 Phaser 8400 8500 8550 8560 Color Printer Service Manual White Stripes Troubleshooting Procedure Print Quality Troubleshooting Step Questions and Actions Yes No 1 Print the Solid Fills test print to reveal an X Goto Step 2 Complete axis problem See Primary Solid Fills 10x The problem on page 5 40 for more information is not with the Are the pinstripes apparent on the prints print engine 2 Check X Axis motion and verify there is Complete Go to Step 3 nothing interfering such as a poorly dressed cable or screw Replace any defective parts Did this correct the problem 3 Check that there are no harnesses Complete Replace the interfering with the Printhead Repair or X Axis Motor replace any defective part or interference with the Printhead Did this correct the problem Wrinkling Damage is usually in a corner with solid fills This problem is more often seen on short grain media Some wrinkling on envelope f
285. o Step 2 run the solid fill test print for the color displaying the discolored jets NOTE For instructions on printing solid fill test prints see Black Red Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Purge the Printhead up to 3 times If improvement is seen the ink could be discolored Did this correct the problem 2 Clean the Drum Maintenance Kit wiper blade Complete Go to Step 3 or replace the kit Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 9 Print Quality Troubleshooting Color is Uneven or Wrong Troubleshooting Procedure Continued Step Questions and Actions Yes No 3 Check thermal regulation of the Drum Go to Step 4 Go to Step 5 Run the Service Diagnostics Drum Thermal Check test see Temperature Status on page 4 47 Are the Drum thermal values out of the appropriate range 4 Check the Drum Fan for correct installation Go to Step 5 Replace the and operation Drum Fan 5 Check that the Drum Temperature Sensor is Complete Replace in the in contact with the Drum following Clean or replace the Drum Temperature order Sensor Drum Did this correct the problem Heater Relay Board m Drum Assembly m Electronics Module 5 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Streaks or Lines Down the Print Print Quality Troubleshooting There are sever
286. o Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Ensure ground integrity see Ensuring Goto Step 3 Resolve Ground Integrity on page 4 65 ground Are all components grounded properly integrity 3 Is the error code associated with an Goto Step 4 Goto Step 6 overheat condition 4 Verify clearance for adequate air flow Advise Go to Step 5 Are any of the vents blocked customer 5 Using Service Diagnostics run the Drum Goto Step 6 Replace the Fan Motor test Drum Fan Did the test pass and or the harness 6 Check the Electronics Module Fan Goto Step 7 Replace the Is the fan operating correctly Electronics Module Fan 7 Using Service Diagnostics run the Drum Goto Step 8 Replace the Temperature Sensor test Drum Did the test pass Temperature Sensor 8 Using Service Diagnostics run the Drum Replace the Heater test Drum Did the test pass Temperature Sensor 9 Check continuity of the F0130 fuse on the Replace the Preheater Preheater Is the fuse blown Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 27 Error Messages and Codes 3 28 13 067 43 The Drum Temperature Sensor circuit is open 13 069 45 The Drum Temperature Sensor circuit is shorted 13 071 47 The Drum Temperature Sensor returned a bad reading or the reading was corrupted by ESD Electrostatic Discharge Troubleshooting Procedure for 13 067 to 13 071 Error Co
287. o determine the paper trailing edge bounce interval at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected Duplex Paper Sensor Bounce Times Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 7 Exit Bounce Reports the interval during Interval us which the Exit sensor bounces following the passage of the paper trailing edge during duplex turnaround 8 Duplex Deskew Reports the interval during Bounce Interval which the Deskew sensor us bounces following the passage of the paper trailing edge 9 Duplex Preheat Reports the interval during Bounce Interval which the Preheat sensor us bounces following the passage of the paper trailing edge 10 Duplex Strip Reports the interval during Bounce Interval which the Strip sensor us bounces following the passage of the paper trailing 11 Duplex Exit Bounce Reports the interval during Interval us which the Exit sensor bounces following the passage of the paper trailing edge Phaser 8400 8500 8550 8560 Color Printer Service Manual Check Drive Menu General Troubleshooting This test moves the wiper drive mechanism through the complete range of its motion in each direction and does an on the fly reversal to verify operability Wiper Drive Typical Typical Value Value 8500 R
288. olt under limit Power supply 2 5 volt over limit Power supply 2 5 volt under limit Power supply 3 3 volt over limit Power supply 3 3 volt under limit Power supply 12 volt over limit Power supply 12 volt under limit Power supply 12 volt over limit Power supply 12 volt under limit Power supply current over limit Power supply current under limit Power supply 50 volt over limit Power supply 50 volt under limit Power supply 50 volt over limit 8500 8550 8560 PEST Description The power supply did not reset properly Reset may be disconnected Power supply 2 5 volt over limit Power supply 2 5 volt under limit Power supply 3 3 volt over limit Power supply 3 3 volt under limit Power supply 12 volt over limit Power supply 12 volt under limit Power supply 12 volt over limit Power supply 12 volt under limit Power supply current over limit Power supply current under limit Power supply 50 volt over limit Power supply 50 volt under limit Power supply 50 volt over limit Phaser 8400 8500 8550 8560 Color Printer Service Manual 37 056 47 37 057 48 37 058 40 37 059 41 37 060 42 37 061 43 37 062 44 37 063 45 37 064 46 37 065 47 37 066 48 8400 PEST Description Power supply 50 volt under limit Power supply 15 volt over limit Power supply 15 volt under limit Power supply 15 volt over limit Power supply 15 volt under limit Power
289. om the jets into the ink Waste Tray A proper purge will layer the length of the Waste Tray with a single layer of ink about 20 mm wide The level of the ink in the reservoir is kept at a constant level If the purge tubing is pinched the Printhead may not purge properly In addition because the purge tubing also acts as a vent to atmosphere when not purging a more serious failure may occur if the ink overfills Overfilling may trap air in the reservoir which would prevent the melted ink from entering the reservoir 2 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Warning When servicing the printer be careful of the purge system as it passes the Printhead If a damaged Wiper Blade catches on the Printhead it could propel hot liquid ink upward into your face Solenoid Valve ee aa Open During Wiper Action Wiper Printhead 8500 018 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 15 Theory of Operation Drum Assembly And Transfix System 2 16 The Drum Assembly and Transfix Module form the key portion of the printer where imaging takes place The Drum Assembly and Transfix Module are separate yet interrelated This section discusses the Drum The next section provides more detail on the Transfix Module In operation the image is rendered on the rapidly rotating drum The Preheater heats the media to prepare it for the image transfer process The hea
290. on last power down If printhead and wiper are in contact the printhead warms first before moving If the printhead was parked the printhead is warm Start the Thermals 13 xxx Unbind Media Path Motor and Home the MPT 31 000 Home the Y Axis 5001 5004 before moving to the print position The dashed line traces what happens if the printhead was parked on last power down Wait for the Head to read OK_TO_WIPE YES Is the head tilt Cam engaged head tilted Temperatures 13 xxx The RED numbers indicate errors that may be displayed at that point in the mech init process Home the CAP wiper without disengaging the Head Tilt Cam 8005 8007 8008 8009 Move XA to HEAD TILT POSITION 6000 8500 029 4 52 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Mechanical Initialization 8400 2 2 home Dmfix 4024 Wiper Alignment Failed 8021 Pump Uninitialized 5003 Warmup will be responsible for Rehome XA moving the head to the print position 6000 after the wipe and purge are performed 8500 030 If not in non thermals Oil Drum 4 times Others Thermal Faults ECM Faults HC PM Faults oiling drum RECOVERY ROUTINE one nee ne ieres YES ses 1 aa I Pa a I at a Home Dmfix a 77 head Parked On s NO 7002 e eg s _Last Power Down ge Try to recover
291. or Printer Service Manual 4 65 General Troubleshooting Key Ground Connections Transfix Roller 0 Board DM Ground Ground Springs und PI p SNT The following illustration shows the grounding points in the printer X Axis Motor sre Zi NU aS D OO N A Y A OI Q VYKON AA W a A Ta X WA X Axis Return ac Spring Ground Y Axis Motor Media Path Drive Ground Ground 8500 032 Phaser 8400 8500 8550 8560 Color Printer Service Manual Testing Motor and Solenoid Resistances General Troubleshooting 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 Motor and Solenoid Resistances Motor or Solenoid Resistance Approximate Process Drive motor 4 3 ohms 15 Difficult to measure due to variability at the brush commutator interface Y Axis Motor 1 4 ohms 15 Difficult to measure due to variability at the brush commutator interface X Axis Motor 12 5 ohms phase red to yellow and blue to orange Media Path Drive motor 1 5 20 ohms Wiper drive clutch 186 ohms 15 Paper pick clutch Deskew clutch 186 ohms 15 MPT Pick solenoid 124 ohms 5 Phaser 8400 8500 8550 8560 Color Pri
292. or are unused depending on the pick tray and if simplex or duplex path was selected Duplex Paper Trail Edge Times R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Exit Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the duple pick process until the Exit sensor deactivates Duplex Deskew Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the transfix process until the Deskew sensor deactivates part way through the paper transfix motion Duplex Preheat Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the transfix process until the Preheat sensor deactivates part way through the paper transfix motion 10 Duplex Strip Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the exit process until the Strip sensor deactivates part way through the paper exit motion 11 Duplex Exit Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the duplex pick process until the Exit sensor deactivates Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 29 General Troubleshooting 4 30 Paper is picked and moved through either the duplex paper path t
293. or broken or wrong type ink replace the ink sticks stick 2 Replace the Ink Loader 3 Run Clear ISC Fault test to clear the error Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 23 Error Messages and Codes Troubleshooting Procedure for Ink Loader Continued Step Questions and Actions Yes No 3 Test the Ink Count Sensor by running Check for Replace the Ink the Monitor Sensors test in Service defects inthe Loader Diagnostics genuine Ink Insert the clean eraser end of apencil Sticks If no thru the lowermost oval slot inthe Ink defects are Loader Actuate the appropriate sensor found go to by sliding the pencil down the white Step 4 channel guide until the sensor is Replace ink if tripped If the sensor is functional a necessary state change appears on the Control Panel as lt co or gt Ink Present H When released the reading changes to L The test only displays a reading when a sensor change occurs If a flag is stuck no reading is displayed Did the test pass 4 _ Test the ink melt heaters Replace the 1 Replace the Ink Run the appropriate Ink Melt 1 2 3 Printhead Loader 4 Heater test 2 Run Clear ISC 1 Yellow Fault test to clear 2 Cyan the error 3 Magenta 4 Black Did the test pass Note Xerox is not financially responsible for the incorrect operation of its products caused by the use of non Xerox ink 9 009 44 and 9 00X 6x Errors Program Faults 9 009 44 Thi
294. or ink spills 3 Re route the wiring 4 Clean around the gears and Printhead Did this correct the problem Complete Go to Step 2 To ensure Process Drive is correctly aligned homed and free from damage see Homing the Process Drive Train on page 6 8 Did this correct the problem Complete Replace the Process Drive 7 008 41 The head tilt is not engaged or the Printhead is stuck in the tilt position by the tilt arms Troubleshooting Procedure for 7 008 Error Code Step Questions and Actions Yes No 1 Reboot the printer Goto Step 2 Complete Did this correct the problem 2 1 Check the printer for ink spills on the Complete Go to Step 3 HeadTilt Gear and the drive train 2 Clean and reboot the printer Did this correct the problem 3 Check that the Printhead moves properly left GotoStep4 Remove any and right obstructions or replace any defective parts 4 Ensure the Process Drive is correctly Replace the Go to Step 5 aligned and homed see Homing the Process Drive Process Drive Train on page 6 8 Are the gears damaged 5 1 Check the Process Drive for obstructions Replace the Go to Step 6 or damaged Process Drive 2 Remove any obstructions Is the gearbox damaged 6 Use Service Diagnostics to run the Tilt Axis Replace the Go to Step 7 Drive test Process Drive Did the test fail 7 Use Service Diagnostics to run the Head Replace the Go to Step 8 Maintena
295. or menu prints an information page Information gt Model Printer Name IP Address amp Menu M iki Serial Printer Identification gt Activation Date Information Pages Sample Pages gt Supplies Info p t Maintenance Kit Life Total Print Count Billing Meters gt Serial Total Impressions Color Impressions Black Impressions Paper Tray Setup a Tray 1 Setup gt Tray 2 Paper Type gt aye nanentyne Optional lower trays Tray 4 Paper Type gt Paper Handling Setup gt Paper Source 2 Sided Printing Load Paper Timeout Tray 1 Prompt Letter A4 Substitution Custom Units Requires Cleaning Page Source i Networked printer Reset Paper Handling Setup Duplex Unit Hard Drive A 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual E amp Configuration Page amp Paper Tips Page amp Connection Setup Page amp Startup Page amp Usage Profile amp PostScript Font List amp PCL Font List Graphics Demonstration Office Demonstration 2 Sided Demonstration Print Mode Demonstration amp CMYK Sampler Pages RGB Sampler Pages 5 Configuration Page PostScript Setup gt PCL Setup gt Control Panel Setup gt Connection Setup gt amp
296. ot drawing the drawing the expected power expected power Check to see if the from the supply ink melter s AC cable is connected Inkmelt 1 Cyan disconnect Inkmelt 0 Yellow disconnect The The inkmelt heater is not inkmelt heater is not drawing the drawing the expected power expected power from the supply from the supply Inkmelt 2 Magenta Inkmelt 1 Cyan disconnect The disconnect The inkmelt heater inkmelt heater is not drawing the is not drawing the expected expected power from the supply power from the supply Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 37 Error Messages and Codes 3 38 8400 PEST Description 8500 8550 8560 PEST Description 37 012 48 Inkmelt 3 Black disconnect Inkmelt 2 Magenta disconnect The inkmelt heater is not The inkmelt heater is not drawing drawing the expected power the expected power from the supply 37 013 40 from the supply Inkmelt 3 Black disconnect The inkmelt heater is not drawing the expected power from the supply Troubleshooting Procedure for Heaters Step Questions and Actions Yes No 1 Check the wiring running from the problem Replace Go to Step 2 component to the Printhead the wiring Is the wiring damaged harness 2 Run the appropriate diagnostic test Replace the 37 002 47 Left Jetstack Heater Printhead 37 003 48 Right Jetstack Heater 37 004 40 37 005 41 Reservoir Heaters Did the test pass 3 Run the app
297. ound to be damaged by e Provide the customer with the Diagnosis Form generic ink the customer will be billed and Onsite Failure notification letters e Provide the customer with the Customer Alert e Once payment has been authorized or assured 8 March 2005 letter replace the printhead and included ink per e Ifthere are weak or missing jets replace the normal procedures printhead and included ink per normal e Check the Non Xerox Tektronix Ink box on procedures the Green tag e Check Non Xerox Tektronix Ink box on the e Enclose all sample prints including two prints Green tag of Service Print 1 ink samples waste ink and e Enclose all sample prints including two prints this checklist with the printhead of Service Print 1 ink samples waste ink Xerox Personnel Please provide full documentation and this checklist with the printhead in FIST Xerox Personnel Please provide full documentation in FIST IN EITHER CASE PLEASE NOTE ADDITIONAL GENERIC INK INFORMATION e Was generic ink or related packaging observed YES NO e Was generic ink present in the ink loader YES NO IMPORTANT Note the brand and lot code of the generic ink if available Xerox Phaser 8400 WorkCentre C2424 Printhead Checklist 075 0882 02 Page 5 A 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference On site Printhead Troubleshooting Checklist 8500 8550 8560 PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8500 8
298. oves oil and drains it back into the maintenance kit drawer through a felt filter The oil roller can then reuse the oil As the Drum completes one rotation the rotating cam lowers the oil roller and then lowers the blade The Drum has a floating deadband the narrow section of the drum containing excess oil and other debris The oil bar is left on the drum surface when the blade is removed from the drum This oil bar location is controlled to keep it outside of the print area An EEPROM chip built in to the Drum Maintenance Kit stores the number of oiling cycles performed and the number of prints remaining to track consumable life At printer startup four oiling cycles condition the Drum _ Drum Oil on Drum Drum Maintenance i Maintenance Roller Camshaft Drum Maintenance Pivot Plate s8500 016 After replacing the Process Drive Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft or any component requiring removal of the Process Drive the printer may experience Front Cover jams from Tray 2 The jam occurs with paper in the Preheater and C3T jam errors strip flag timeout during transfix recorded in Jam History In many cases Tray 1 MPT prints with no jams These symptoms indicate that the Transfix Load Module is incorrectly timed resulting in a late arrival of the leading edge at the strip flag The likely cause is the position of the Drum Maintenance Camshaft gear in relation to the Process Drive gear To correct thi
299. p 8560 269 Blank Prints Troubleshooting Procedure Step Questions and Actions Yes No 1 Check the area around the Printhead and Complete Go to Step 2 Drum for debris Clean if necessary Did this correct the problem 2 Complete the Printhead Troubleshooting Complete Go to Step 3 Checklist Did this correct the problem 3 Check all connections to the Printhead Complete Replace in Replace or repair any defective cables this order Did this correct the problem Electronics Module m Printhead 5 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Color is Uneven or Wrong This may be due to incorrect colors in the ink loader old ink in the Printhead color mixing at the faceplate or Drum thermal problems Using non Xerox ink may cause unpredictable color results Initial Actions m Check the media used is supported by this printer m Check that the Ink is Genuine Xerox Troubleshooting Reference Applicable Parts Example Print a Ink Sticks Drum Fan m Drum Heater Relay Board Drum Temperature Sensor m Electronics Module m Drum Assembly ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyzab ABCDEFGHIJKLMNOPQRSTUV abcdefghiikimnopqrstuvwxvzab 8500 034 Color is Uneven or Wrong Troubleshooting Procedure Step Questions and Actions Yes No 1 To remove discolored jets in the Printhead Complete Go t
300. p of eight major subsystems which are described in this section Process Drive Media Drive Ink Loader Printhead Drum Maintenance Kit Purge System Drum Assembly and Transfix Assembly Electronics Module The Process Drive Transmits torque to two camshafts The Transfix Camshaft controls the Transfix Roller loading and the Drum Maintenance Camshaft actuates the Drum Maintenance Kit and Printhead tilt system The Media Drive Controls each roller in the media transport path The Media Drive consists of a drive motor a gearbox two clutches and a solenoid The Media Drive motor also controls the movement of the Wiper Blade and headlock mechanism through a gear train and solenoid on the Exit Module Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation The Ink Loader Stores and melts the ink The melted ink drops into the Printhead ink reservoirs underneath the ink loader The Printhead Delivers ink onto the drum surface to create an image The Printhead includes 1236 interleaved jets 309 of each primary color to provide the ability to electronically turn off a weak or missing jet to restore image quality The Drum Maintenance Kit Creates a thin layer of silicone oil on the surface of the Drum prior to printing The oil keeps the ink from sticking to the Drum s surface and facilitates image transfer to the media The Purge System Uses air pressure and a wiper blade to remove any debris or air bu
301. page 5 3 Smudges or Smears Smudges or smears appear on the page The likely cause is ink residue in the media path Check for residue on the rollers Stripper Blade guide ribs or inside the Preheater High coverage images with small margins may leave ink debris on the Stripper Blade which is then re deposited on other pages This condition usually self corrects the debris is cleaned off the blade by lower coverage images Note To avoid future problems remind the customer to select 2nd Side as the paper type if manually printing duplex with preprinted solid ink images on the reverse This reduces Preheater temperatures to prevent partial melting of the preprinted image Initial Actions m Check that the media used is supported m Run the Remove Print Smears routine from the Control Panel m Check the exit path for debris or contamination Troubleshooting Reference Applicable Parts Example Print Drum Maintenenace Kit Drum Maintenance Pivot Plate Drum Maintenenace Camshaft m Preheater Stripper Carriage Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 5 Print Quality Troubleshooting Smudges or Smears Troubleshooting Procedure Step Questions and Actions Yes No 1 Clean the exit path including the Stripper Complete Go to Step 2 Blade with a lint free cloth Did this correct the problem 2 1 0n the Control Panel select Info
302. per otherwise the print appears mottled Causes Use the diagnostics to check the Printhead and Drum for correct thermal regulation Ensure the Drum Fan is running properly A vertical band 1 3 of a page wide running the length of the page is caused by a stuck heating plate in the paper preheater Run the Clean Print Smears procedure 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 Ib through the paper preheater to jar the plate free Light spots that repeat every 11 63 cm 4 58 in down the length of the page are caused by a defective transfix roller The roller has a soft spot that is not pushing the ink into the paper as well as the rest of the roller If you observe variations in the glossiness of the print replace the maintenance kit If there is ink on the top and bottom margin of the page or ink on the back of the page it may be caused by the roller remaining down during the print You may hear an unusual noise if the Transfix Roller stays down and rubs against the Drum Inspect the Drive Train and ensure that it self homes between prints The drive train is in its home position when the two 1 5 mm holes found on the clear plastic cover align axially with corresponding holes in the gear Another way to verify that the drive train is in its home position is to verify that the two small leaf springs from the clear plastic cover
303. per stall point at which the head lock latch releases 10 Lock Disengage 800 to 30 to 1 2 Reports the peak following Peak uin 150 error at the point the latch releases Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 31 General Troubleshooting 4 32 Wiper Drive Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 11 Bottom Encounter 2500 to 4250 to Reports the distance up from Distance uin 1800 3900 the upper limit of travel at which the wiper first encounters the lower travel limit 12 Turnaround 0 001 to 0 05 to 35 Reports the time following the Recovery time 0 250 start of the turnaround motion sec that the motion drive error return to normal in the opposite direction This test moves the gear train in one direction while capturing data does a reversal to capture reversal transient data then operates in the other direction Paper Path Drive Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Forward Drive 1 0 to 4 0 Reports the average drive Power Level power level in the foreword watts direction 1 Up Motion Drive Oto 1 5 Reports the average drive Error Ripple watts ripple level in the forward direction 2 Reverse Drive 4 0 to Reports the average power in Power Level 1 0 the reverse direction watts 3 Down Motion Drive Oto
304. perimeters are for the actual connectors Some have extra n c pins added to prevent misplugging errors 1 0 color coding Black input Magenta output Red temp 8500 124 10 3 Right Side Wiring Diagram 10 4 The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel J400 Drum Heater J110 Waste Tray 2 I lt Wiring Harness Ground Clip P GX ON Pass Through XO l 3 gt ews YZ Gs J610 No me ZS K 2 Va Ns 37006 4x KK K Drum Heater anit N X Pre heater g SN S r X Drum AC is routed thru pre heater prior to relay board and drum f 5002 42 37014 4x Drum Fan 8500 125 Phaser 8400 8500 8550 8560 Color Printer Service Manual Right Side Wiring Diagram Continued The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel Routes to Top of Channel 13387 4x J4AC 37006 4x N J800 Dead J400 37027 4x i J Signal Cable 37027 4x X Motor Ribbon Cable Routed in Routed on Middle of Channel Bottom of Channel 8500 126 Phaser 8400 8500 8550 8560 Color Printer Service Manual 10 5 Left Side Wiring Diagram The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel 37023 4x Purge V
305. press the Back button to bypass the remaining POST test Low level Power On Self Test POST diagnostics are performed The Control 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 Control Panel displays the Xerox logo and turns on the green LED If the test detects an error the error message displays 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 Print Engine Self Test PEST diagnostics are then performed These test the heaters clutches motors and solenoids As each clutch is tested you hear clicking with four high tones as each motor is tested This test takes about 30 seconds The printer now runs the mechanical initialization The exact sequence depends on the initial position of the printhead and wiper assembly Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 51 General Troubleshooting Mechanical Initialization 8400 1 2 Start Mechanical Recovery Set FIRMWARE states CapState UNKNOWN Head Tilt State UNKNOWN DmfixState UNKNOWN YaState HOMELESS Xa State HOMELESS Mechanical Recovery POWER ON Values in the NVRAM are used to determine if printhead and wiper have contact or if the head was parked
306. print Tray 4 pick flag triggered unexpectedly while transfixing the print Tray 4 pick flag triggered unexpectedly while the printer Drum maintenance cycle was being performed Tray 4 pick flag triggered unexpectedly during printer imaging Tray 4 pick flag triggered unexpectedly while exiting print 1 Ensure ground integrity of the printer see page 4 65 2 Run the Monitor Sensors test to test the media size sensor 3 Replace the 525 Sheet Feeder 4 Replace the pivot arm Z3B Z3D Z3E Z3F Z3L Z3M Z3N Z3P 230 Z3R Z3V Z3W Z38 Z3T Z3Z Tray 4 pick flag sensor timed out during normal shutdown Tray 4 pick flag sensor timed out during warm up Tray 4 pick flag sensor timed out during wile printer ready Tray 4 pick flag sensor timed out while printer in fault state Tray 4 pick flag sensor timed out while printer in standby Tray 4 pick flag sensor timed out while pick from Tray 2 Tray 4 pick flag sensor timed out while pick from Tray 4 Tray 4 pick flag sensor timed out while pick from Tray 4 Tray 4 pick flag sensor timed out while pick from Tray 1 Tray 4 pick flag sensor timed out while duplexing Tray 4 pick flag sensor timed out while the printer Drum maintenance cycle was being performed Tray 4 pick flag sensor timed out while printer imaging Tray 4 pick flag sensor timed out while paper staged for print Tray 4 pick flag sensor timed out while transfixing the print Tray 4 pick flag sensor timed out whil
307. r 0 0 Paper at exit sensor 1 Tray 1 14 31 unused always 0 1 13 No media present 1 0 12 width value 2 3 4 Tray 2 3 and 4 9 31 unused 2 3 4 8 No tray 2 3 4 7 No paper 2 3 4 6 plate not lifted 2 3 4 5 Paper at tray pick sensor 2 3 4 4 media length top 2 3 4 3 media length bottom 2 3 4 2 Media width top 2 3 4 1 media width middle 2 3 4 0 Media width bottom 4 46 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting This test scans the thermocouples and reports data on the current temperature with the goal of providing a picture of the current temperature state of the printer All degrees are reported in Celsius Temperature Status Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Reservoir Temp 127 7 135 0 Reports the current temperature 1 Left Jetstack 134 138 Reports the current temperature 2 Right Jetstack 134 138 Reports the current temperature 3 Preheater Temp 20 70 Reports the current temperature 4 Drum Temp 60 60 Reports the current temperature 5 Ink Melt 1 Temp 50 50 Yellow usually off 6 Ink Melt 2 Temp 50 50 Cyan usually off 7 Ink Melt 3 Temp 50 50 Magenta usually off 8 Ink Melt 4 Temp 50 50 Black usually off This test determines if the purge pump system pump hose purge valve pr
308. r Unit RTC Charge Roller Note A note indicates an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action Caution A caution indicates an operating or maintenance procedure practice or condition that if not strictly observed results in damage to or destruction of equipment Warning A warning indicates an operating or maintenance procedure practice or condition that if not strictly observed results in injury or loss of life Caution A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area Danger A personal injury hazard exists in the area where you see the sign Phaser 8400 8500 8550 8560 Color Printer Service Manual iii Symbols Marked on the Product Read and obey all posted warning labels Throughout the printer warning labels are displayed on potentially dangerous components As you service the printer check to make certain that all warning labels remain in place Use caution or draws attention to a particular component Refer to the manual s for information injury Hot surface on or in the printer Use caution to avoid personal Power Safety Precautions Power Source For 115 VAC printers do not apply more than 135 volts RMS between the supply conductors or
309. r cracking Drum Maintenance Pivot Plate Drum Maintenance Camshaft Did this correct the problem Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Incomplete Image Transfer Troubleshooting Procedure Continued Step Questions and Actions Yes No 4 Check and clean the Drum Maintenance Kit Complete Go to Step 5 wiper blade Replace the kit if necessary Did this correct the problem 5 1 Test the Drum Temperature Sensor with Complete Go to Step 6 Service Diagnostics 2 Check that the Drum Termperature Sensor is clean and properly positioned Did this correct the problem 6 Is the incomplete image on the left and right Complete Go to Step 7 sides but fine through the center This indicates incomplete transfix cam rotation Check for a damaged Transfix Camshaft or a malfunction of the Process Drive replace any defective parts Did this correct the problem 7 Test the Preheater temperature Complete Replace the Does the Preheater operate within the Transfix Load normal operating range Replace the Assembly and Preheater if necessary TransfixLoad Did this correct the problem Arms Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 27 Print Quality Troubleshooting Ink Smears on First Printed Side of Auto Duplex Print Preheater temperature is too high Initial Actions Note For 8500 8550 8560 models only If t
310. r deactivates Tray 3 Pick 3 Tray 3 Pick Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the tray 3 pick process until the Tray 3 Pick sensor deactivates Tray 2 Pick 2 Unused 3 Unused Tray 1 Pick 2 Unused 3 Unused Common 4 Deskew Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the transfix process until the Deskew sensor deactivates part way through the paper transfix motion Preheat Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the transfix process until the Preheat sensor deactivates part way through the paper transfix motion Strip Trailing Edge Interval us Reports the interval from the time the engine software is commanded to start the exit process until the Strip sensor deactivates part way through the paper exit motion Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 25 General Troubleshooting Paper Trail Edge Times Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Simplex Path 7 Exit Trailing Edge Reports the interval from the Interval us time the engine software is commanded to start the duplex pick process until the Exit sensor deacti
311. r may experience Front Cover jams from Tray 2 The jam occurs with paper in the Preheater and C3T jam errors strip flag timeout during transfix recorded in Jam History In many cases Tray 1 MPT prints with no jams These symptoms indicate that the Transfix Load Module is incorrectly timed resulting in a late arrival of the leading edge at the strip flag The likely cause is the position of the Drum Maintenance Camshaft gear in relation to the Process Drive gear To correct this problem see Timing the Drum Maintenance Camshaft on page 6 9 Strip flag time out during transfix 1 Ensure media is correct size and type for the tray If envelope jam try a different style 2 Check the Drum Maintenance Kit for proper operation replace if necessary 3 Ensure the Process Drive is correctly homed see page 6 8 4 Ensure the Stripper Carriage moves freely run the Stripper Contact test 5 Run the Transfix Drive Slow and Transfix Drive Fast tests C3X Strip flag time out during exit 1 Open the Exit Cover and ensure the springs for the idler rollers are present and installed correctly they should be the same for all 5 rollers 2 Verify the metal bar is installed on top of the exit guide Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued C5X Print pulled back into transfix nip during exit 1 Ensure the media is not too thick
312. rable to damage by Electrostatic discharge ESD These components include Integrated Circuits ICs Large Scale Integrated circuits LSIs field effect transistors and other semiconductor chip components The following techniques will reduce the occurrence of component damage caused by static electricity Be sure the power is off to the chassis or circuit board and observe all other safety precautions Immediately before handling any semiconductor components assemblies drain the electrostatic charge from your body This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source Wearing a wrist strap will also prevent accumulation of additional bodily static charges Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock m After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surface If the anti static bag is conductive you may ground the bag and use it as a conductive surface Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices Donot remove a replacement component or electrical sub assembly from its protective package until you are ready to install it m Immediately before removing the protective material from the leads of a replacement device touch the protective material to the chassis or circuit assemb
313. re are three key restraining elements 1 The Printhead is restrained from rotating from the shipping position by pins extending from both ends of the Printhead into a pocket These pockets are defined by dampening pads that limit motion to the lockarms that pivot into the lock position limiting forward motion toward the drum The wiper carriage holds the locks in the lock position which are normally spring loaded in the unlocked position 2 The Printhead is restrained at the X Axis shafts by the right and left head restraints that limit motion at both ends of the Printhead 3 The Printhead is limited to the nominal motion of 1 7 mm in the X Axis left right side motion when the Printhead is back and locked by the right lock and the left home stop on the left side frame 2 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Printhead Restraint DM Cam Gear W amp In the print position 0 degrees the Printhead is forward and rests against the right and left head to drum buttons The head to drum buttons define the space between the jet stack and the drum When the Process Drive is activated it drives the Drum Maintenance Camshaft to engage the tilt gear train The tilt cam tilts the Printhead into the print position The cam is combined with a missing tooth gear that allows the cam to be inactive in the print position freeing the Process Drive to perform other printer operations The cam has
314. red in the printer A variety of test prints are available in the Hidden Service Menu to aid in determining the quality of output from the printer and to assist in troubleshooting problems To enter the Hidden Service Menu from the Service Tools menu press and hold the Up Arrow and Down Arrow buttons Note Defects revealed by the prints may not occur in the course of ordinary printing In servicing the printer you should minimize the defects shown by the prints but not necessarily eliminate them This print shows which jets are not outputting enough if any ink compared to its neighboring jets Note that the yellow jets bands have a small amount of cyan ink added to them which tints them green to make them more visible 8500 048 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 poorly performing jet If jet substitution mode is required see Jet Substitution Mode on page 6 9 Test the purge system and the wiper blade performance Turn the printer off for 4 to 6 hours or overnight if practical Then perform a clean purge cycle again There may be a problem in the Purge Pump or the Wiper Assembly Verify that Xerox ink
315. reheater may be scraping ink off the print 1 Look for ink shavings along the streaks on the printed paper 2 Clean the Preheater using the Remove Print Smears routine Did this correct the problem 5 Check for weak or missing jets Print the Complete Go to Step 6 weak missing jet test print see Weak Missing Jet on page 5 34 Did this correct the problem 6 Check for discolored jets Print the solid fill Complete Go to Step 7 test print see Black Red Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Did this correct the problem 7 Check X Axis drive motion Complete Go to Step 8 If the X Axis drive does not move the Printhead smoothly and evenly during printing vertical lines appear on the print See White Stripes Pinstripes on page 5 30 Did this correct the problem 8 Check the Preheater s temperature Replace the Replace the Smears on a duplex print can be caused by Preheater Electronics the preheater operating at a temperature Module that is too high or debris is in the Duplex Roller or duplex guides Run the Service Diagnostics Duplex Path test Is the operating temperature within the correct value range 5 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Scratches or Marks Parallel to the Long Axis of Printing Particularly with Film Scratches or marks are usually caused by debris
316. relief valve 4 Pumping Time To Reports the time from pump Max sec on until the pressure relief valve opens May indicate the conditions discussed in R3 as well as the system volume 5 No Pressure Reports the average pumping Pumping Power power after the pressure has watts fully decayed May indicate pump motor condition efficiency 6 Pressure Decay Reports the time between Time sec purge valve opening and the point when the pumping power relative to the current pressure fades back into the ripple of the no pressure pumping power see the R5 discussion above This time could indicate the operation of the purge valve and the condition of the bleed orifice plugged etc Phaser 8400 8500 8550 8560 Color Printer Service Manual This test determines averaged readings for key system voltages General Troubleshooting Voltages Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Main Board Voltages 0 5 Volts volts 5V 5V 1 1 8 Volts volts 1 8V 1 8V 2 2 5 Volts volts 2 5V 2 5V 3 3 3 Volts volts 2 5 2 5 4 unregulated12 20 20 Volts volts 5 2 5 Volts volts 2 5 2 5 6 unregulated 20 20 Negative 12 Volts volts Control Board Voltages 7 DC Power watts 8 50 Volts 47 to 52 47 to 52 9 Negative 50 Volts 47 to 52 4
317. ring which the Preheat sensor bounces following the passage of the paper trailing edge Strip Bounce Interval us Reports the interval during which the Strip sensor bounces following the passage of the paper trailing edge Exit Bounce Interval us Reports the interval during which the exit sensor bounces following the passage of the paper trailing edge Test picks paper from selected tray test currently supports picking from Tray 2 only and moves it through either the simplex or duplex paper path to determine paper path power requirements Duplex Paper Drive Power Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Tray Reports the tray from which the test paper was picked 1 Paper Size Reports the size of the picked paper 2 Unused 3 Unused 4 Tray 2 Pick Average Reports average of the power Power watts over the pick interval begin pick to Deskew sensor Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 27 General Troubleshooting 4 28 Paper is picked and moved through either simplex or duplex paper path to determine leading edge arrival time at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected Duplex Paper Lead Edge Times Typical Typical Value Value 8500 R Definition 8400 8550 8560
318. rinter Configure the new connection using the COM port configured in step 3 then click OK Set Bits per second to 19200 and set Flow control to Hardware then click OK 7 From the Hyper Terminal tool bar click on Transfer and select Capture Text Click on Browse and in the browse window navigate to the location where you wish to save your diagnostic results Enter a file name for your trace and click Save 8 Turn on the printer and monitor the backchannel trace 9 The back channel trace should appear in the Hyper Terminal window When you have captured the necessary trace data click Transfer gt Capture Text gt Stop to end data capture This data is saved as a text file to the location specified in step 7 Fax or email this data to EHS for help with troubleshooting problems on power up or other out of the ordinary problems where normal diagnostics may not run Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 75 General Troubleshooting 4 76 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Quality Troubleshooting Print Quality Problems Overview Chapter 5 Print Quality Troubleshooting Print Quality Problems Overview Print quality defects can be attributed to printer components consumables media internal software external software applications and environmental conditions To successfully troubleshoot print quality problems as many variables as possible must be elimin
319. rmation Go to Step 3 Complete gt Troubleshooting gt Print Quality Problems 2 Select Remove Print Smears and then press the Enter button This cleans ink from the Preheater and Exit Rollers 3 Reprint test pages Did this correct the problem 3 1 Repeat Step 2 up to 3 times if the smears Complete Go to Step 4 persist 2 Open a fresh ream of supported paper and reprint the test page Did this correct the problem 4 Remove the Drum Maintenance Kit and wipe Complete Go to Step 5 the clear plastic wiper blade with a lint free cloth Did this correct the problem 5 Manually clean visibly dirty feed rollers and Complete Go to Step 6 the Stripper Blade Did this correct the problem 6 1 Check the Drum Maintenance Pivot Plate Complete Replace the for damage Preheater 2 Check the Drum Maintenenace Camshaft rollers are working properly 3 Replace any damaged or defective parts Did this correct the problem 5 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Print Too Light or Too Dark The overall image density is too light or dark Initial Actions Print Quality Troubleshooting m Check the media used is supported by this printer m Check the media settings are correct at the Control Panel Troubleshooting Reference Applicable Parts Example Print a Ink Sticks a Media ABCDEFGHIJKLMNOPQRSTUV abcdefghijkimnopqrstuvwxyza
320. rom the left side of the printer when the arrows are not aligned the tilt gear is engaged Head Tilt Compond Gear Tilt Gear Engaged Tilt Drive Gear 8500 133 To accommodate Printhead maintenance the Printhead is tilted back away from the Drum This creates room for the Wiper Blade to move into position in front of the Printhead faceplate The Process Drive drives the gears to the tilt compound gear train The Drum Maintenance Camshaft drives the gear train to tilt the Printhead 2 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Drum Maintenance Kit The Drum Maintenance Kit creates a thin layer of silicone oil on the surface of the Drum prior to printing The oil keeps the ink from sticking to the Drum s surface and facilitates image transfer to the media The oil is contained in porous foam rollers made from rolled paper fiber material Prior to each print the Process Motor drives the Drum Maintenance Camshaft to raise the Drum Maintenance Pivot Plate which raises the oil roller against the rotating Drum The same camshaft raises a wiper blade to assure that the oil film is smooth and even across the Drum s surface The Process Drive rotates in one direction This rotates the Drum Maintenance Camshaft and raises the drum maintenance system to the Drum The Process Drive then rotates in the opposite direction to lower the drum maintenance system The blade rem
321. roper error code and LED doesn t appear after each I O connector is reconnected repair or replace the faulty circuit If the proper code appears repeat the procedures until all I O board connectors are plugged back in If repairs are made during this step plug in all connectors to printer and retest If printer is fixed reattach covers to printer and perform a full test If no defects are found in this step replace Electronics Module test printer reattach covers to printer and perform a full test Verifying Print Engine Operation by Printing Stored Pages 1 Turn On the printer If the printer does not begin initializing go to the topic Measuring AC Power Supply Voltages on page 4 64 2 Once the Power light is on not blinking and the Control Panel displays Ready to Print it is now possible to print a stored page 3 If a page prints the print engine is working correctly If not a problem exists with the print engine Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 63 General Troubleshooting Verifying Power Supply Operation 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 1 Checking for proper AC voltage 2 Inspecting the power supply fuses 3 Testing for a shorted motor or solenoid which shuts down the power supply OOOO
322. ropriate diagnostic test Replace the 37 006 42 Drum Heater Drum Did the test pass Assembly 4 Run the appropriate diagnostic test Replace the 37 008 44 Preheat Heater Preheater Did the test pass 5 Run the appropriate diagnostic test Replace the 37 009 45 8500 8550 8560 All melters Ink Loader 8400 Ink Melt 1 37 010 46 8500 8550 8560 Ink Melt 1 8400 Ink Melt 2 37 011 47 8500 8550 8560 Ink Melt 2 8400 Ink Melt 3 8500 8550 8560 Ink Melt 3 8400 Ink Melt 4 37 013 48 8500 8550 8560 Ink Melt 4 Did the test pass 37 012 48 8400 PEST Description 37 013 40 Electronics module cooling fan disconnect The electronics cooling fan is not drawing the expected power from the supply 8500 8550 8560 PEST Description Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 8400 PEST Description 8500 8550 8560 PEST Description 37 014 41 Drum Fan disconnect The Electronics Module Fan Drum Fan is not drawing the Disconnect The Electronics Module expected power Fan is not drawing the expected power 37 015 42 Drum Fan disconnect The Drum Fan is not drawing the expected power Troubleshooting Procedure for Fans Step Questions and Actions Yes No 1 Run the appropriate diagnostic test Go to Step 2 Go to Step 2 37 013 40 8400 Electronics Fan 37 014 40 8500 8550 8560 Electronics Fan 37 014 41 8400 Drum Fan 37 015 41 8500 8550 85
323. roubleshooting Procedure for 7 006 Error Code Step Questions and Actions Yes No 1 Ensure the Process Drive system is Isthe problem Go to Step 2 correctly homed as described in Homing fixed the Process Drive Train on page 6 8 2 Reboot the printer Goto Step 4 Go to Step 3 Is the solenoid activating the Head Tilt Gear 3 Is ink blocking Head Tilt Gear motion Clean or Go to Step 4 Is the tilt head latch properly installed reinstall the head tilt and start over with Step 1 Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 15 Error Messages and Codes Troubleshooting Procedure for 7 006 Error Code Continued Step Questions and Actions Yes No 4 Review instructions for 7 008 xx and Follow recommended actions 7 010 xx fault codes for error codes and reboot the printer 7 0XX 4x Errors Printhead Tilt Faults The 7 007 49 7 008 41 7009 42 and 7 010 43 errors indicate that the Printhead was unable to tilt normally on its axis Possible causes include m The printer was powered off in the middle of a cleaning cycle and the Wiper Blade has frozen to the Printhead A Drum Maintenance Camshaft lobe is broken and holding the Drum Maintenance Kit s oil roller against the Drum when it should be retracted to its home position m Process Drive not being aligned correctly m A damaged Printhead Restraint Em Ink spilled in the Roll Block preventing proper Printhead motion m Ink or other
324. rror code 21 1 02 01 Flutter then 02 blinks Hard Failed machine check 19 1 02 02 Flutter then 02 blinks Hard Printer panic 19 2 03 01 Flutter only Soft ID read failure 31 1 03 02 Flutter then 03 blinks Hard Mismatch 31 2 03 03 Flutter only Soft Version mismatch 31 3 03 04 Flutter then 03 blinks Hard Access failure 31 4 04 01 Flutter then 04 blinks Hard ID read failure 23 1 04 02 Flutter then 04 blinks Hard ID mismatch 23 2 04 03 Flutter then 04 blinks Hard TMVL mismatch write read failed 23 3 04 04 Flutter then 04 blinks Hard TMVH mismatch write read failed 23 4 05 01 Flutter then 05 blinks Hard Communications error PLD I O Board 32 1 serial link down bad parity 05 02 Flutter only Soft Communications error PLD I O Board 32 2 serial mismatch 3 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes POST Error Reporting Blink Pattern Definition Table Continued 8400 PS PE and Control POST 8500 Error Panel LEDs for Error 8550 8560 Code 8400 Type Description Error Code 6 08 N A Soft IDE drive general failure Reseat IDE 6 808 cable and power cable If problem persists replace the IDE drive The printer will work without the IDE drive 07 01 Flutter only Soft Control Panel link is invalid or bad 16 1 parity 07 02 Flutter only Soft Control Panel version mismatch 16 2 08 01 Flutter only Soft Control Panel failed to in
325. rty Cleaning is indicated by any of the following 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 inside 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 Drum Maintenance Kit blade Most print quality problems can be corrected by running the cleaning procedures on the printer s Control Panel menu Supplies Required 90 pure isopropyl alcohol Alcohol moistened lint free wipes Foam swabs Clear packaging tape Caution Do not use Rubbing Alcohol as it can contain water and oils that leave undesirable residue on the printer parts Never use Water to clean the printer s internal components Clean dust build up on the exterior of the printer Inspect the vents on the exterior of the printer for dust Clean if necessary 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 Phaser 8400 Reference Guide or the Phaser 8500 8550 User s Guide Light Stripes or Missing Colors Problem type Solution Missing or light colored Select the automated procedure Eliminate Light stripes on prints
326. rvice Manual Service Parts Disassembly 9 Disconnect the heater harness and free the harness from its restraint Finger Holes Cable Restraint megs Flex Cable a ten al Heat S eater Cable EMI Tape Heater Harness Plug 8500 8550 8560 Ground Strap 8500 8550 8560 Only s8500 077 10 Lift the Printhead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame Cradle Notches LEX 8500 078 11 Disconnect the data cable from the Printhead Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 13 Service Parts Disassembly 12 Disconnect the flex cable from the Printhead Phaser 8400 printers have two cables Caution Do not pinch or tear the air hose while removing the Printhead as this will damage the printer 13 Lift the Printhead free of the printer chassis Replacement The following replacement steps are basically the reverse of the disassembly steps and provide important precautions Perform these steps in the order given 1 Ensure that the Head Tilt Gear is in the home position page 6 5 2 Rest the Printhead on the cradle notches provided while reconnecting the cable and flex connector Caution Three types of Printhead Flex Cables have been used One type provides a locking ZIP connector Ensure that the flex cable is inserted into the flex connector on the Printhead fully and squarely If the cabl
327. s 1 3 8500 series 1 4 physical dimensions 1 10 pick roller cleaning 7 3 disassembly 8 37 feeder faults 3 8 jam codes 3 62 media skews 4 70 parts assembly 9 9 skew margins 5 43 theory 2 5 pivot plate 2 13 poor primary colors 5 18 POST error codes 3 4 POST error reporting 3 4 POST tests 4 2 power control board 2 20 power supply 2 20 power supply operation 4 64 power supply verifying 4 64 power up sequence 4 51 predominate light stripes 5 4 preheat exit sensor 2 27 preheater cleaning 2 33 2 34 disassembly 8 20 errors 3 28 jams 4 69 lift solenoid disassembly 8 42 parts 9 7 smudges or smears 5 5 temperature 4 47 test 3 28 thermister 3 28 transfixing 2 27 print position 2 11 print process 2 23 print quality problems menu 2 34 print speeds 2 31 print eject jams troubleshooting 4 69 printer clearances 1 10 printer orientation 8 2 printer part locator 1 7 printer view rear 1 8 right side with interfaces 1 7 printer inspecting 7 5 printhead 2 3 printhead maintenance cycle 2 14 printhead movement 2 10 printhead overview 2 3 printhead restraints disassembly 8 10 print quality defects 5 2 process control faults 3 10 process drive 2 18 assembly train 6 4 definition 2 2 error faults 3 15 homing 6 8 parts list 9 11 relation to drum 2 13 Phaser 8400 8500 8550 8560 Color Printer Service Manual relation to printhead 2 11 relation to transfix system 2 18 process
328. s If you go through the procedures in a troubleshooting table and still are unable to solve the problem re read the Theory of Operations for the problem area and ensure that you understand how that section of the printer is supposed to function The Hidden Service Menu provides access to a large group of information pages and functions usable for diagnosing and correcting printer malfunctions and accessing special features Display the Hidden Service Menu as follows 1 On the Control Panel press the Down Arrow button to select Troubleshooting and then press OK 2 Press the Down Arrow button to select Service Tools and then press OK 3 While pressing and holding down the Up Arrow button press the Down Arrow button to display the Hidden Service Menu Menu Item Description Test Prints See Analyzing Service Test Prints on page 5 34 for a complete explanation of each test print available Startup Page Prints a page with basic configuration and networking information Eliminate Light Stripes Performs a cleaning procedure to remove light stripes in prints this process will take about 5 minutes Fault History Displays available information regarding the last 15 faults reported by a test and or the print engine Jam History Displays available information regarding the last 20 Jams reported by a test and or the print engine Diagnostic History Displays a list of all recent diagnostic tests Enter Diagnosti
329. s document Xerox U S personnel and Service Delivery Partners please record non Xerox ink use in the FIST system as well as in this document Phaser 8400 8500 8550 8560 Color Printer Service Manual A 13 Reference aaa e ese If Line 631 Printhead ID Profile It is Printhead ID 00 09 a lists a date record the date 10 29 ggated in the month day year here 30 99 front panel di l 100 menu Troubleshooting If Line 636 IDU Service Tools IDU lists any values record 00 09 the numbers here 10 29 30 99 100 Xerox U S personnel please record these dates in the FIST system as well as in this document Step Does the printer YES If YES please write down the error code 3 display an error NO code indicating 3a If error code 13 264 4x is present in the Fault History replace the a problem with Circle electronics module continue to 3b the printhead ong 3b Ifa printhead thermistor open or shorted error code 13 195 45 13 197 47 13 259 46 13 261 48 13 323 47 13 325 49 is displayed or a PEST error code 37 002 47 37 003 48 37 004 40 or 37 005 41 perform the following steps 3c Inspect and reseat the printhead interface cable gray ribbon cable and retest 3d Replace the printhead The repair is complete Visually inspect If NO replace the printhead The repair is complete the ink ves ER O reservoirs Do NO Ink visible in reservoirs they all contain i
330. s fault indicates a device failure attempting to access NVRAM a Reset NVRAM and retest b Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 11 0XX xx Errors Electronics Module Interface Fault 11 001 47 Upper 525 sheet feeder broken serial link detected 11 002 41 Lower 525 sheet feeder broken serial link detected 11 002 48 Lower 525 sheet feeder broken serial link detected 11 003 42 Control Panel broken serial link detected 11 003 49 Control Panel broken serial link detected 11 004 41 Control Panel or I O Board broken serial link detected 11 004 43 I O Board broken serial link detected 11 005 42 Power control broken serial link detected 11 005 44 Power control broken serial link detected 3 24 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 11 006 43 Printhead broken serial link detected 11 006 45 Printhead broken serial link detected 11 007 44 PCI error detected 11 008 45 The DMA hardware is not responding 11 009 46 Communication timeout failure detected 11 010 47 Hardware version mismatch 11 010 48 Hardware version mismatch 11 011 48 Software version mismatch 11 012 49 The power control PLD does not match the expected version 11 013 41 I O PLD version mismatch 11 014 42 Control Panel version mismatch 11 015 43 Printhead PLD version mismatch 11 016 44 Lower 525 sheet feeder PLD version mismatch 11 017
331. s first before moving the wiper Path Motor and The BLUE line traces what happens if printhead HOME the MPT was parked on last power down 31 001 NOTE Headtilt CAM will be engaged when the f Home the Y Axis printhead is in the PARKED restrained position 5001 5004 The RED numbers indicate errors that may be Wait for head to read displayed at that point in the process OK_TO_WIPE temperatures 13 0 Is the head tilt CAM engaged Home XA and move XA to the head tilted HEADTILT position 6000 Engage the Headtilt Solenoid Use the Headtilt as os tae Home the CAP wiper lead to Standby p i i 7007 7006 7008 8005 neit een 8055 8007 8008 8009 8005 Move the wiper and the head to determine if 8007 8008 8009 the head is fully restrained or not This will allow the head to tilt to the standby position so the wiper can be homed 7007 7006 s8500 137 Yes _headParkedOn Move Cap Wiper to the PARK LastPowerDown ARMS and restrain head again Yes 8035 7009 RECOVERY ROUTINE Try to recover from Did Process Motor Stall homeDmfix the Process Motor 7002 Device Fault Yes Home XA RE E SE 6000 No
332. s from the Process Drive motor Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 43 Service Parts Disassembly 8 44 Replacement Note X Axis Motor PL4 0 12 After replacing the Process Drive Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft or any component requiring removal of the Process Drive the printer may experience Front Cover jams from Tray 2 The jam occurs with paper in the Preheater and C3T jam errors strip flag timeout during transfix recorded in Jam History In many cases Tray 1 MPT prints with no jams These symptoms indicate that the Transfix Load Module is incorrectly timed resulting in a late arrival of the leading edge at the strip flag The likely cause is the position of the Drum Maintenance Camshaft gear in relation to the Process Drive gear To correct this problem see Timing the Drum Maintenance Camshaft on page 6 9 1 Remove the Right Side Cover page 8 5 2 Disconnect the harness 3 Remove 4 screws securing the motor to the chassis and remove the motor gt U UW ie 008 f H 0 8 O 0 0 Side Rail 8500 108 Replacement Note When reinstalling the X Axis Motor ensure that the fork extending out from the side of the cone nut on the motor shaft is engaged with the side rail Install and torque the 4 screws to 12 in lbs Reconnect the harness Before restoring power center the Printhead in its range of motion using a flatblade screwdriver to
333. s increase the force when the Transfix Camshaft engages Caution Never attempt to adjust or increase the transfix pressure on the springs 8500 021 Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Electronics Module The Electronics Module includes the main board the power control board and the power supply The Electronics Module is a Field Replaceable Unit FRU Main Board The main board performs the image processing functions Communication ports on the board receive the print job image data and convert it to drive signals for the Printhead The main board also contains the mechanical process controller which commands the function of the power control board The main board sends signals through the power control board to the wave amp board which amplifies the signal that drives the jets on the Printhead The main board supports Non Volatile RAM NVRAM memory the hard drive input output ports and the configuration card NVRAM The NVRAM memory device located on the main board stores Control Panel defaults network settings calibration data copy counts usage profile data and the printer serial number which is also referred to as the Engine Tracking Number ETN When the electronics module is replaced the NVRAM must be transferred to the main board in the replacement electronics module Memory For Phaser 8400 printers the main board supports two PC 133 compatible SO D
334. s performed to re attach any cables that were unplugged during debugging Attach printer covers Perform full test of printer Short circuit on 3 3 V power supply within the printhead a Required Follow all procedures from Short circuit on 3 3 V power supply within the Electronics Module before proceeding The following procedure relies on a working Electronics Module to determine if the printhead is causing a short circuit With power cord connected touch the metal Electronics Module to discharge any static electricity ESD damage to the printer may occur if static electricity is discharged to printer electronics Turn off printer and wait 30 seconds for power supply capacitors to discharge Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge Plug in the printhead interface connector J130 to the Electronics Module This step adds the Control Panel back to a working Electronics Module and I O board in order to see if the short circuit is also removed Turn on power to the printer Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting If the PE and PS indicators do not flash momentarily the short is on the printhead Replace the printhead and retest the printer Skip the rest of this section if the PE and PS indicators flash because the problem is elsewhere in the printer Carefully test the printer to ensure da
335. s problem see Timing the Drum Maintenance Camshaft on page 6 9 Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 13 Theory of Operation Purge System Proper Printhead operation is dependant on the correct operation of the purge system The purge system uses air pressure and a Wiper Blade to purge any debris or air bubbles that may be obstructing the Printhead nozzles The waste ink that is expelled during the purge is funneled into the Waste Tray Following the purge a wipe operation is performed on the faceplate using the Wiper Blade After the wipe a Cleaning page is printed Wiper Blade Kae Printhead Purge Pump 1 8500 017 To perform a Printhead maintenance cycle the Printhead is first tilted away from the Drum to allow the Wiper Blade to pass by The Wiper Blade is then raised in front of the Printhead Wiper movement is driven by the Media Path Drive by engaging a clutch on the exit shaft of the printer The Purge Pump applies pressure to the ink reservoir for approximately 2 5 seconds Valves in the reservoir seal when pressure is applied The pressurization ejects a small amount of ink from the jets Following the pressure purge the Printhead is tilted into the wiper assembly and the wipe cycle begins The pump runs again with the solenoid for approximately 30 seconds creating a neutral balance between pressure and ink The Wiper Blade lowers and wipes excess ink fr
336. s supported 2 Verify that the Process Drive Gearbox is correctly aligned and homed 3 Run the Process Motor test 4 Replace the process motor if necessary 5 Run the Transfix Fast and Slow tests 6 Replace the transfix camshaft and load arms if necessary 7 Run the Tilt Drive test replace if necessary 8 Replace the Process Drive T2A T2B T2C T2D T2E The Exit Cover open flag unexpectedly tripped while the printer was performing an abnormal shutdown The Exit Cover open flag unexpectedly tripped while the printer was performing a normal shutdown The Exit Cover open flag unexpectedly tripped while the printer was performing a mechanical recovery The Exit Cover open flag unexpectedly tripped while the printer was warming up The Exit Cover open flag unexpectedly tripped while the printer was ready T2F T2G T2H T2J T2K T2L The Exit Cover open flag unexpectedly tripped while the printer was in a fault state The Exit Cover open flag unexpectedly tripped while the printer was performing an automatic Drum maintenance cycle The Exit Cover open flag unexpectedly tripped while the printer was performing a Printhead maintenance cycle The Exit Cover open flag unexpectedly tripped while the printer was performing a Printhead purge cycle The Exit Cover open flag unexpectedly tripped while the printer was performing a transfix oiling cycle The Exit Cover open flag unexpectedly tripped
337. s two or more sheets of paper 1 oa kf Ww oN 4 68 Inspect the paper path for obstructions 2 Ensure that the side guides are set correctly by sliding the guide gently against the media Try printing from a fresh unopened ream of paper Flip over the media in the tray Ensure the Pick Rollers for Trays 2 3 and 4 are installed correctly Clean the Pick Roller using the cleaning procedures Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of the tray Also clean the transport rollers if they are visibly dirty Refer to page 7 4 for proper cleaning procedures Check that the Pick Roller is being rotated Run the Paper Path test Replace the Pick Roller if damaged 10 Inspect the rollers bushings and gears of the paper path Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Paper Pick Errors Tray 1 1 Verify the media being used is the correct size and weight 2 Clean the Tray 1 pick roller and separator pad refer to the cleaning procedure 3 Ensure the printer is operating under the right environmental conditions see Chapter One for more information 4 Run the Tray 1 Pick Solenoid test replace if necessary 5 When Tray 1 is opened or closed with media present the pick roller will home and pick paper Remove all media open and close Tray 1 and then try printing again Preheater and Transfix Jams 1
338. sconnect the 2 connectors from the printer and remove the Ink Loader s8500 069 Replacement Note For the 8400 route the gray harness from the chassis between the Ink Loader and printer side The harness from the Ink Loader must be routed towards the left side see inset For the 8500 8550 8560 the harness comes from the side of the chassis and plugs directly into the Ink Loader After replacing the 8500 8550 8560 Ink Loader reset the ink stick count using the Hidden Service Menu Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 7 Service Parts Disassembly Imaging Y Axis Belt Y Axis Tension Spring and Y Axis Motor PL 2 0 4 PL 2 0 14 PL 4 0 4 Warning The use of safety glasses is recommended for this procedure 1 Remove the Left Side Cover page 8 6 2 Relieve tension on the belt by pulling the end of the spring arm toward the front of the printer using your fingers 3 Slide the belt off the pulley Y Axis Belt 8500 070 4 Using a spring hook or pliers remove the Y Axis Tension Spring from the chassis retainer and spring arm Brace the printer to keep it from moving during removal of the spring Caution This is a strong spring that can cause damage if it slips during removal use care when removing 5 Move the wires out of the way 6 Disconnect the motor harness 8 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly 7 Remove 3 screws
339. seat or Replace the Is the wiring damaged or not connected replace the Wave Amp wiring Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 47 Error Messages and Codes Jam Codes 3 48 The printer stores the most recent 20 events in Jam History To access this information for 8400 models in Customer Mode press and hold the red Cancel button followed by pressing the OK button when the jam code message displays When Service Tools is displayed release both keys Next scroll to Jam History and press OK to display the most recent jam list Phaser 8500 8550 8560 models have improved jam reporting When the printer is in a jam condition in Customer Mode pressing HELP displays the jam code The jam code contains 4 digits compared to the 3 digit codes produced by 8400 models The fourth digit indicates one of the following m The tray number at which the jam occurred 1 2 3 or 4 m The jam occurred while processing a chase page 5 m The jam occurred when generating a duplex print 6 If the Jam code is still not visible by pressing HELP when in customer mode press and hold the red Cancel button followed by pressing the OK button when the jam code message displays When Service Tools is displayed release both keys Then scroll to Jam History and press OK to display the most recent jam list Note Jam History is not accessible from Service Diagnostics It is only accessible from Customer Mode Phaser 8400 85
340. sensor unexpectedly activated during printer ready V2F Tray 2 media size sensor unexpectedly activated while printer was in a fault state V2K Tray 2 media size sensor unexpected event during oil transfix V2L Tray 2 media size sensor unexpectedly activated while the printer was in standby V2M Tray 2 media size sensor unexpectedly activated while picking from Tray 2 V2N Tray 2 media size sensor unexpectedly activated while picking from Tray 3 V2P Tray 2 media size sensor unexpectedly activated while picking from Tray 4 V2Q Tray 2 media size sensor unexpectedly activated while picking from Tray 1 V2R Tray 2 media size sensor unexpectedly activated while duplexing V2S Tray 2 media size sensor unexpectedly activated while paper staged for print V2T Tray 2 media size sensor unexpectedly activated while transfixing the print V2V Tray 2 media size sensor unexpectedly activated while print Drum maintenance cycle was being performed V2W Tray 2 media size sensor unexpectedly activated during printer imaging Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes Jam Code Troubleshooting Procedures Continued V2X Tray 2 media size sensor unexpectedly activated while exiting print 1 Ensure ground integrity of the printer see page 4 65 2 Ensure the Tray 2 paper guides are correctly set 3 Run the Monitor Sensors test to test the media size sensor 4 Replace the media size sensor board 5 Repl
341. sist of two basic cleaning cycles performed sequentially A cleaning cycle is performed when the printer is first powered on if the ink reservoir has cooled to the point that a cleaning cycle is triggered A cleaning cycle is not performed when the printer is coming out of standby mode Refer to the purge system topic in this chapter for more detail on the Printhead maintenance cycle Warning When servicing the printer be careful of the purge system as it passes the Printhead If a damaged Wiper Blade catches on the Printhead it could propel hot liquid ink upward into your face Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 33 Theory of Operation Paper Preheater Cleaning Remove Print Smears This customer initiated cleaning procedure is selected by choosing Remove Print Smears on the Control Panel s Print Quality Problems menu This procedure cleans ink out of the Preheater that may have been deposited there Heavier weight high grade quality paper works best for this procedure Ink can also be deposited if a jammed print with ink on it was pulled backwards through the Preheater In the Preheater cleaning cycle these events take place 1 The customer selects the Remove Print Smears menu item 2 The printer overheats the Preheater to about 110 C softening ink trapped inside the Preheater Ordinarily the Preheater runs at temperatures of between 60 C and 70 C 3 The printer picks and passes approximately 12 2
342. sso index cfm fuseaction sso partnerLogin THE DOCUMENT COMPANY XEROX PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8400 WorkCentre C2424 Version 2 IMPORTANT This checklist outlines proper printhead troubleshooting procedures All Xerox service employees and any other service personnel on any job involving a printhead replacement should perform it Service person name Service Company Phone Number Date of printhead replacement Printer serial number Printhead serial number OUT Request ID number Troubleshooting Summary Follow the checklist below and fill in spaces as they apply as you complete the troubleshooting procedures Check List Value What to look for Items to or Complete Result Step Do you suspect 1a Did the customer state that they have used generic ink in this 1 or have YES printhead YES NO evidence of use NO 1b Did you observe generic sticks or related packaging at the site of generic ink YES NO Circle 1 Are there generic ink sticks in the ink loader ae YES NO 1d Does the service history indicate possible use of generic ink YES NO Indicate brands and lot codes of generic ink if used If you answered YES to any of the above be sure to document the use of non Xerox ink in the Comments section of this document Xerox U S personnel and Service Delivery Partners please record non Xerox ink use in the FIST system as well as in this document
343. st turns on the process motor and runs it very slowly for one revolution Process Motor Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Motor fe ripple 2 8t06 0 0to 02 Reports amount of variation of ticks the motor following error 1 Motor fe average 4 to 3 0 015 to 01 Reports the motor following ticks error average value 2 Motor drive voltage 5 to 11 8 to 11 Reports amount of variation of ripple volts the motor drive voltage 3 Motor drive voltage 1 3t02 3 9to 1 5 Reports the motor drive volts voltage average value 4 Motor drive power 1 03 to 3 6 7 to 2 0 Reports amount of variation of ripple watts the motor drive power 5 Motor drive power 1 5t03 5 1 2to 2 75 Reports the motor drive power average watts average value This test turns on the media path motor and runs it very slowly for one revolution Media Path Motor Typical Value Typical 8400 Value 8500 R Definition 8550 8560 Actions 0 Motor fe ripple A0 to 1 3 001 to 0035 Reports amount of variation of ticks the motor following error 1 Motor fe average 0 8 to 2 0 0033 to 007 Reports the motor following ticks error average value 2 Motor drive voltage 4 to 10 4to 8 Reports amount of variation of ripple volts the motor drive voltage 3 Motor drive voltage 5 5 to 2 0 5 to 2 0 Reports the motor drive
344. stics to run the Drum Maintenance Drive test 36 001 67 Errors Drum Maintenance Fault 1 Replace the Drum Maintenance Pivot Plate 2 Replace the Drum Maintenance Kit 36 002 44 Errors Drum Maintenance Program Fault Printer can t write to Drum Maintenance Kit 1 Ensure the Drum Maintenance Kit sits correctly in the Drum Maintenance Pivot Plate 2 Replace the Drum Maintenance Kit 3 Replace the Drum Maintenance Pivot Plate 37 0XX xx Errors PEST Faults AC power supplied by power sources such as uninterruptible power supplies UPSs or DC to AC inverter systems may not supply correct voltage to properly power up the printer Likewise other devices sharing the same AC circuit can cause AC voltage sags that cause the printer to fail its AC heater PEST tests Print Engine Self Test The printer may produce any of the following disconnected heater errors m Printhead jet stack 37 002 47 or 37 003 48 3 36 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes m Reservoir heater 37 004 40 or 37 005 41 m Drum heater error 37 006 42 m Preheater error 37 008 44 m Ink melters errors 37 009 45 thru 37 013 40 The printer includes several heaters powered by AC The printer itself can power up despite insufficient or irregular AC voltage but it may fail its AC heater tests This is due the test not measuring sufficient current flowing through the heater at the moment the test runs Devi
345. t Some printers are not shipped as Energy Star compliant and don t have the power saving mode enabled by default 2 Electronics Module failure a Required Follow Step 1 before proceeding b With power cord connected touch the metal Electronics Module to discharge any static electricity c Turn off printer and wait 30 seconds for power supply capacitors to discharge d Unplug power cord and remove printer s covers e Replace the Electronics Module 4 60 Phaser 8400 8500 8550 8560 Color Printer Service Manual f g h i General Troubleshooting Plug in all cables removed during service Trace through all service steps performed to reattach any cables that were unplugged during debugging Attach printer covers Perform full test of printer Printer Reports Missing Drum Maintenance Kit 1 Drum Maintenance Kit missing or not fully seated a Fully install Drum Maintenance Kit 2 Connector not fully seated a Check I O Board connector J860 for proper mating 3 Check that the Drum Maintenance Kit stop on left end of the Drum Maintenance Pivot Plate is not broken 4 Chack that the Waste Tray Sensor is correctly installed at the end of the Waste Tray Cover Printer Reports Missing Waste Tray 1 Waste Tray missing or not fully seated a Fully install waste tray 2 Connector not fully seated a Check I O Board connector J110 for proper mating Optional Features Not Available
346. t Substitution Mode 8500 8550 8560 Resetting NVRAM 6 14 After the Printhead is replaced disable Jet Substitution Mode to restore normal operation To deselect Jet Substitution Mode 1 a fF WO NY On the Control Panel scroll to Troubleshooting then press the OK button Select Print Quality Problems and then press the OK button Select Eliminate Light Stripes and then press the OK button Select Turn Jet Substitution Mode Off and then press the OK button Print the Eliminate Light Stripes test page to verify that Service Mode is disabled for all jets Resetting NVRAM returns all the image processor board NVRAM stored parameters to their factory default values The print counts and the Adobe firmware serial number are not affected by this reset You can reset the PostScript NVRAM using the Service Tools menu or the Service Diagnostics menu Phaser 84000 8500 8550 8560 Color Printer Service Manual Cleaning and Maintenance m Maintenance m Inspection Cleaning Chapter Cleaning and Maintenance Service Cleaning Maintenance Procedure Cleaning 7 2 Cleaning is indicated if the printer is having print quality or paper feeding problems Some cleaning procedures such as purging the jet nozzles are done automatically when necessary Other procedures such as scrubbing the paper feed rollers with an alcohol moistened lint free wipe must be done by customers but only if the rollers are visibly di
347. t ened ene e eens 1 5 LED IINGIGATONS 34 sai erd Scses edad Soe Bence abhi a Bua ec ear 4 eth deus o geld ee ous en oe aa ack 1 5 Control Panel Feature Descriptions 0 ccc cc cece eee teen ene teens 1 5 IV TM IVA OS feos sete co EE E T Retin ces oe cere ascent EET EEE TES cytes EEEE T 1 6 Control Panel Shortcuts 2 0 ndia eeka ea n E e ene teens 1 6 Parts Of the IPRNtefiis chase occas hie bbd de a E DE ew hed ChE bedhead Sub ed bade ad 1 7 Front VIEW 225 55h a ual ea aed aes LONG ou doa in cus ea E E eure ches 1 7 Right Side View with Printer InterfaceS 2 0 cece nee eee n ene t eens 1 7 Rear VIEW 2 e ont ak bed Bae ind ted ae CATE ded en deed a aa tes aRos aa a 1 8 Routine Maintenance Items and Consumables 0 ccc cece eee eect e nent eens 1 9 Printer Specifications ss ounsi cree tide a Ot Rawanda an aa ee aa pek ws Pic ah el a a 1 10 Physical Dimensions and Clearances 0 ccc cee cece tenet e teen nee tenes 1 10 Functional Specifications 0 0 cence eee eee e ene t tbe eee e teens 1 12 Electrical Specifications 6 0 0 nen e ene e eee teen ene e teens 1 12 Environmental Specifications 0 ce eee teen nee teen ene e ees 1 12 Media and Tray Specifications 0 0 cette ene eet eee n eee tenes 1 13 2 Theory of Operation Main Printer SubSySteMS 6 4 0 0 044 0444 doade sp inedoiens pdagddiade sae gbiaa oeeeeewoae bobhhe dunes 2 2 Printer Subsystem OvervieW 0 cc en ee een n nee
348. tant velocity and samples the Y Axis position Uses the data to determine Y Axis motor and drum vibration and the most significant other vibrational frequencies Y Axis Geometry Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Drum Normalized 3900 to Reports the normalized FFT FFT Power none 6000 power amplitude of the drum frequency The normalized value is generated by dividing the drum FFT power by 1 0xE13 1 Drum Frequency 1 25 to 7 5 Reports the current drum hz frequency 2 Motor FFT Power 200 to 250 Reports the ration of the FFT Ratio none power amplitude of the motor frequency to the FFT power amplitude of the drum frequency 3 Motor Frequency 44 to 48 Reports the current motor hz frequency 4 FFT Power Ratio 1 20000 to Reports the ratio of the FFT none 25000 power amplitude of the most powerful FFT frequency not including the drum or motor to the FFT power amplitude of the drum frequency 5 Frequency 1 45 to 110 Reports the frequency of the Frequency hz most powerful FFT frequency not including the drum or motor 6 FFT Power Ratio 2 14000 to Reports the ratio of the FFT none 17000 power amplitude of the second most powerful FFT frequency not including the drum or motor to the FFT power amplitude of the drum frequency 7 Frequency 2 70 to 140 Reports the frequency of the Frequency hz second most powerful
349. ted media is then passed between the Drum now rotating much more slowly and the Transfix Roller The pressure applied by the Transfix Roller transfers the image to the heated media An encoder disk and sensor on the left end of the Drum monitors the Drum s speed and position Preheater Drum Drum Heater 8500 019 The drum heater heats the surface of the Drum to about 60 C 140 F for imaging The drum heater does not rotate The heater is inside the drum and is controlled by the Drum Heater Relay Board The drum heater consists of two resistive heater coils that operate in series for 220 V and in parallel for 110 V operation The Drum Heater Relay Board controls the series parallel operation The Drum Temperature Sensor monitors the drum temperature The main board interprets the sensor s signal and turns on the drum heater and Drum Fan to heat the Drum or turns on the Drum fan alone to cool the Drum The Y Axis Motor drives the Drum Through a single reduction belt drive the Y Axis Motor rotates the Drum at a high speed for imaging and a constant low speed for image transfer The Y Axis Belt uses an active tension system to allow the pulley to float while the spring actively adjusts the belt tension Note The drum rotates in different directions for each process Transfix CW Maintenance CCW Printing CCW Phaser 8400 8500 8550 8560 Color Printer Service Manual Theory of Operation Single Reduction Belt Drive
350. ter Service Manual General Troubleshooting Operating System and Application Problems Print an internal test print from the printer s Control Panel to ensure the problem is not printer related There is additional help available at www xerox com office support You can access PhaserSMART Technical Support Technical Support via email driver downloads and much more PhaserSMART Technical Support is an automated Internet based support system Use your default web browser to send diagnostic information from your printer to our web site for analysis PhaserSMART Technical Support examines the information diagnoses the problem and proposes a solution To access PhaserSMART Technical Support 1 Go to www phaserSMART com 2 Enter your printer s IP address in the browser address window Testing Communications Ports Testing the communication ports can isolate communication problems to the computer network or software Test the communications ports after the printer is installed or when the Electronics Module has been replaced Test the communications ports as follows Ethernet Port Verification Note The Ethernet port can be tested without connecting to the network by using a crossover cable and the PING command 1 Connect a crossover cable between the Ethernet ports on the printer and computer 2 Verify that the printer is Ready To Print 3 At the computer click the Start button and select Run 4 Type in t
351. the watts printhead from the right hard stop to the left hard stop An abnormal value may indicate a problem with roughness in the drive mechanism or an interference with the printhead motion 4 Left Right Traverse 4 0to 8 5 5to 1 75 Same as R2 except for the Power Average other direction of motion Level watts 5 Left Right Traverse 1 2t01 5 01 to 05 Same as R3 except for the Power Ripple other direction of motion watts 6 Turnaround Power 02 to 11 Reports the width of the Blip Width watts momentary drop in the required drive power when the printhead motion is being reversed An abnormal value may indicate an unusual amount of play in the drive mechanism Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 33 General Troubleshooting 4 34 With the drum turning at a constant velocity the transfix roller is loaded against the drum held for one revolution then raised The velocity with which the transfix roller is moved differs for the two tests Transfix Drive Slow and Transfix Drive Fast Typical Value R Definition Fast Slow _ Actions 0 Time to first 0 22 to 0 22 to Reports the time from the load contact sec 0 29 0 50 command to the engine until the drum indicates contact with the pressure roller 1 Loaded 2600 to 2600 to Reports the average Y Axis following average Y 4200 3400 error during the Roll With Transfix A
352. the Replace the 1 0 Board power control board J800 2 0XX 6x Errors 1 0 Board Program Faults 2 001 69 The Electronics Module failed to initialize 2 002 61 This fault code indicates a problem with the printer program The engine firmware was unable to initialize the queues used for inter task communication 2 003 62 This fault code indicates a problem with the printer program The engine firmware was unable to start the Service Diagnostics tasks 2 004 63 Failure to start the print engine in suspend mode 2 005 64 This fault code indicates a problem with the printer program ROM could not be opened for reading idiags 2 006 65 This fault code indicates a problem with the printer program ROM could not be loaded idiags 2 007 66 This fault code indicates a problem with the printer program idiags entry point cannot be found a Reset NVRAM and retest b Ensure ground integrity see Ensuring Ground Integrity on page 4 65 c Replace the EEPROM chip d Reboot the printer 2 008 67 Configuration card is missing 2 009 68 Configuration card is bad 2 010 69 Configuration card is blank 2 011 61 Configuration card is for the wrong product 2 012 62 Configuration card is an invalid model a Turn off printer Verify that configuration card is correct card for printer Insert or replace configuration card Turn on printer If problem continues replace the Electronics Module 920 5 Phaser 8400 8500
353. the gear engaged properly 12 Use Service Diagnostics to run the Tilt Axis Replace the Go to Step 13 Drive test Process Drive Did the test fail 13 Use Service Diagnostics to run the Process Replace the Motor test Process Drive Did the test fail 7 0XX 6x Errors Program Faults 1 Reset NVRAM and retest 2 Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 3 20 Phaser 8400 8500 8550 8560 Color Printer Service Manual Error Messages and Codes 8 0XX xx Errors Wiper Media Drive Faults 8 005 48 The Media Drive stalled while moving the Wiper to home position 8 006 49 The Wiper cannot verify the home position 8 007 41 The Wiper stalled finding home 8 008 42 The Wiper stalled while trying to move away from home position 8 009 43 The Media Drive stalled while moving without the Head Maintenance Clutch engaged 8 015 49 The Media Drive stalled while moving the cap wipe to park position 8 025 41 The Media Drive stalled while moving the cap wipe from park position 8 035 42 The Media Drive stalled while moving the cap wipe Up 8 045 43 The Media Drive stalled while moving the cap wipe Down 8 055 44 The Media Drive stalled while engaging headtilt Troubleshooting Procedure for Wiper Media Gearbox Step Questions and Actions Yes No 1 Check for obstructions in the Wiper Clear any Go to Step 2 Assembly path obstructions Is the Wiper Assembly obstr
354. the printer you will see one heater cable connector on the left near the power switch and two under the ink loader 7 Place the power switch in the On position and make the following measurements a Using an ohmmeter measure the resistance between the lowest pin on the left side just above the power switch and the lowest pin on the AC input connector If the meter measures 0 ohms F3 is intact b Measure between the right most pin under the ink loader and again the lowest pin on the AC input connector If the meter measures 0 ohms F2 is intact 8 The heater triacs are not accessible for measurement and are disconnected from loads if the switch is off or the printer is powered down 9 Reinstall the Ink Loader following the test Measuring DC Power Supply Voltages 1 Check the power supply status LEDs they should be bright 2 If the printer is operational use the diagnostic test Monitor Voltages Note DC voltage test points can be found on the power control board When you remove the rear access cover you will see the test points below the RAM DIMM s on the power control board Ensuring Ground Integrity Intermittent or missing ground connections can result in minor interferences in the printer As examples Control Panel display can be affected blank I O board errors False jam reporting Erroneous thermistor readings Major interruptions Damage to the electrical boards Phaser 8400 8500 8550 8560 Col
355. tics History Enter Diagnostic Mode amp Service Usage Profile Email Service Report amp Troubleshooting Print Quality Page Eliminate Light Stripes Remove Print Smears Network Log Pages gt _ _ gt 5 NetWare Start Log amp NetWare Runtime Log Si TCP IP Start Log amp TCP IP Runtime Log amp AppleTalk Start Log amp AppleTalk Runtime Log Reset NVRAM Shutdown gt sa Power Saver Recommended Restart Printer Power Down To minimize ink usage leave the printer on Requires Network Configuration Duplex Configuration Optional Lower Tray s 8400DX only with stored jobs present Phaser 8400 8500 8550 8560 Color Printer Service Manual Page 2 of 2 Reference Menu Map 8500 8550 8560 Main Menu Ready To Print Printer Setup gt Troubleshooting gt v Walk Up Features E Personal Print Jobs Secure Print Jobs kkk Displays when print jobs are stored on the hard drive Proof Print Jobs Saved Print Jobs Walk Up Printing _ _ Prints jobs using the Walk Up printer driver Select for Installation SS Installs Windows printer drivers Control Panel Buttons Walk Up Features gt Information gt Cancel Paper Tray Setup gt Back _ 9 ee Arrow i Help be Down Arrow Displays information about the message
356. tion If the hole does not point at the arrow while the Drum Maintenance Kit is being pressed against the cams a cam may be broken on the Drum Maintenance camshaft Clear the harnesses from the mounting location and insert the Process Drive to the frame Insert and seat all 3 screws before torquing the screws to final tightness of 12 in lbs Torquing the screws individually before seating all components or applying too much torque can break or put undue strain on the mounting bosses Phaser 84000 8500 8550 8560 Color Printer Service Manual Adjustments and Calibrations 7 Check that the hole in camshaft gear is aligned with the arrow embossed on the ground plane The hole in the upper mating gear should align with the adjacent hole in the frame Holes in process drive frame aligns with holes in gears aligns with arrow on frame Hole in gear aligns with arrow on frame 8 Remove the pins holding the Process Drive gears in their disengaged positions 9 Route the Drum heater Y Axis encoder and Drum Fan harnesses through the guides provided on the Process Drive gearbox 10 Replace the covers and test the installation Replacement Note Tighten the Process Drive screws to 12 in Ibs Over tightening can result in irreversable damage to the printer Phaser 84000 8500 8550 8560 Color Printer Service Manual 6 11 Adjustments and Calibrations Jet Substitution Mode On 8400 models the Jet Substitution Mode
357. tions Physical Dimensions and Clearances 1 10 Print Engine Only Value Width 422 mm 16 6 in Depth 514 mm 20 24 in Height 368 mm 14 48 in Weight 26 8 kg 59 Ib Optional 525 Sheet Feeder Value Width 422 mm 16 6 in Depth 514 mm 20 24 in Height 132 mm 5 2 in Weight 5 4 kg 12 Ib Minimum Clearances Supplemental Information Left side and rear 102 mm 4 in Required for airflow Right side 394 mm 15 5 in Required for maintenance kit and waste tray access and airflow Front Unrestricted Required for media tray and jam access Top 559 mm 22 in printer only Required for inkload and jam access Bottom No obstruction between mounting surface and printer Required for airflow Min install width 711 mm 28 in Requires placing printer at an angle to remove waste tray Phaser 8400 8500 8550 8560 Color Printer Service Manual General Information Print Engine Only Value 10 cm 8500 141 Note Check that the printer is on a stable non vibrating suface Advise the customer to use care not to shake the printer excessively when loading media or closing the Front Door During operation the ink is in liquid form an can spill from the Printhead reservoir resulting in output defects Phaser 8400 8500 8550 8560 Color Printer Service Manual 1 11 General Information
358. tions Yes No 1 Check that the ambient room temperature is Advise Go to Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Ensure the ground integrity see Ensuring GotoStep3 Resolve Ground Integrity on page 4 65 ground Are all components grounded properly integrity 3 Run the Right Jetstack Temperature test GotoStep4 Replace the Did the test pass Printhead 4 Check and reseat all wiring to the Printhead Complete Replace the Did this correct the problem Printhead 13 264 42 The Printhead reservoir heater got too hot 13 266 44 The Printhead reservoir heater took too long to reach its setpoint 13 323 47 The Printhead reservoir thermistor circuit is open 13 325 49 The Printhead reservoir thermistor circuit is shorted Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 29 Error Messages and Codes 13 327 42 The Printhead reservoir thermistor returned a bad reading or the reading was corrupted by ESD Troubleshooting Procedure for 13 264 to 13 327 Error Code Printhead Step Questions and Actions Yes No 1 Check that the ambient room temperature is Advise Go to Step 2 within specifications see Environmental customer Specifications on page 1 12 Is the room too cold or too hot 2 Ensure ground integrity see Ensuring Goto Step 3 Resolve Ground Integrity on page 4 65 ground Are
359. to 1500 Reports the average MP fe mpts during the run in interval before the pick shaft is engaged 4 18 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting Tray 1 Pick Shaft Continued Typical Typical Value Value 8400 8500 R Definition 8550 8560 Actions 1 On response time 1 5 to 0 95 Reports the time between pick sec solenoid activation and a detectable response from the MP drive system indicating that pick shaft engagement A higher value of R1 could indicate that the missing tooth gear engaged more slowly than usual which could be a problem with the lift plate spring tension the condition of the sliding surfaces between the cams and the followers drag on the pick shaft or problems with the drive gears missing teeth etc 2 Initialaverage MP 1 to 1400 Reports the average MP fe fe mpts immediately following the pick shaft engagement A higher value of R2 could indicate extra friction between the cams and the lift plate followers wear contamination etc as well as high lift plate spring tension or higher shaft bearing drag Also if the missing tooth gear did not kick forward and engage this value would be unchanged from RO 3 Transition MP fe 750 to 1800 Reports the minimum MP fe min mpts value at the transition point between breaking separator pad contact and the continued depression of the lift plate V
360. tors to discharge Unplug the following Electronics Module connectors Power Control to I O Board J800 Power Control right J400 Printhead data J130 Wave Amp signal J790 Power Control left J390 Y Axis motor J280 This step prevents any faults from the motors clutches and sensors from preventing the I O Board and Control Panel from functioning Plug in the I O Board connector P J800 in the Electronics Module This step adds the I O Board and Control Panel to the Electronics Module m Turn On power to the printer Phaser 8400 8500 8550 8560 Color Printer Service Manual n General Troubleshooting If the Electronics Module I O Board and Control Panel are working the error code 34 001 43 should appear on the display to indicate the Printhead is disconnected If the correct error code is displayed continue with the next steps of the procedure If the correct error code is not displayed replace the Control Panel and I O Board and verify the correct error code appears Retest Electronics Module I O board Control Panel combination If no error code displays return the original Control Panel and I O Board to the printer Replace the Electronics Module and then continue with the next steps of the procedure If a different error code is displayed see the Fault Code Error Message Troubleshooting on page 3 7 for a definition of the problem and the procedures needed to solve the problem 2 Repeat these proc
361. tory control Green Tag filled out e Sample prints that clearly show the observed print quality defect not applicable for printheads replace because of an error code Service Print 1 A 16 Phaser 8400 8500 8550 8560 Color Printer Service Manual Index Numerics 525 sheet feeder parts list 9 9 8 pin NVRAM parts list 9 13 A AC power 2 20 adjust x axis scale service menu 4 3 back button 1 5 basic positions printhead 2 10 basic printhead cleaning cycle 2 33 belts drive single reduction 2 16 drum 2 17 parts for wiper drive 9 7 parts for y axis 9 7 printer 7 6 removing from drum assembly 8 27 wiper alignment 6 3 y axis disassembly 8 8 y axis slip test 3 56 4 40 y axis tension 3 13 y axis tension test 4 40 BIST Error Codes 3 3 C cables circuit board and cables part list 9 13 crossover 4 71 drum encoder 8 27 drum heater 8 27 drum temperature sensor 8 27 exit module 8 30 1 0 and electronic 3 25 IDE hard drive 2 19 ink loader 8 7 media drive motor 8 30 pick solenoid 8 41 power cord parts list 9 16 printhead power 3 14 ribbon connector 8 5 serial modem 4 73 USB 4 72 wave amp 3 40 cabling parts list 9 13 calibration faults 3 33 3 35 cancel button 1 5 Phaser 8400 8500 8550 8560 Color Printer Service Manual chase page 2 34 4 3 4 55 check menu tables 4 10 check activators menu 4 10 deskew clutch 4 11 drum heater relay 4 12 head maintenance clut
362. turn the X Axis Motor shaft Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Head Tilt Gear PL4 0 9 Remove the Printhead page 8 10 2 At the left side remove the KL clip Remove the Waste Tray Cover without disconnecting the Waste Tray Detect Sensor harness Reach in to the Waste Tray cavity and remove the Head Tilt Gear o A Remove KL Clip 8500 109 Replacement Note On reassembly the leaf spring on the back side of the chassis must be behind the gear to engage Also lubricate the curved cam surfaces of the gear using a small quantity of Rheolube 768 grease P N 070E00890 Phaser 8400 8500 8550 8560 Color Printer Service Manual 8 45 Service Parts Disassembly Electronics Electronics Module PL5 0 5 Caution Touch the back of the Electronics Module before starting this procedure to discharge any electrostatic charge present on the case Also do not completely remove EMI tape if added to a connector Note Do not fully remove EMI tape if included with any connector 1 Disconnect the Power Cord and all connections to the Electronics Module 2 Remove the Ink Loader page 8 7 3 Remove 5 screws from the back of the Electronics Module and two screws from inside the chassis 4 Remove the Electronics Module EMI Tape 8500 8550 8560 8500 110 Replacement Note When replacing the Electronics Module transfer the Configuration Card
363. uated unexpectedly when paper picked from Tray 2 The strip flag actuated unexpectedly when paper picked from Tray 3 The strip flag actuated unexpectedly when paper picked from Tray 4 The strip flag actuated unexpectedly when paper picked from Tray 1 Strip flag unexpected event during pick from the duplex path Strip flag unexpected event during transfix 1 Ensure ground integrity of the printer see page 4 65 2 Check the paper tray for overfill 3 Run the Stripper sensor test 4 Inspect the stripper blade for damage or debris 5 Run the Paper Lead Edge Times test 6 Replace the stripper carriage assembly C2x Strip flag unexpected event during exit 1 Ensure the media is not too thick and that it is supported by the printer 2 Use a less glossy media 3 Ensure the guides in the tray are snug against the media 4 If the Drum maintenance unit is near the end of its life replace it 5 Clean and inspect the exit rollers 6 Run the Paper Path Drive test C3M C3N C3P C3Q C3T The strip flag timed out waiting for the paper picked from Tray 2 The strip flag timed out waiting for the paper picked from Tray 3 The strip flag timed out waiting for the paper picked from Tray 4 The strip flag timed out waiting for the paper picked from Tray 1 NOTE After replacing the Process Drive Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft or any component requiring removal of the Process Drive the printe
364. ucted by the Printhead or wiring 2 Foran 8 005 48 error Complete Go to Step 5 1 Check for paper in the paper path that is adding drag to the rollers Look for paper or wiring interfering with the take away roller 2 Remove the Tray 1 Pick Solenoid to view the meshing of the Take Away Roller s gears to the Media Drive Assembly Did this correct the problem 3 Foran 8 007 41 error Complete Go to Step 5 Check for a missing KL clip securing the Head Maintenance Clutch Replace if missing Did this correct the problem 4 Foran 8 009 43 error Complete Replace the 1 Ensure that there is no paper in the paper Media Drive path adding drag to the rollers Assembly 2 Ensure the Media Drive Assembly is fully seated and correctly installed 3 Remove the Tray 1 Pick Solenoid to view the meshing of the take away roller s gears to the Media Drive Assembly 4 Ensure the feed rollers are properly engaged in the drive gears Did this correct the problem 5 Run the Wiper Drive test Go to Step 6 Goto Step 7 Did the test pass Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 21 Error Messages and Codes Troubleshooting Procedure for Wiper Media Gearbox Continued Step Questions and Actions Yes No 6 Run the Wiper Alignment test see Wiper Alignment Procedure on page 6 2 Did the test pass Go to Step 8 Go to Step 7 7 1 Inspect the wiper system for improper oper
365. udes the feature value ethernet address and personality parameters The card reads a combination of feature values and the printer hardware capabilities this will determine the printer model configuration You can migrate the Configuration Card from one printer to another to transfer the printer configuration Feature value and ethernet address are configured at the factory and are read only The feature value is fixed in the Configuration Card and does not change Ethernet address is stored only on the Configuration Card and cannot be rewritten The Ethernet address is not written to the NVRAM chip Personality parameters are a subset of network configuration parameters which are populated to the Configuration Card when the customer configures the printer The personality parameters are copied shadowed from the main board s NVRAM chip to the Configuration Card during the normal operation of the printer When the configuration card is inserted into a new printer the personality parameters on the Configuration Card are written into the NVRAM chip of the new printer When a printer is powered on if it contains the Configuration Card of another printer the personality parameters copy automatically to the NVRAM chip When removing the Configuration Card for the Phaser 8400 the printer reboots as a B non networking configuration Refer to the Configuration Card Personality Parameters section at the end of this chapter for a det
366. urred xx yyy Zz 123 xx yyy 4x Device faults are indicated by a 4 in the tenths place of the fault code This indicates a hardware problem The most common device faults troubleshooting procedures are documented in this section xx yyy 6x Program faults are indicated by a 6 in the tenths place of the fault code 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 xx yyy 7z CPU exceptions are indicated by a 7 in the tenths place of the fault code The error code indicates both the PowerPC exception number and the region of firmware that was executing when the exception occurred Engine PostScript Network or Operating System Note A CPU exception can either be caused by hardware or firmware error Refer to the infoSMART Knowledge Base for descriptions of the most common faults Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 7 Error Messages and Codes 1 000 4x Errors 525 Sheet Feeder Faults 1 001 46 The upper 525 sheet feeder had an overcurrent condition The lift motor or clutch may be shorted 1 002 47 The lower 525 sheet feeder had an overcurrent condition The lift motor or clutch may be shorted Troubleshooting Procedure for for 525 Sheet Feeder Step Questions or Actions Yes No 1 1 Unplug
367. ut 2 ea m 8 SAE washer 5 ea Thumbscrews 2 ea m M4 x 12 delta pt hexhead 5 ea M4 x 82 partial thread flanged hex 5 ea M4 x 82 partial thread flanged hex left hand thread yellow 5 ea M4 x 12 taptite flanged 5 ea ASMO clip lift motor 2 ea a E ring bent M6 5 mm 5 ea Bushing 6 mm 2 ea m Cable Restraint 2 ea Left hand Drum screw yellow 2 ea m Frame Replace Screw red tint 5 ea 604K42210 Repackaging Kit 065062800 8400 659K22810 8500 8550 8560 Cleaning Kit 016184500 Power Cords Description Part Number Cable Assembly 3 18 AWG 115 V 98 OL 117E29520 Cable Power EURO 220 V 99 L 117E29500 Cable Power U K 240 V 96 L 117E29510 Cable Power AUST 240 V 96 L 117E29490 Cable Assembly SWISS 220 240 V 50 Hz 117E35050 Cable Assembly PWR DANISH 250 V 117E29460 Cable Assy PWR CHINESE 117E35030 Cable Power 240 V ARGENTINA 117E35040 Upgrade Kits and Options Description Part Number Hard Drive Upgrade Kit 097803172 8400 121K44410 8500 8550 8560 Hard Drive Upgrade with Japanese Fonts 097803173 8400 121K44420 8500 8550 8560 Phaser 8400 8500 8550 8560 Color Printer Service Manual Upgrade Kits and Options Parts Lists Description Part Number Memory 8400 128 MB 16M x 64 PC133 Memory DIMM ZMD128 256 MB 32M x 64 PC133 Memory DIMM ZMD256 Memory 8500
368. vates Paper is picked and moved through either the simplex paper path to determine the paper trailing edge bounce interval at each paper path sensor R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected Paper Sensor Bounce Times Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Common 0 Tray Reports the tray from which the paper was picked 1 Paper Size Reports picked media size Tray 4 Pick 2 Tray 4 Pick Bounce Reports the interval during Interval us which the Tray 4 Pick sensor bounces following the passage of the paper trailing edge Tray 3 Pick 3 Tray 3 Pick Bounce Reports the interval during Interval us which the Tray 3 pick sensor bounces following the passage of the paper trailing edge Tray 2 Pick 2 unused 3 unused Tray 1 Pick 2 unused 3 unused Common 4 Deskew Bounce Reports the interval during Interval us which the Deskew sensor bounces following the passage of the paper trailing edge 4 26 Phaser 8400 8500 8550 8560 Color Printer Service Manual Paper Sensor Bounce Times Continued General Troubleshooting R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions Preheat Bounce Interval us Reports the interval du
369. vides read write access to selected PE NVRAM parameters Clear Fault History Clears Fault History NVRAM Clear ISC Fault Resets the Ink Stick Count ISC fault condition To avoid a reoccurrence check the ink shapes and the ink stick flags Clear PS NVRAM Clears the PS NVRAM to be rebuilt with defaults at the next power up Clear PE NVRAM Clears the PE NVRAM to be rebuilt with defaults at the next power up Set PE NVRAM to Defaults Sets the PE NVRAM parameters to the default values Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 9 General Troubleshooting Check Menu Definition Tables 4 10 A submenu containing a set of extensive tests that return measured mechanism parameters for comparison against stated limits Refer to the table associated with each test for their normal operating ranges In cases where insufficient baseline data is available the Typical Values have been left blank All results from tests that move paper through the printer were collected using 24 Ib bond paper Note Collect 2 or 3 samples of the test data before deciding on a course of 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 If a test result differs significantly from the typical valu
370. void damage use only Rheolube 768 grease P N 070E00890 Replace the rollers when you see any of the following defects m Flat spots m Out of roundness m Cracked rubber Loss of traction tackiness causing pick or feed failures Replace gears that show any signs of wear or damage Look for these problems m Thinned gear teeth Bent or missing gear teeth check especially where a metal gear drives a plastic gear m Fractured or cracked gears Oil or incorrect grease on a plastic gear can cause the gear to crack Phaser 8400 8500 8550 8560 Color Printer Service Manual 7 5 Cleaning and Maintenance Belts There are 3 rubber belts in the printer Inspect the belts for wear Look for these problems m Loose rubber particles below the belts indicate a worn belt Missing teeth in the belts m Cracking or moderate fraying a small amount of fraying is inevitable so look for other signs of wear before replacing the belt 7 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual service Parts Disassembly In this chapter m Overview m General Notes on Disassembly m Covers m Imaging m Paper Path Motors Gears Solenoids Clutches and Fans m Electronics Chapter O Service Parts Disassembly Overview This section contains the removal procedures for selected printer parts listed in the Field Replaceable Units Service Parts Parts List In general replacement procedures are not given because re
371. volts voltage average value 4 Motor drive power 0 8 to 6 8 to 3 9 Reports amount of variation of ripple watts the motor drive power 5 Motor drive power 1 9 to 7 2to8 Reports the motor drive power average watts average value Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting This test turns on the specified motor and runs it at constant velocity for approximately 20 revolutions while recording drive data The test is the same for each motor Requesting a test for tray not installed generates an Option Not Detected message Tray 2 Tray 3 Tray 4 Lift Motor Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Motor Peak Power 1 to 2 5 Reports max amount of power watts 1 Motor Average 25 to 55 Reports the average motor Power watts drive power over the last half of the run interval 2 Brake Average 10 to 20 Reports the average motor Power watts brake power over the stop with brake interval This test turns on the specified motor and runs it at constant velocity for approximately 25 revolutions while recording drive data The test is the same for each motor Requesting a test for a tray not installed generates an Option Not Detected message Tray 3 and Tray 4 Pick Feed Motor Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Motor
372. while the printer was in Standby mode Phaser 8400 8500 8550 8560 Color Printer Service Manual 3 57 Error Messages and Codes 3 58 Jam Code Troubleshooting Procedures Continued T2M _ The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 2 T2N The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 3 T2P The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 4 T2Q The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 1 T2R The Exit Cover open flag unexpectedly tripped while the printer was duplexing T2S The Exit Cover open flag unexpectedly tripped while the paper was staging for the transfix cycle T2T The Exit Cover open flag unexpectedly tripped while the print was being transfixed T2X The Exit Cover open flag unexpectedly tripped while the printer was ejecting the print T2Z The Exit Cover open flag unexpectedly tripped while the printer was shutting down 1 Ensure the media is supported 2 Ensure ground integrity of the printer see page 4 65 3 Run the Monitor Sensors test 4 Inspect the door switch for damage and proper operation 5 Check the Drum maintenance unit to ensure it is functioning properly and the blade is not covered with ink debris 6 Replace the Drum maintenance unit 7 Replace the transfix roller V2D Tray 2 media size sensor unexpectedly activated during warm up V2E Tray 2 media size
373. xis Roller Down interval following error mpts 2 Loaded Y 75 to 1200 150 to Reports the difference between the Axis 1100 max and min Y Axis following errors following during the Roll With Transfix Roller error ripple Down interval mpts 3 Timetolast 300to 0 30 to Reports the time from the unload contact sec 0 450 0 80 command to the engine until the drum indicates no further contact With the Y Axis rotating the drum maintenance unit is loaded against the drum for a short time in each configuration roller and blade blade only Drum Maintenance Drive Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions 0 Time to blade first 01to 35 15 to 4 Reports the time from the load contact sec command to the engine until the drum indicates blade contact 1 Time to roller first 03t0045 2to 50 Reports the time from the load contact sec command to the engine until the drum indicates roller contact 2 Roller Bladeloaded 700 to 650 to 150 Reports the average Y Axis average Y Axis 250 following error during the Roll following error With Both Loaded interval mpts 3 Roller Bladeloaded 50 to 300 0 to 600 Reports the difference Y Axis following between the max and the min error ripple mpts Y Axis following error during the Roll With Both Loaded interval Phaser 8400 8500 8550 8560 Color Printer Service Manual Drum M
374. y 3 Pick sensor activation until the Deskew sensor activates Tray 3 Pick 2 Unused 3 Tray 3 Pick Interval us Reports the interval from the time the engine software is commanded to start the tray 3 pick process until the Tray 3 Pick sensor activates Tray 3 Transport Interval us Reports the interval from the Tray 3 Pick sensor activation until the Deskew sensor activates Tray 2 Pick 2 Unused 3 Unused 4 Tray 2 Pick Interval us Reports the interval from the time the engine software is commanded to start the tray 2 pick process until the Deskew sensor activates Tray 1 Pick 2 Unused 3 Unused 4 Tray 1 Interval us Reports the interval from the time the engine software is commanded to start the tray 1 pick process until the Deskew sensor activates Phaser 8400 8500 8550 8560 Color Printer Service Manual 4 23 General Troubleshooting Paper Lead Edge Times Continued Typical Typical Value Value 8500 R Definition 8400 8550 8560 Actions Common 5 Stage Interval us Reports the interval from the time the engine software is commanded to start the stage process until the Preheat sensor activates part way through the stage paper motion 6 Transfix Interval Reports the interval from the us time the engine software is commanded to start the transf
375. yan If the bands vary in intensity 12 experiencing YES and or location over the 10 prints the customer is experiencing vertical bands NO stagnant ink discoloration Continue to print solid fills of the not light offending color until the output is uniform It may take as many as 60 stripes in solid Circle solid fill pages to refresh all of the ink in the printhead reservoir The color areas one repair is now complete If No the repair is complete Comments Xerox U S personnel please add all comments into FIST A completed checklist and sample prints must be returned with each printhead Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed troubleshooting checklist and a sample print with each returned printhead Please return the following items with the defective printhead e Two prints of Service Print 1 e This Printhead Troubleshooting Checklist filled out e Inventory control Green Tag filled out e Sample prints that clearly show the observed print quality defect not applicable for printheads replace because of an error code Service Print 1 Phaser 8400 8500 8550 8560 Color Printer Service Manual Reference Ink Failure Checklist For the latest policy information on Non Xerox Supplies visit the Xerox Service Partners Web Site https www office xerox com smart sso index cfm fuseaction sso partnerLogin GENERIC INK FAILURE CHECKLIST
376. zab 8500 041 Wavy Vertical Lines Troubleshooting Procedure Step Questions and Actions Yes No 1 Check and clean the Drum Maintenance Kit Complete Go to Step 2 wiper blade Replace the kit if necessary Did this correct the problem 2 Check X Axis motion and verify there is Complete Go to Step 3 nothing interfering such as a poorly dressed cable or screw Replace any defective parts Did this correct the problem 3 Test the Y Axis Encoder Goto Step 4 Clean the 1 Run the Service Diagnostics Y Axis Drum encoder Encoder test Is the Y axis encoder working properly or replace the Drum Assembly Phaser 8400 8500 8550 8560 Color Printer Service Manual 5 23 Print Quality Troubleshooting Wavy Vertical Lines Troubleshooting Procedure Step Questions and Actions Yes No 4 Test Drum maintenance operation Complete Replace the 1 Run service diagnostics to verify the correctly 2 Check and if necesary replace these parts check for cracking Drum Maintenance Pivot Plate Drum Maintenance Camshaft Did this correct the problem Drum maintenance system is operating pivot plate or Drum maintenance cam roller if damaged Oil Streaks on Print Oil stains the edge of the print This problem is likely caused by too much oil on the Drum or poor Drum Maintenance Kit grounding Initial Actions m Check the media used is supported by this printer

Phaser 8400/8500/8550/8560 Color Printer Service Manual

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