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Service Guide

141

7.

Remove the three screws securing the drum position sensor assembly
housing to the print engine. Insert the gap tool to hold the encoder
wheel in position. Slide the assembly off the drum shaft. If necessary,
use the small flat-blade screwdriver to push the encoder disk hub along
the shaft as you remove the assembly.

Reverse these steps to reinstall the drum position sensor assembly. Use the
encoder wheel gap tool to space the encoder wheel to the drum position sensor.

Removing the drum position sensor assembly (Phaser 850 printer)

840-4-78

Screws

Drum position
sensor
assembly

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Summary of Contents for Phaser 840

Page 1: ...ervice personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing November 1999 071 0388 01 P H A S E R 8 4 0 a N D 8 5 0 C O L O R P R I N T E R S Service Manual ...

Page 2: ...itch does not de energize the printer You must remove the power cord to disconnect the printer from the mains Keep the power cord accessible for removal in case of an emergency Safety instructions Read all installation instructions carefully before you plug the product into a power source Terms on product CAUTION A personal injury hazard exists that may not be apparent For example a panel may cove...

Page 3: ...suscitation is present Use care when servicing with power on Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is on Disconnect power before removing the power supply shield soldering or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objec...

Page 4: ...panel LED error codes 29 Error messages 32 Troubleshooting 55 Front panel shortcuts 55 Access fault history 55 Set front panel language 55 Access service menu 55 Fast time to ready 55 Network Event Logs Phaser 850 56 System power up sequence 57 No lights no sound on power up 59 Verifying main board CPU operation 59 Verifying print engine operation by printing its startup page 59 Verifying power su...

Page 5: ...ion of density on second side of print 72 Ghost of first side image on second side of print 72 Poor primary color fills 73 Ghosting 74 Poor small text resolution 74 Vertical line appear wavy 75 Oil streaks on print 75 Incomplete image transfer to paper 76 Ink smears on first side of duplex print 77 Repeating print defects on print 77 Banding parallel to long edge of print 78 Wrinkling 78 Image is ...

Page 6: ...t tension adjustment 97 Y axis belts tension adjustment Phaser 840 printer 98 Y axis belts tension adjustment Phaser 850 printer 100 Printhead to drum spacing adjustment Phaser 840 printer 102 X axis scale adjustment 105 Cap wipe purge assembly belt adjustments 106 Drum position encoder gap 108 Transfix roller pressure spring adjustment 110 Vacuum check 112 Cleaning and Maintenance 115 Cleaning 11...

Page 7: ...ssembly Phaser 840 printer 138 Drum position sensor assembly Phaser 850 140 Printhead 142 X axis motor and drive assembly 145 Y axis belt drive assembly Phaser 840 printer 146 Y axis belt drive assembly Phaser 850 printer 147 Cap wipe purge assembly Phaser 840 printer 148 Cap wipe purge assembly Phaser 850 printer 150 FRU List 153 High capacity Paper Tray Assembly 170 Service tools 172 Supplies an...

Page 8: ...treaks 80 Faceplate showing streaks and smudges from a poor wipe 81 Connecting the vacuum gauge to the printer 82 Maintenance tray showing good purge 84 Damaged printhead data cable 86 Inadvertently disconnected thermistor cable connector 87 Setting process belt tension 96 Setting exit roller drive belt tension 97 Setting the Y axis belt tension 99 Setting the Y axis belt tension 101 Attaching the...

Page 9: ...moving the Y axis belt drive assembly Phaser 840 printer 146 Removing the Y axis belt drive assembly Phaser 850 printer 147 Removing the cap wipe purge assembly Phaser 840 printer 149 Removing the lower cap wipe purge retainer clip 150 Removing the lower cap wipe purge retainer clip 151 Removing the cap wipe purge assembly Phaser 850 printer 152 Cabinet FRUs 155 Imaging FRUs 157 Paper path FRUs 15...

Page 10: ...Electrical specifications 26 Environmental specifications 27 Main board power up self test error codes 29 Front panel and fault history log error codes and messages 32 Motor and solenoid resistances 63 Hidden Service Menu 93 Cabinet FRUs 154 Imaging FRUs 156 Paper path FRUs 158 Motor and fan FRUs 160 Circuit board FRUs 162 Solenoid and clutch FRUs 164 Gear and belt FRUs 166 Sensor and flag FRUs 16...

Page 11: ...xii Phaser 840 and 850 Color Printers ...

Page 12: ...Unit list Topics such as printer theory of operation detailed removal replacement procedures configuration page details and verifying printer operation are located on the companion Color Printer Service Support Resources CD ROM To ensure complete understanding of the product we recommend participation in Phaser 840 and Phaser 850 printer service training The Phaser 850 printer shown with optional ...

Page 13: ...one image and process the data for the next image at the same time First Page Preview mode prints the first page of a multiple page print job while holding the remainder of the job pending front panel approval The Phaser 840DX The extended features option has all the features of the Phaser 840 Plus printer but includes additional RAM to bring the printer to 128 Mbytes of RAM It also includes a Hig...

Page 14: ... protocol support for EtherTalk Novell NetWare NDS TCP IP and DHCP When installed this card disables the standard 10baseT port A third card provides a Token Ring board providing protocol support for TokenTalk Novell NetWare NDS and TCP IP When inserted this card also disables the standard 10baseT port A second rear panel slot accommodates an internal IDE hard drive for print job collation job acco...

Page 15: ...ended features DX option has all the features of the Phaser 850DP printer but includes additional RAM to bring the printer to 128 Mbytes of RAM It also includes a High capacity Paper Tray and an internal IDE hard drive Like the Phaser 840 printer all printers support four available paper trays They also support the optional 500 sheet High capacity Paper Tray Assembly The printer can also print sev...

Page 16: ...ary About RAM upgrades The printer features two DIMM connectors which accept both 32 or 64 Mbytes RAM DIMMs 16 Mbyte RAM DIMMs work but are not offered The Phaser 850 also supports 128 Mbytes RAM DIMMs The printer can use SDRAM DIMMs meeting these specifications 168 pin DIMM Synchronous DRAM 3 3 volts 10 nsec speed Valid on board Serial Presence Detect ROM Unbuffered Latency of 2 9 address columns...

Page 17: ... capabilities Feature 32 Mbytes 840N 850N 64 Mbytes 840DP 850DP 128 MBytes 840DX 850DX Fast Color draft printing yes yes yes Standard Printing yes yes yes Enhanced Printing yes yes yes High Resolution Photo Printing no yes yes 2 sided printing no yes The printer supports fast standard and enhanced 2 sided prints yes The printer supports 2 sided high resolution 1200 x 600 dpi print Color PCL 5C yes...

Page 18: ...n DIMM will be enabled Size Maker Part Number Printer 32 Mbytes Samsung KMM366S403CTL G0 840 850 32 Mbytes Micron MT16LSDT464AG 662XX 840 850 64 Mbytes Samsung KMM366S823BTL G0 840 850 64 Mbytes Micron Crucial CT8M64S4D10 MBTBGLP 840 850 32 Mbyte Samsung KMM366S424DTS GL 850 see note 64 Mbyte Samsung KMM366S823DTS GL 850 64 Mbyte Samsung KMM366S924BTS GL 850 128 Mbytes Samsung KMM366S1623DT GL 850...

Page 19: ...ters Print engine assemblies Internal features of the print engine 0388 02 Ink load assembly X axis drive and motor Paper feed motor Paper drum heater Cap wipe purge assembly Transfix roller Process motor Y axis motor Drum Printhead ...

Page 20: ...inter boards and many of the printer motors The power supply converts the AC line voltage into internal AC and DC voltages The front panel provides a user interface to the printer The printhead drive board a part of the printhead manages the signals and voltages of the printhead s printing elements and sensors The optional network card and internal hard drive could be considered eight and ninth ci...

Page 21: ...50 Color Printers Circuit boards of the print engine left rear view 0388 04 I O board left Power control board Printhead drive board Internal hard drive Network card Main board Power supply Drum Maintenance counter EEPROM ...

Page 22: ...I O boards for the state of the printer s sensors as well as actuate the printer s solenoids This data bus greatly simplifies the wiring that would otherwise be required for monitoring numerous sensors and solenoids The I2C bus also extends down to the High capacity Paper Trays The printer s I2C bus 0388 05 I2 C bus High capacity Paper Tray connection ...

Page 23: ... printhead faceplate and clear clogs from the printhead nozzles The system consists of a vacuum pump assembly the cap wipe purge assembly and the cap wipe purge carriage drive Printhead maintenance system of the print engine Cap wipe purge carriage drive Cap wipe purge assembly Vacuum pump assembly 0388 06 ...

Page 24: ... Note Unlike the Phaser 840 printer the Phaser 850 printer does not have a separate drum home position sensor Sensors and switches on the right side of the print engine 0388 07 Maintenance blade position sensor Paper empty sensor Cap wipe purge home sensor A4 size media sensor Ink load cover sensor Ink stick low sensor Ink stick out sensor Exit tray full sensor Top cover switch Front cover switch ...

Page 25: ...ter Drum encoder sensor Process gear position sensor Drum home position sensor Phaser 840 only Drum temperature sensor Preheater exit sensor Duplex paper sensor Transfix exit sensor 0388 34 Preheater exit sensor located on inside wall of drum transfix frame Drum Transfix roller Preheater ...

Page 26: ...ries to position the assemblies For example the printhead could be tilted forward and crash into the raised cap wipe purge assembly Before turning on the printer ensure the printhead is tilted forward centered in front of the drum and the cap wipe purge assembly is in the retracted home position The tilt cam gear should be disengaged from the gear drive train Electric clutches and solenoids are us...

Page 27: ... size This tray is sized for 8 5 x 11 inch U S paper as well as low volumes of A size transparency film Metric Letter A4 size This tray is used for 210 x 297 mm Metric paper as well as low volumes of A4 size transparency film High volume Transparency Label A This tray supports high volumes of U S size transparency film as well as laser quality adhesive label stock High volume Transparency Label A4...

Page 28: ...uilt in 10BaseT port in the Phaser 840 printer and a 10 100BaseT port for the Phaser 850 printer For the Phaser 840 printer a plug in SCSI interface adapter board provides a SCSI port for an external hard drive or scanner The Phaser 840 printer stores unique printer status and PostScript values in its socketed NVRAM and EEPROM modules The printer s Ethernet address unique to each printer is stored...

Page 29: ...rs Features of the Phaser 840 printer main board Features of the Phaser 850 printer main board 0388 09 SCSI riser board RAM DIMMs NV RAM Real Time Clock Code ROM DIMM EEPROM Printer ID 0388 76 RAM DIMMs EEPROM Printer ID Code ROM module ...

Page 30: ...per Jam Add ink as well as error messages Customers can review and modify certain NVRAM I O ports and peripheral parameters Using the front panel to review and change parameters is discussed in the topic Adjustments on page 91 Buttons Four of the six buttons are arranged as a diamond shaped keypad The other two buttons are used as Select and Help Refer to Adjustments on page 91 for details on usin...

Page 31: ...nnectors Note When an Ethernet or Token Ring PhaserShare card is installed the printer s built in 10BaseT Ethernet port is disabled The second slot accommodates an internal IDE hard drive for print job collation job accounting font storage and PDF direct printing Phaser 850 printer connectors The rear panel of the Phaser 850 printer features the host interface connectors to the printer Standard pa...

Page 32: ...the error On or Off or blinking a coded error indication A hard error condition has occurred that would keep the image processor board from operating Refer to the topic Error Codes and Messages on page 29 for the meaning of a coded indication Switches Four DIP switches allow you to reset the printer or place the printer in different operating modes Table 2 Rear panel DIP switch settings Function S...

Page 33: ...10 100Base TX 10Base2 TP LINK TX RX PhaserShareTM Series B Ethernet Card 0388 11 IDE hard drive Network card SCSI Service RS 232 Parallel USB DIP switches Ethernet 10BaseT Engine health light PostScript health light 0388 77 IDE hard drive Optional Token Ring card Service RS 232 Parallel USB DIP switches Ethernet 10 100BaseT Engine health light PostScript health light ...

Page 34: ...ed Cap wipe purge assembly This is a new assembly It also uses a new mounting system that does not require the disassembling of the timing belts in order to remove the cap wipe purge assembly Preheater entry flags New sensor flags less prone to snagging paper when jammed paper is pulled from the printer are mounted on the upper feed roller assembly Drum maintenance clutch A new clutch is used in t...

Page 35: ...Weight Approximately 36 kgs 79 lbs Print engine weight only add 9 kgs 20 lbs for each optional High capacity Paper Tray Assembly Printer installation clearances Clearances Value Top 45 7 cm 18 ins Left 10 2 cm 4 ins Right 10 2 cm 4 ins Front Unrestricted to replace trays and clear paper jams Rear 10 2 cm 4 ins Bottom No obstruction under printer that could block its cooling vents Mounting surface ...

Page 36: ...t times do not include image processing time which varies due to image complexity 25 mm 1 in margins assumed with 35 ink coverage Minimum printing margins All sides 5 mm 0 2 in Maximum print area A size 8 1 x 10 6 in A4 size 200 x 283 mm Usable paper sizes Tray fed A size and A4 size auto duplex Manual fed A size and A4 size auto duplex Phaser 850 only single sided printing only Executive 7 25 x 1...

Page 37: ... 4 10 amp slo blo Fuses are not user accessible Secondary voltages 5V 2 5 12 V 5 12 V 5 40 V 5 12 52 V 10 54 V 10 RF emissions Both 115 and 220 VAC configured instruments pass these standards EC EN60950 1992 Safety of Information Technology Equipment including Business Equipment EC EN55022 1992 Limits and methods of measurement of radio interference characteristic of Information Technology Equipme...

Page 38: ... m 50 000 ft Vibration shock Non Operating vibration Non operating shock Operating shock Will withstand 0 15 G excitation 5 to 200 Hz 3 axes for up to 7 minutes with no impairment or subsequent damage 0 5 g 25 minute sweep 5 200 5 Hz 100 200 sec sweep cycles The printer may have any corner raised and dropped 1 5 cm 0 6 in while printing is in progress without impairment of operation that cannot be...

Page 39: ... Class B VCCI CISPR 22 Class B EN61000 3 2 Flicker on AC Mains Susceptibility The packaged product meets National Safe Transit Committee Test Procedures Listed UL 1950 Information Technology Equipment Certified to CSA C22 2 No 950 Safety of Information Technology Equipment Including Electrical Business Equipment GS licensed IEC 950 1991 Second Edition EN60950 Information Technology Equipment ...

Page 40: ...ern as the PS LED The possible LED encoded error codes are listed in the following table Other failures are indicated by the failure being printed on the Startup Page After successful power up the left LED flashes at a regular heartbeat rate The front panel Power light turns on the Error light flashes and the LCD is cleared Table 3 Main board power up self test error codes Left LED flashes Long fl...

Page 41: ...hip on the main board 18 TEA error Phaser 850 only The error occurs during power up self tests when one of the main devices previously enabled fails to respond unexpectedly causing a TEA Normal TEAs cause the corresponding specific error none SCSI Phaser 840 only This test verifies the functionality of the SCSI I O processor Any test failures with this component are treated as non fatal errors wit...

Page 42: ... internal loopback failure MII internal loopback failure none Token Ring Option Card This test verifies the functionality of the processor chip Any test failures with this component are treated as non fatal errors with the error information written to the Start Page If a failure is detected the message Token Ring Option Card with one of the following messages will be sent to the Startup Page Gener...

Page 43: ..._HEAD _ZEROS Printhead NVRAM data was all 0s has this printhead been through normalization If so check wiring to printhead 4 003 42 PC_DEV_FAULT_HEAD _ONES Printhead NVRAM data was all 1s has this printhead been through normalization If so check the wiring to the printhead 4 004 43 PC_DEV_FAULT_HEAD _CHECKSUM Printhead NVRAM checksum failure the data within the printhead NVRAM has been corrupted C...

Page 44: ...e cam position should have been at blade up oil roller down the drum maintenance cam home sensor should have been FALSE and was instead TRUE Check the drum maintenance cam solenoid clutch home sensor and related hardware 4 012 42 PC_DEV_FAULT_DM_ CAM_END At the end of a drum maintenance cycle when the drum maintenance cam position should have been at blade down oil roller down the drum maintenance...

Page 45: ...splaced to the right 3 8 mm 0 15 in and the disengage was repeated but the motor stalled again This fault is then declared Table 4 Front panel and fault history log error codes and messages Error code Meaning Remove obstruction printhead heater cable C W P assembly poorly installed ink loader 4 013 43 Printhead unable to tilt Tilt arm motion obstructed Tilt arm parked on its locking pin Resistance...

Page 46: ...with a heater 4 018 48 PC_DEV_FAULT_LATE_ CLEAN_REQUEST After the printer determined at power up that the printhead was warm enough not to need cleaning and while the printer was warming up the printhead temperature dropped below the head clean needed threshold Something may be wrong with a heater 4 019 40 PC_DEV_FAULT_ 193DPI_CAL Calibration Failure Target Volt Sec Area of Fast Color mode could n...

Page 47: ...here is a problem with the Y axis encoder signal 6 000 X axis system 6 000 41 XA_FAULT_MCURRENT X axis motor over under current Indicates motor coil s are open or shorted or the motor fuse has opened 7 000 Process motor 7 002 44 PM_FAULT_PROCESS_ MOTOR_STALL The process motor stalled during operation This has several possible causes depending on what the process motor was gear connected to at the ...

Page 48: ...itions of the drum maintenance home flag Observe drum maintenance home flag motion while turning on the printer Does flag rotate during power on sequence Check operation of the compound gear belt and drive train Does process gear train rotate smoothly Replace or reseat gears replace or retension belt Remove maintenance drawer and inspect drum maintenance cam bushings and cam lifters All parts inst...

Page 49: ...k alignment of C W P assembly belts C W P belts aligned OK With C W P out of home position observe exit roller while turning on the printer Does the exit roller turn No Replace C W P clutch or reseat belt No Replace or reseat flag Replace power control board With C W P out of home position observe C W P assembly motion while turning on the printer Does C W P assembly move at all Is C W P home sens...

Page 50: ...k stick jam will be reported three times before an ink melter fault is declared Replace the ink loader If the problem persists replace the power supply 9 007 42 and 9 037 42 IL_FAULT_Y_JAM The yellow ink melt heater is on but ink does not seem to be dripping Check that the ink stick is able to advance in the chute An ink stick jam will be reported three times before an ink melter fault is declared...

Page 51: ...3 017 47 TCH_JS_RIGHT_OPEN The thermistor in the right jet stack appears to be open Check the printhead cabling Replace the printhead 13 018 48 TCH_JS_RIGHT_ SHORT The thermistor in the right jet stack appears to be shorted Check the printhead cabling Replace the printhead 13 019 40 TCH_JS_RIGHT_HOT The right jet stack heater is running away Unplug the printer NOW Check the printhead cabling Repla...

Page 52: ... is too close to the drum it acts like a heat sink not allowing the drum to heat as quickly as it should Replace drum heater followed by the power supply 16 000 Preheater thermals Preheater thermal faults are determined by a thermistor in contact with the preheater Ensure that there is adequate clearance for airflow at least 4 inches 10 cms on all sides and that the room temperature is below 90oF ...

Page 53: ... The printhead was not found parked upon power up Phaser 850 printer only 22 LSS TC Media jams L indicates the location of the jam 1 Bottom Hi capacity Paper Feeder 2 Middle Hi capacity Paper Feeder 3 Top standard tray 4 Handfeed 5 Front cover 6 Top cover 7 Y axis jams see following error codes 9 Door opened jams see following error codes T indicates whether a timeout or an event occurred 0 event ...

Page 54: ... media picked from Lower Feeder 2 1 Media flat in tray a Excess friction in pick flag motion a Replace the Lower Feeder 22 102 18 Time out on pick flag of Lower Feeder 2 with media picked from Lower Feeder 2 1 Leading edge jam right corner is folded a Media is low in tray b Media has natural curvature c Media is short grained d Using light weight media a Add more media b Flip over media or replace...

Page 55: ...tray sensor damaged missing or mis installed a Verify that upper tray type plug is present replace sensors 22 106 13 Time out on pick flag of printer with media picked from Lower Feeder 2 Same as 22 104 11 22 201 08 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 1 Same as 22 101 06 22 203 00 Unexpected Lower tray present sensor event in Lower Feeder 1 with ...

Page 56: ...lose to fill line Replace pick pad if needed 8 Media at lower roller pick flag area a Pick lag problem b Sensor Problem c Lower roller problem a Reseat flag b Verify I O right is installed correctly reinstall or replace if needed c Check bushings and e clips 22 322 13 Unknown standard tray event Same as 22 105 01 22 411 01 Handfeed width A or A4 sensor event 1 None a Media is not pushed far enough...

Page 57: ...y lower feeder pick flag c Missing support foil clear L shaped plastic media guide on the front left side of the lower tray a Refill tray can be common with low media stack b Replace lower feeder c Replace lower tray 2 Media came from lower feeder and missed preheat entry flag a Lower feeder bias problem a Make sure media is on the left side of the tray 3 Media damaged in center a Pick pad a Don t...

Page 58: ...ts from the paper path group to check for stall or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed 4 Media found flat right at deskew roller a Feed clutch problem a Replace feed clutch 22 514 05 Unexpected duplex sensor event 1 Media in both duplex path and simplex path a Media was pulled from exit into duplex path while printing b Short grained media c...

Page 59: ...ommand stop event with media in exit cover area See SF144 1 Media perfect in media path exit door area a Drum maintenance clutch b PostScript fault c Front panel error d Power supply problem a Replace the drum maintenance clutch b Try again cycle power or NVRAM reset c Replace front panel assembly d Replace power supply 22 601 02 Unexpected Lower tray present sensor event in Lower Feeder 2 with me...

Page 60: ...ove media after first side and didn t let it enter the duplex path a Train the customer 2 Media damage left lead corner a Hitting the left wall under control panel a Move front panel to left If necessary replace front panel assembly Replace printer if chassis warped 3 More than one sheet in duplex path a Media was pulled from exit into duplex while printing a Empty exit tray 4 Excess skew a Last s...

Page 61: ...er c Remove media from output tray 22 700 02 Command stop event while transfixing 1 More than one sheet of media in the path a Multiple pick a Try again 2 Media perfect in media path exit door area a Check for drum rotation b Y axis encoder defective or not seated properly c Drum maintenance clutch d PostScript fault e Front panel error f Power supply problem a Check for Y axis motion blockage b R...

Page 62: ...ort determined from A4 sensor right side 1 Skew a Last sheet in tray b First sheet in tray c Media was hand fed and was loaded skewed d Failure of deskew system a Refill tray s b Make sure tray s is loaded properly and media is square in tray c Reload media more carefully d Check deskew fingers on inside of front door If chronic check preheat entry assembly for deformation 2 Media deformed or dama...

Page 63: ... guide margin good stripper down on eccentric cam location good a Excess plastic on end of stripper fingers part defect b Deformed stripper fingers c Damaged from jam earlier a Replace stripper fingers or rapid release guide b Replace stripper fingers or rapid release guide c Replace stripper fingers or rapid release guide 5 Media jammed on stripper fingers or rapid release guide margin good strip...

Page 64: ...t grained media a Use PC based diagnostics to run verify drive current requirements from the paper path group to check for stall or feel for unevenness in motor rotation by manually turning Replace paper path motor if needed Check electronics if needed b Use long grained media 22 900 04 Unexpected front door event 1 Media perfect in media path or tray a Unknown static b Someone opened a door a Run...

Page 65: ...54 Phaser 840 and 850 Color Printers ...

Page 66: ... and press the Help button This displays the fault history menu with the most recent code at the top Set front panel language Press and hold the right arrow and then the Select button This can be done at any time Access service menu Scroll to and enter the Troubleshooting menu Press and hold the left arrow and then press the Select button Fast time to ready Turn the printer on When the Tektronix l...

Page 67: ...er problems The log indicates that network hardware is properly functioning with messages like NETWORK HARDWARE PROVEN GOOD USING IPX The logs can be accessed through the front panel menu 1 Navigate to Menu Printer Configuration Network Setting Network Logs 2 Scroll to Hardware Startup Log or TCP IP Startup Log or NetWare Startup Log and press Select The log can also be accessed remotely via Phase...

Page 68: ...he front panel Error LED with a repeating error code pattern as well as the rear panel PS LED On the Phaser 840 printer the pattern is displayed only on the rear panel PS LED left side of the DIP switches 4 The mechanical initialization is conditional on the initial position of the printhead and cap wipe purge assembly Two NVRAM parameters are checked for the last known position If the printhead i...

Page 69: ...panel display shows the warm up progress The Ready LED flashes when warm up completes the Ready LED lights solid 10 The drum begins to rotate 11 If the temperature of the printhead ink reservoirs or jetstack are below the purge threshold then the printer performs a head clean cycle a When the ink in the printhead is molten and printhead temperatures are correct the cap wipe purge assembly is posit...

Page 70: ... LED represents the operation of the PostScript firmware The right LED represents operation of the main board s print engine firmware During the POST tests the two LEDs toggle back and forth for each successful pass through each DRAM test A failure in the power on self tests is indicated by the Phaser 840 printer s left rear panel LED the PS LED flashing in a specific pattern of long and or short ...

Page 71: ...s are present on the power supply and possibly in the printer via the heaters while the printer is plugged into an AC outlet even if the power switch is off 1 Turn off the printer and unplug it from its power outlet 2 AC Input With a DMM set to measure AC voltages measure the power being supplied to the printer it should measure between 87 to 128 VAC 115 VAC nominal or 174 to 250 VAC 220 VAC nomin...

Page 72: ...er they protect the power supply from most often a shorted triac If F2 or F3 blows replace the power supply rather than the fuse Otherwise with the fuse replaced but the triac shorted AC power may be applied to the heater without the printer even being turned on resulting in a thermal runaway condition If the fuses are functional but the printer s power supply does not output DC voltages proceed t...

Page 73: ...ly 5 Turn off the printer Reconnect the 40 volt service connector to the power control board then disconnect all load connectors from the power control board Turn on the printer If the rear panel LEDs still do not illuminate the power control board has a shorted driver and must be replaced If the LEDs do illuminate isolate which motor or fan is overloading the power control board and power supply ...

Page 74: ...g the measurement Testing the cap wipe purge vacuum system Refer to the topic Evaluating the printhead and cap wipe purge system on page 80 Table 5 Motor and solenoid resistances Motor or solenoid Phaser 840 printer Resistance approximately Phaser 850 printer Resistance approximately Process motor 2 9 ohms 15 Difficult to measure due to variability at the brush commutator interface 4 3 ohms 15 Dif...

Page 75: ...f the acceptable size and orientation with the side flap up Paper pick errors Paper pick errors occur when the media in the media tray mispicks or the printer double picks two or more sheets of paper 1 In humid environments keep media sealed in packaging until it is needed for printing Flip over the media in the tray 2 Ensure that the media fits properly in the tray With the left edge of the stack...

Page 76: ...ransfer jams 1 If a piece of paper is trapped in the paper preheater try pushing out the paper by inserting a stiff piece of cardstock into the paper preheater 2 Using PC based diagnostics test the paper preheater sensors If the test fails replace the paper drum heater assembly 3 Check to see if the upper feed roller drive belt is broken or slipped off of its pulleys In such a case the upper feed ...

Page 77: ...ect the wiring harness for nicks crimps opens or other problems If the harness is functional then replace the power control board 5 Inspect the gear train on the left side of the printer frame look for stripped gears loose or damaged belts unseated bushings or broken teeth Be sure to inspect the inner teeth on the process motor gear Media skews passing through the paper path 1 Check to see if the ...

Page 78: ...s to the printhead Check for a loose connector leading to the printhead 2 Replace the power control board 3 Refer to the topic Evaluating the printhead and cap wipe purge system on page 80 A properly functioning printhead maintenance system is essential for proper printhead operation 4 Replace the printhead Streaks or lines across the print 1 Check the Y axis belt tension If the Y axis drive is no...

Page 79: ... If weak or missing jet cannot be recovered replace the printhead Color is uneven This may be due to poor thermal regulation in the printer resulting in uneven heating of the printhead which in turn results in uneven ink drop jetting 1 Clean the wiper blade of the drum maintenance drawer Inspect the operation of the drum maintenance cam roller and the left and right cam actuators it pushes against...

Page 80: ...e the X axis drive if indicated 4 Calibrate the x axis scale as described in the topic X axis scale adjustment on page 105 5 Check for media in the exit path 6 If streaks are on the front side of a 2 sided print the paper preheater may be scraping ink off the print Look for ink shaving alongside the streak Clean the preheater using the front panel initiated cleaning process Remove ink smears 7 Sme...

Page 81: ...to buff the paper preheater heating surfaces With the leading and trailing ends of the sheet of paper extending from the entry and exit of the paper preheater gently pull the sheet of paper back and forth several times and then remove the sheet of paper Be careful of the paper sensor flags 3 Clean the stripper fingers or the rapid release guide Printing too light or too dark 1 Make sure the printe...

Page 82: ...e contaminated with ink Clean for ink smears using the front panel Troubleshooting function Remove Ink Smears 3 Run diagnostics to ensure that printer temperatures are in tolerance Ensure that the drum heater is properly positioned Print using a smoother laser quality paper Some recycled paper brands may be too rough 4 Dark rectangular marks on transparency film can be caused by an accumulation of...

Page 83: ...erify the operation of the Y axis encoder using PC based diagnostics Replace the encoder if needed Variation of density on second side of print 1 The transfix spring pressure is incorrect Perform the procedure Transfix roller pressure spring adjustment on page 110 Ghost of first side image on second side of print Incomplete image transfer is taking place on the first side of the print 1 Inspect th...

Page 84: ...d in the topic Printhead to drum spacing adjustment Phaser 840 printer on page 102 4 Verify the paper preheater temperature using PC based diagnostics 5 Refer to the topic Evaluating the printhead and cap wipe purge system on page 80 A properly functioning printhead maintenance system is essential for proper printhead operation 6 If the problem persists replace the printhead Ghosting Drum is too w...

Page 85: ...e system on page 80 A properly functioning printhead maintenance system is essential for proper printhead operation 6 If the problem persists replace the printhead Vertical line appear wavy Straight vertical lines appear to be wavy and ill formed 1 Too much oil on the drum Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer 2 Are the drum...

Page 86: ...m roller Incomplete image transfer to paper All of the image does not transfer to the paper Part of the image remains on the drum to be picked up by a chase page or the next print usually caused by insufficient or non uniform drum oiling 1 Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer 2 Inspect the drum maintenance system Does the d...

Page 87: ...ntenance cam roller 5 The drum may be too warm verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 6 Verify the paper preheater temperature using PC based diagnostics 7 Try a different paper if a specialty coated paper is being used ...

Page 88: ...ary Repeating print defects on print The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect 1 Repeating defect 13 6 cm 5 34 in are caused by the transfix roller Clean the transfix roller If the problem persists replace the transfix assembly 2 A single repeating defect on the page is probably due to a defect on the drum 0388 73 0388 54 ...

Page 89: ...ts replace the printhead Wrinkling The print is usually damaged in a corner with solid fills 1 Try different media from a sealed package In high humidity environments paper left exposed unpacked absorbs moisture and begins to warp 2 Increase the margin size of the image if feasible Wrinkling generally occurs in solid fills near the print s edge 3 Ensure the deskew fingers inside the front cover ar...

Page 90: ...n poor image durability 1 For transparencies verify that the media tray is set to Transparency 2 Verify the paper preheater temperature using PC based diagnostics 3 The drum is too cold Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 4 Try a different paper if a specialty coate...

Page 91: ...eases customer ink usage 2 Print Service Test Print 2 Weak and Missing Jets Use this test print to evaluate the cap wipe purge assembly and printhead performance If you see color mixing from one row to the next for example magenta jet 46 to cyan jet 46 the cap wipe purge assembly blade may be damaged Visually inspect the wiper as described in Step 4 below If you see weak or missing jets the proble...

Page 92: ...e assembly wiper blade is damaged and the cap wipe purge assembly needs to be replaced In this example the blade has several defects in most cases there is only one smudge or streak 4 Visually check cap wipe purge assembly wiper and gasket a Open the front cover and remove the drum maintenance drawer b If not in its standby position lower the cap wipe purge assembly to its standby position under t...

Page 93: ...ays use a vacuum gauge to test the performance of the vacuum system Simply listening for the kiss sound at the end of a purge cycle as the printhead separates from the cap wipe purge assembly gasket is not enough to verify the vacuum system s performance Connecting the vacuum gauge to the printer 0388 35 Vacuum guage 40 20 0 60 76 Cap wipe purge vacuum hose T connector Vacuum assembly ...

Page 94: ...nnector can be partially seated allowing the pump to run but not the solenoid valve Vacuum decay too long If the DECAY time is much longer than 6 seconds there may be kinked tubing or ink in the tubing to the vacuum module or a clogged cap wipe purge assembly orifice Inspect the tubing for kinks or crimps To test the tubing for blockage disconnect it from the vacuum module Blow through the tube to...

Page 95: ...ap wipe purge assembly from sealing on the printhead 8 Another way to evaluate a cap wipe purge assembly gasket leak is to examine the distribution of ink in an empty waste bin following a purge cycle When the system is sealing properly a purge cycle produces approximately 18 mm 3 4 in of ink across the waste tray If the vacuum system suffered from low vacuum either caused by a poorly sealed gaske...

Page 96: ...esort a new printhead should be installed 3 Install a new printhead only after completing the cap wipe purge assembly check and performing 6 clean cycles If you are not sure the printhead is the problem change the cap wipe purge assembly assembly first Note The front panel Head to Drum Adjust will time out after 20 minutes resulting in a 4 015 45 error To clear the error cycle power on the printer...

Page 97: ...e is not making a good connection the incorrect data will be sent to the main board Reseat or replace the printhead ribbon cable before replacing the printhead 13 004 43 or 13 020 41 errors The printhead jet stack is not heating as quickly as it should Readjust the left or right head to drum adjustment the printhead is too close to the drum which prevents it from warming up If the error reoccurs a...

Page 98: ... it is check the gray data cable If the gray data cable is good replace printhead If the error happens on the new printhead replace the power control board 13 035 47 and 13 036 48 reservoir heater is running away or reservoir is not heating With these errors it is most likely a problem with the printhead Note A broken ink loader can cause the cap wipe purge assembly gasket to not seal Look for sig...

Page 99: ...e for further assistance Please have the error page in hand 6 If available try printing to a black and white PostScript Level 2 printer such as an Apple LaserWriter If the file does not print on the black and white PostScript printer this may mean that the problem is application or network related Image is rotated 90 degrees 1 In the application s Page Setup make sure that the image is selected to...

Page 100: ...e printer s Configuration Page 6 Verify that the printer is correctly cabled to the network and that the Ethernet cable functions properly 7 Locate and remove and Windows NT shared printers that have captured the AppleTalk queue for the printer 8 Verify the driver version for the built in Ethernet port on a Macintosh G3 9 Reset the printer s NVRAM settings 10 Disable QuickDraw GX Windows printing ...

Page 101: ...90 Phaser 840 and 850 Color Printers ...

Page 102: ...up and initialize in the background 1 At the rear of the printer set DIP Switch 2 into the down position Ensure Switches 1 3 and 4 are up Normal operation is all switches up 2 Turn on the printer The printer will not print a Cleaning Page Phaser 840 printer nor a Startup Page when placed in Bypass Mode Cool down mode The printer features a menu item that accelerates the cooling down of the printhe...

Page 103: ...left arrow button 5 While holding the left arrow button press Select to enter the hidden service menu 6 Scroll to the menu item Test Prints Select a test print Refer to Test Prints on page 177 it discusses each test print and what printing defect it reveals Printing the Configuration Page 1 Turn on the printer 2 Allow the printer to complete its power up self tests The front panel displays Ready t...

Page 104: ...f Fault History Reset Printer Reset NVRAM Head Adjust Cool Down for Power Off Adjust X axis Scale Reset Printer Drift Compensation On Off Head Adjust Head to Drum Adjust Adjust X axis Scale Execute Head Wipe Drift Compensation On Off Print Usage Profile Head to Drum Adjust Engine Copy count xxxxx Execute Head Wipe Head SN xxxxxxxx Print Usage Profile Head Cal Date dd mmm yyyy Print OCR Usage Profi...

Page 105: ...rn the menu item on 4 Exit the hidden service menu Selecting Envelope Oil Chase When this menu item is turned enabled the printer will process a blank sheet of paper through the printer when ever the printer is switched from printing envelopes to printing on paper or transparency film This removes ink artifacts from the drum that might otherwise appear on a print 1 Scroll to the hidden service men...

Page 106: ...er servicing the printer When you service the printhead x axis drive cap wipe purge assembly or other relevant printer components leave the printhead in its print position centered in front of the drum Upon power up the printer can safely move the printhead Manually locking the printhead If you must manually lock the printhead 1 With the printer powered off carefully tilt the printhead back about ...

Page 107: ... the belt tension loosen the process belt tensioner With a spring scale press inward on the tension idler of the process belt with a pressure of 0 7 kgs 1 5 lbs and then tighten the tensioner in place Do not over tension the belt 3 Reinstall the left side panel Setting process belt tension 0388 28 Process belt tensioner Press here to set belt deflection ...

Page 108: ...exit roller drive belt tensioner With a spring scale press downward on the idler tensioner of the exit roller drive belt with a pressure of 0 5 kg 1 lb then tighten the tensioner in place Do not over tension the belt 3 Reinstall the left side panel Setting exit roller drive belt tension Press here to set belt deflection Exit roller drive belt tensioner 0388 29 ...

Page 109: ... side frame of the printer just below and in front of the Y axis drive assembly The tool s fishhook should engage the eyelet of the Y axis drive assembly 3 Pull forward and down on the lever arm of the tension tool to apply tension to the Y axis belts 4 While the belts are under tension rotate the drum pulley 5 times to rotate the belts and seat them in place For an old Y axis drive assembly conti...

Page 110: ...ter and make a test print Setting theY axis belt tension Attach tension tool to keyholes Y axis belt assembly 0388 30 Pull lever arm to set tension Tighten 3 mounting screws after setting tension Mark the pulleys Never loosen these 3 screws ...

Page 111: ...ailures associated with low belt tension for example a growling sound heard upon cold power ups 2 If not in place attach the tension spring between the Y axis drive assembly and the tension spring bracket Note that a metal clip attaches the spring to the Y axis drive assembly the spring DOES NOT attach directly to the plastic housing of the Y axis drive assembly Refer to the illustration on page 1...

Page 112: ...Service Guide 101 8 Reassemble the printer and make a test print Setting theY axis belt tension Y axis belt assembly 0388 78 Tighten screws 3 after setting tension Mark the pulleys ...

Page 113: ...h the head tilt spring 3 For the hot adjustment scroll to the printer s hidden service support menu Activate the diagnostic s Printhead to Drum Gap Adjustment Hot routine The routine automatically centers the printhead and brings the printhead and drum to their operating temperatures 4 Lift the ink loader up and back slightly so that the printhead can be accessed Do not unplug the printhead 5 If n...

Page 114: ...nthead and the drum Check the indicator for a hot adjustment it should read 0 0070 0 0010 inches and 0 0030 0 0010 inches for a cold adjustment Adjust the printhead s spacing adjustment screws until the indicator reads the correct value Attaching the digital gap indicator 0388 31 0388 36 Secure indicator in place with screw provided in frame Attach bracket in forward most position to tilt arm Ensu...

Page 115: ... ribbon cable to ensure they are properly seated 12 Recheck the gap at both ends of the printhead 13 Remove the head to drum gap indicator and bracket from the frame 14 Reinstall the ink loader and metal heat cover 15 Select Complete from the front panel Reinstall the top cover 16 Print service test print Head to Drum Gap to check alignment Spacing the printhead to the drum RIGHT Tighten locking s...

Page 116: ...d hold the Left arrow button and while holding the Left arrow button press Select 3 Scroll to the service menu item Test Prints and press Select Choose the test print 1 X axis Motion and press Select to print it 4 Interpret the second of the two X axis motion prints The print features four purple columns each containing a jagged black band The black bands should all align horizontally with each ot...

Page 117: ...rinthead faceplate and the cap wipe purge assembly 1 Ensure that the cap wipe purge assembly is properly installed 2 Tilt the printhead back to its locked position 3 Rotate the large drive gear to pull the cap wipe purge assembly to about the middle of its travel in the chassis frame slot 4 Ensure each timing belt lock is tightened to its fourth tooth as illustrated 5 Position the right side timin...

Page 118: ...belts Unlock Index mark on right frame Belt lock Right cap wipe purge assembly belt Fan Latch Lock Leave gap between latch and belt tensioner 0388 32 Idler pulley Left belt lock align pointer between two index marks For new belt break off actuator on left side belt lock ...

Page 119: ...th a marker pen draw an alignment mark on the shaft end and the encoder wheel to help ensure their positions to each other do not change 1 Phaser 840 printer only Ensure that the retaining spring is not in the drum position sensor assembly s encoder wheel groove This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft 2 If not already mounted in place secure the d...

Page 120: ...Service Guide 109 Setting the drum position encoder gap Drum position sensor assembly 0388 33 Groove Phaser 840 Gap tool Retaining spring Phaser 840 ...

Page 121: ...on the both the left and right spring set screws 6 On the side of the printer corresponding to the wrinkling tighten the set screw clockwise 1 8 of a revolution using a 4 mm hex driver On the side that does not wrinkle loosen its set screw 1 8 of a revolution Note Whatever adjustment is added to one side must be taken away from the other side to maintain roller balance 7 Reassemble the printer and...

Page 122: ...Service Guide 111 Adjusting the transfix roller pressure springs Tension spring set screws Original registration mark 3 8 turn maximum 3 8 turn maximum 0388 38 ...

Page 123: ...r 2 Remove the top and right side covers 3 Turn on the printer The cap wipe purge seal must be checked while the printhead is hot 4 With a T connector connect the vacuum gauge to the between the vacuum pump module and the cap wipe purge unit Tools required Magnetic screwdriver Vacuum gauge T 20 TORX tip T 15 TORX tip PC diagnostics Connecting the vacuum gauge to the printer 0388 35 Vacuum guage 40...

Page 124: ...de the vacuum module At the moment the solenoid valve opens you should hear a click as the valve opens the PEAK vacuum of about 50 cm Hg 20 in Hg 10 psi 10 is applied to the printhead faceplate and the vacuum gauge Immediately the vacuum should then drop to 25 cm Hg 10 in Hg 5 psi 10 The vacuum should then bleed off to 0 with a DECAY time of 4 to 6 seconds If the vacuum does not reach the expected...

Page 125: ...114 Phaser 840 and 850 Color Printers ...

Page 126: ...ter should be cleaned when any of the following symptoms occur Light stripes or missing colors appear in prints Ink smears or random streaks appear on the front or back of prints Oily spots appear along the tops of prints Mispicks or multiple picks occur at the media tray Persistent paper jams inside the printer or at the media tray if the rollers are visibly dirty Wiggly vertical stripes caused b...

Page 127: ...cedure Remove Ink Smears from the front panel Troubleshooting menu Check the drum maintenance tray for ink and paper dust build up on the wiper blade Oil drum fluid on top edge of print Select the automated procedure Remove Ink smears from the front panel Troubleshooting menu Media jams Most media jams cannot be fixed by cleaning refer to Media jams and the paper path on page 64 Problem type Solut...

Page 128: ...When the printer exits the Energy Star mode When customers initiate the Eliminate Light Stripes automatic cleaning procedure from the front panel Vacuum Vacuum dust from the top cover the metal heat duct over the printhead and plastic dust cover under the stripper fingers or rapid release guide Drum temperature sensor With a dry swab clean any buildup around the drum temperature sensor You can acc...

Page 129: ...t the maintenance roller is empty the maintenance roller and its counter must be replaced before continued printing is possible Refer to the instructions included with the kit to replace the maintenance roller kit Phaser 840 and Phaser 850 maintenance cartridges are interchangeable Note The drum fluid an oil poses no known adverse health effects Refer to the Material Safety Data Sheet for amino oi...

Page 130: ...uction purposes Apply grease sparingly so that it does not fling off of the gears when they turn You need only to apply a dab of grease to a single gear and the grease will migrate throughout the entire gear train Do not apply oil to gears only use approved grease Note Do not apply lubricant to the head tilt gear or the head tilt gear guide X axis drive Apply a small amount of grease on the tip of...

Page 131: ... motor drive A belt from the lower paper feed roller to the upper paper feed roller Two belts on the cap wipe purge drive An exit roller drive belt A small belt for driving the cap wipe purge assembly from the cap wipe purge clutch Look for these problems Loose rubber particles below the belts indicate a worn belt Missing teeth in the belts Cracking or moderate fraying a small amount of fraying is...

Page 132: ...t the printer to its factory default values follow this procedure 1 If possible print the Configuration Page for a record of all the printer s port settings and other customer unique settings 2 Enter the Troubleshooting menu 3 Press and hold the Left arrow button 4 While holding the Left arrow button press Select to enter the hidden service menu 5 Scroll to the menu item Reset NVRAM 6 Press OK to ...

Page 133: ...e NVRAM contents or the PostScript NVRAM contents to their factory default values as shown in the following illustrations Running Reset PE NVRAM to Default or Clear PS NVRAM downloads a file to the printer that performs the indicated reset function there is no confirmation or cancel function Resetting print engine NVRAM menu item ...

Page 134: ...Service Guide 123 Clearing PostScript NVRAM menu item ...

Page 135: ...124 Phaser 840 and 850 Color Printers ...

Page 136: ...Color Printer Service Support Resources CD ROM Procedures included here are Main board and its components Power control board Power supply Upper feed roller assembly Preheat drum heater assembly Drum transfix assembly Drum position sensor assembly Printhead X axis motor and drive assembly Y axis belt drive assembly Cap wipe purge assembly This topic concludes with a discussion about printhead lock...

Page 137: ...ut the main board Phaser 840 printer If you are replacing the main board transfer the socketed realtime clock NVRAM chip and the printer ID chip to the new board so that the printer s settings and Ethernet address are retained Also swap the SCSI riser board code ROM DIMM and the SDRAM DIMMs Removing the Phaser 840 printer main board 840 4 36 Main board Press here when installing RAM DIMMS Realtime...

Page 138: ... ID chip to the new board so that the printer s settings and Ethernet address are retained Also swap the code ROM DIMM and the SDRAM DIMMs Removing the Phaser 850 printer main board 840 4 85 Main board RAM DIMMS Boot ROM Printer ID Code ROM Module When installing press on indents to seat board ...

Page 139: ... Turn off the printer and remove the power cord 2 Remove the right cover Remove the left cover 3 Remove the rear cover 4 Remove the top cover 5 At the right side of the printer disconnect the two wiring harnesses leading to the power supply 6 Remove the four screws securing the power supply in place Remove the power supply Removing the power supply 840 4 32 Power supply Wiring harnesses ...

Page 140: ...he network card or its cover plate whichever is in place 8 Remove the internal hard drive or cover plate which ever is in place 9 Disconnect the wiring harnesses leading to the power control board 10 Remove the four screws securing the power control board cover plate Remove the plate 11 Remove the four screws securing the power control board in place Lift and remove the board Removing the power co...

Page 141: ...belt and compound gear from the left end of the upper feed roller Note the small slot in the compound gear to ease removal 6 Front Open the front door and remove the drum maintenance drawer Also remove the bright metal duplex paper guide from the front of the printer It is held in place with two screws Remove the upper feed roller assembly left side 840 4 13 Compound gear Slot Feed drive belt Uppe...

Page 142: ...side of the printer frame 9 Disconnect the wiring harness leading from the upper feed roller assembly to the inside the left side of the printer frame 10 Remove the C clip located on the left inside printer frame securing the upper feed roller assembly in place 11 Remove the upper feed roller assembly Separate the assembly into its two halves Removing the upper feed roller assembly front Keyed bus...

Page 143: ...d roller as described in the topic Upper feed roller assembly on page 130 4 Disconnect the locking wiring harness from the right side of the paper drum heater 5 At the front of the paper drum heater remove the two screws securing the heater to the inside of the printer frame Do not confuse the mounting screws with the nearby smaller brass colored assembly screws Removing the paper drum heater Pape...

Page 144: ...assembly 7 Remove the paper drum heater 8 Remove the drum temperature sensor 9 Remove the C clip securing the compound gear and remove the gear and drive belt 10 Loosen the exit roller drive belt tensioner Remove the exit roller drive belt 11 Remove the duplex roller pulley and keyed bushing from the left end of the shaft 12 Remove the three screws securing the paper path motor in place Remove the...

Page 145: ...Color Printers Removing the drum transfix assembly left side 840 4 19 Exit roller drive belt tensioner Exit roller drive belt Wiring harness Tilt arm spring Hex screw Compound gear Remove drum transfix assembly screws C clip ...

Page 146: ...ith two screws 17 Remove the two screws securing the front of the drum transfix frame to the inside printer frame 18 Remove the five screws securing the left side of the drum transfix assembly to the print engine Note that one screw is removed with a 3 32 hex key 19 Remove the five screws securing the right side of the drum transfix assembly to the print engine Note that one screw is removed with ...

Page 147: ...lor Printers Removing the drum transfix assembly right side 840 4 20 Left frame bridge Remove hex screw Remove 4 screws Remove 2 inside screws Right frame bridge Wiring harnesses Transfix solenoid bracket Drum transfix assembly ...

Page 148: ...on page 119 c Set the Y belt tension refer to the topic Y axis belts tension adjustment Phaser 840 printer on page 98 or Y axis belts tension adjustment Phaser 850 printer on page 100 d Power up the printer in Bypass Mode to skip the startup and mud pages e Select service test print 10 Manufacturing Paper Path to verify the paper path and that all ink jets operate f Print service test print 9 Seal...

Page 149: ...osition assembly 5 Precisely mark the end of the drum shaft relative to the drum home flag on the drum position sensor assembly this is not necessary if you are also replacing the drum as part of the drum transfix assembly 6 Rotate the X axis drive gear to move the printhead to its print position 7 Rotate the tilt gear to orient the gear s missing teeth to the drum position sensor assembly s rear ...

Page 150: ...ust be in the same position relative to the drum position encoder wheel when the drum position sensor assembly was removed This ensures that the stripper fingers contact the drum in the same location as before otherwise print artifacts will result Install the encoder wheel on the drum shaft precisely aligning the home flag to the alignment mark drawn on the shaft Use the encoder wheel gap tool to ...

Page 151: ...position assembly 5 Precisely mark the end of the drum shaft where it aligns with the home reference line on the encoder so that the encoder can be reinstalled in the same position on the shaft This is not necessary if you are also replacing the drum as part of the drum transfix assembly 6 Rotate the tilt gear to orient the gear s missing teeth to the drum position sensor assembly s rear mounting ...

Page 152: ...the drum shaft If necessary use the small flat blade screwdriver to push the encoder disk hub along the shaft as you remove the assembly Reverse these steps to reinstall the drum position sensor assembly Use the encoder wheel gap tool to space the encoder wheel to the drum position sensor Removing the drum position sensor assembly Phaser 850 printer 840 4 78 Screws Drum position sensor assembly ...

Page 153: ...Remove the top cover 4 Remove the ink loader 5 Remove the metal heat duct from over the printhead 6 Disconnect the power wiring and data harnesses leading from the printhead to the power control board Also disconnect the two ground wires from the printer frame 7 Carefully plug the printhead s reservoir chamber holes with the silicone plugs The plugs keep liquid ink from spilling if you should inad...

Page 154: ...r to tilt the printhead forward about 2 5 cm 1 inch 11 If you use the removal tool slide the standoff locks outward to secure the tool to the printhead Loosen the two mounting screws securing the printhead in place 12 Carefully lift on the plastic posts at each end of the printhead to remove the printhead and place it on a flat surface If you are using the removal tool lift and remove the printhea...

Page 155: ...thead spacer between the printhead and the drum Check the indicator it should read 0 0030 0 0010 inches If needed lighten the four locking screws and then adjust the printhead s spacing adjustment by twisting a flat blade screwdriver in the adjustment slot to move the printhead s position until the indicator reads the correct value This sets the cold printhead to drum gap Refer to the illustration...

Page 156: ... drive yoke Lift up the yoke and remove the upper portion of the yoke 7 Rotate the X axis cone gear counterclockwise to remove it from the X axis shaft For reassembly apply a small amount of grease on the tip of the nose cone Apply a small amount 3 dabs on the threads of the X axis shaft Be sure to rotate the black plastic retainer so its end locks the yoke in position Perform the X axis scale adj...

Page 157: ...rientation it blows into the drum Caution Never loosen or remove the three screws securing the assembly parts together 4 Remove the three tension set screws securing the Y axis belt drive assembly to the engine frame Remove the assembly with its two belts Note Tension the drive belts using the procedure Y axis belts tension adjustment on page 68 Removing theY axis belt drive assembly Phaser 840 pr...

Page 158: ...to flip off forcefully causing injury 4 Insert a flatblade screwdriver through the tension bracket as a holder Anchor the screwdriver tip against the Y axis belt drive assembly 5 Remove the tension bracket s mounting screw Using the screwdriver as a lever slowly tilt the bracket up and away from the frame 6 Remove the three mounting screws securing the Y axis belt drive assembly to the engine fram...

Page 159: ... to position the cap wipe purge assembly 25 mm 1 in from the top of its travel 8 Place a few sheets of paper between the drum and the cap wipe purge assembly to prevent scratching the drum 9 Remove the right timing belt s lower pulley to create slack in the right timing belt 10 Remove the metal vacuum line from the assembly 11 Remove the wiring from the right cap wipe purge assembly bracket 12 Pus...

Page 160: ...Service Guide 149 Removing the cap wipe purge assembly Phaser 840 printer Short pin screw Cap wipe purge assembly Vacuum inlet 840 4 43 Long pin screw Short pin screw ...

Page 161: ...the top cover 4 Remove the ink loader 5 Remove the metal heat duct over the printhead 6 Tilt back the printhead and center it 7 Remove the maintenance drawer 8 Remove the right maintenance drawer guide 9 Disconnect the wiring harness leading from the cap wipe purge assembly to the power supply wiring harness Clip the tie wraps securing the cap wipe purge wiring harness Disconnect the green ground ...

Page 162: ...p wipe purge assembly 11 Rotate the cap wipe drive gear to position the cap wipe purge assembly at the top of its travel 12 Place a few sheets of paper between the drum and the cap wipe purge assembly to prevent scratching the drum Removing the lower cap wipe purge retainer clip 840 4 81 Cap wipe purge assembly Plastic retainer clip ...

Page 163: ...e holding onto the cap wipe purge assembly remove the guide pin that holds the cap wipe purge assembly in place 17 Push the wiring through the print engine s frame so that you can free the cap wipe purge assembly Reverse these steps to reinstall the cap wipe purge assembly Refer to Wiring Diagrams on page 191 for details on dressing the cap wipe purge wiring Removing the cap wipe purge assembly Ph...

Page 164: ...he printer produced on that day The serial number is coded as follows BLxxDMY B indicates the headquarters city of the manufacturing company Beaverton L indicates the modification level of the printer ranging alpha numerically from 0 to Z xx alpha numerically indicates the sequence of the printer among the printers produce on that day of manufacture ranging from 01 to ZZ representing 1 to 1296 the...

Page 165: ... Front cover pivot 4 650 4028 00 650 4121 00 650 4143 00 1 1 1 Front cover control panel Phaser 840 Front cover control panel 840GP Designer Edition Front cover control panel Phaser 850 5 200 4365 00 200 4589 00 1 1 Left cover Left cover 840GP Designer Edition 6 200 4375 00 200 4599 00 200 4604 00 1 1 1 Exit cover Phaser 840 Exit cover 840GP Designer Edition Exit cover Phaser 850 7 200 4367 00 200...

Page 166: ...Service Guide 155 Figure 1 Cabinet FRUs 7 5 6 8 1 2 4 0388 21 3 9 9 ...

Page 167: ...t of 650 3617 00 Drum Transfix Assy Kit Phaser 840 Drum transfix assembly Part of 650 4140 00 Drum Transfix Assy Kit Phaser 850 8 441 2137 03 650 4179 00 1 Cap wipe purge assembly Phaser 840 Cap wipe purge assembly Phaser 850 9 650 3623 00 650 4112 00 1 Printhead kit Phaser 840 Printhead kit Phaser 850 10 174 3807 00 1 Cable printhead data 11 650 4025 00 650 4141 00 1 Ink loader Phaser 840 Ink loa...

Page 168: ...Service Guide 157 Figure 2 Imaging FRUs 4 2 3 6 5 7 8 11 9 13 15 17 16 12 14 1 2 0388 79 18 10 19 ...

Page 169: ...m paper heater assembly Phaser 850 7 351 1047 01 351 1048 00 351 1079 00 1 1 1 Upper feed assy top half with circuit bd Upper feed assy lower half Phaser 840 Upper feed assy lower half Phaser 850 8 351 1035 00 1 Duplex paper guide 9 401 0841 01 401 0867 00 1 Duplex roller Phaser 840 Duplex roller Phaser 850 10 650 4026 00 1 Upper stripper finger assembly 11 11a 11b 386 7018 00 384 1849 00 650 4158...

Page 170: ...Service Guide 159 Figure 3 Paper path FRUs 0388 80 2 1 5 11 10 9 12 6 4 3 7 13 8 11a 11b ...

Page 171: ...or with gear 2 650 3621 00 650 4147 00 1 X axis drive assembly Phaser 840 X axis drive assembly Phaser 850 3 119 5876 00 1 Drum fan 4 147 0180 01 1 Paper path motor 5 147 0082 00 147 0113 00 1 Y axis motor Phaser 840 Y axis motor Phaser 850 6 147 0108 01 147 0112 01 1 Process motor with encoder Phaser 840 Process motor with encoder Phaser 850 7 119 5781 00 1 Main fan ...

Page 172: ...Service Guide 161 Figure 4 Motor and fan FRUs 0388 14 7 4 3 5 6 2 1 ...

Page 173: ...apanese Morisawa Code ROM DIMM Chinese Traditional Code ROM DIMM Chinese Simplified Code ROM DIMM Korean Hangul Code ROM DIMM Japanese Heisei Phaser 850 One Time Programmable Code ROM DIMM English Base Code ROM DIMM English Plus Code ROM DIMM Japan Heisei Base Code ROM DIMM Japan Heisei Plus Japanese Morisawa and Heisei Chinese Traditional and Simplified Korean Hangul fonts on the internal hard dr...

Page 174: ...Service Guide 163 Figure 5 Circuit board FRUs 4 3 5 2 1 9 7 6 8 10 11 13 0388 81 12 7a ...

Page 175: ...r exit roller Phaser 840 Electric clutch upper feed roller exit roller Phaser 850 2 401 0808 01 1 Electric clutch pick roller 3 401 0807 00 401 0871 00 1 Electric clutch drum maintenance Phaser 840 Electric clutch drum maintenance Phaser 850 4 401 0792 00 401 0855 00 1 1 Electric clutch cap wipe purge drive Phaser 840 Electric clutch cap wipe purge drive Phaser 850 5 148 0301 01 1 Solenoid transfi...

Page 176: ...Service Guide 165 Figure 6 Solenoid and clutch FRUs 4 5 3 2 1 0388 23 ...

Page 177: ... 1015 00 1 Guide head tilt 9 650 3615 00 2 Head maintenance timing belt and ratchet clip Part of 650 3615 00 Belt Kit 10 650 3619 00 5 Pulley drive head maintenance Part of 650 3619 00 Gear Kit 11 650 3615 00 1 Exit roller drive belt Part of 650 3615 00 Belt Kit 12 650 3619 00 5 Pulley exit drive Part of 650 3619 00 Gear Kit 13 650 3615 00 1 Tensioner exit drive belt Part of 650 3615 00 Belt Kit 1...

Page 178: ...Service Guide 167 Figure 7 Gear and belt FRUs 0388 22 9 7 3 4 2 13 15 11 5 10 6 14 12 16 17 18 19 1 8 ...

Page 179: ... 8 119 5803 00 1 Preheater exit sensor assembly 9 119 4968 00 1 Process gear sensor 10 650 3622 00 650 4144 00 1 1 Y axis encoder kit Phaser 840 Y axis encoder kit Phaser 850 11 650 3618 00 650 4156 00 1 1 Transfix exit sensor flag Phaser 840 Transfix exit sensor flag Phaser 850 12 640 4028 00 650 4121 00 650 4143 00 1 1 1 Par t of Front cover Control Panel Front cover open sensor Phaser 840 Front...

Page 180: ...Service Guide 169 Figure 8 Sensor and flag FRUs 0388 15 7 3 2 1 4 5 9 8 10 16 12 17 14 18 19 6 11 13 15 ...

Page 181: ...er Serial number Effective Discont d Qty Name and description 1 436 0328 00 436 0329 00 1 High capacity paper tray A size High capacity paper tray A4 size 2 116 0272 00 1 Paper pick roller 437 0467 00 437 0468 00 1 High capacity paper tray assembly A size includes tray High capacity paper tray assembly A4 size includes tray ...

Page 182: ...Service Guide 171 Figure 9 High capacity PaperTray 0388 65a 1 2 ...

Page 183: ...346 00 1 1 Service diagnostics diskette SW Phaser 840 Service diagnostics diskette SW Phaser 850 650 3973 00 650 4103 00 Phaser 840 Tool kit Encoder Alignment Tool Head to Drum Gap Tool Assy Y Axis Belt Tensioner tool Serial Adapter Cable 40 v Service Plug PC DB 9F to DB25M Cable Vacuum gauge assembly Phaser 850 Tool kit Encoder Alignment Tool Serial Adapter Cable 40V Service Plug PC DB 9F to DB25...

Page 184: ... 1 Phaser 840 Magenta Ink 2 pack plus 1 black sticks 016 1584 00 1 Phaser 840 Yellow Ink 2 pack plus 1 black sticks 016 1831 00 1 Phaser 850 Black Ink 3 pack 016 1825 00 1 Phaser 850 Cyan Ink 5 pack plus 2 black sticks 016 1826 00 1 Phaser 850 Magenta Ink 5 pack plus 2 black sticks 016 1827 00 1 Phaser 850 Yellow Ink 5 pack plus 2 black sticks 016 1833 00 1 Phaser 850 Rainbow pack 1 stick each col...

Page 185: ...nsparency 50 sheets A size 016 1721 00 Standard Transparency 50 sheets A4 size 016 1194 00 A size transparency pockets 016 1130 00 A size transparency sleeves 016 1131 00 A4 size transparency sleeves 013 0299 00 Parallel cable adapter 1284C to 1284B 070 9102 00 Phaser 840 User Guide English 070 9102 10 Phaser 840 User Guide French 070 9102 20 Phaser 840 User Guide Italian 070 9102 30 Phaser 840 Us...

Page 186: ...nd Utilities Diskettes Simplified Chinese 063 2627 80 Phaser 840 Drivers and Utilities Diskettes Traditional Chinese 063 2627 90 Phaser 840 Drivers and Utilities Diskettes Korean 063 2627 05 Phaser 840 Drivers and Utilities Diskettes Russian 061 4208 00 Phaser 850 Manual pack English 061 4208 10 Phaser 850 Manual pack French 061 4208 15 Phaser 850 Manual pack Pacific MNL C K 061 4208 20 Phaser 850...

Page 187: ...sh 063 3178 10 Network Setup Guide French 063 3178 20 Network Setup Guide Italian 063 3178 30 Network Setup Guide German 063 3178 40 Network Setup Guide Spanish 161 0066 00 Power cord Standard U S 115V 161 0066 09 Power cord Euro 220V 161 0066 10 Power cord United Kingdom 240V 161 0066 11 Power cord Australian 250V 161 0154 00 Power cord Swiss 220V 161 0240 00 Power cord Danish 065 0580 00 065 058...

Page 188: ...he print may be caused by incorrect transfix roller pressure A defective printhead can also cause uniformity problems particularly if the density difference is about 1 3 of an A size page wide Narrower density problems may be caused by a paper preheater Print Service Print 6 3 Wrinkling See Service Print 8 Causes Gaps could either be caused by a defective X axis drive or by something else such as ...

Page 189: ...head and drum thermals are correct A weak jet can also cause banding refer to the Weak missing Jets test print Make sure that the drum temperature sensor is correctly mounted and in proper even contact with the drum If necessary remove the sensor and check it for an accumulation of debris at its contact point As a last resort replace the printhead 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2...

Page 190: ...RSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 10 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 8 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 6 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 5 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 4 point Times Roman A...

Page 191: ... 50 blue as this is a popular background for overhead transparencies Look for Uniformity of fill with no scratching Evaluate the print on an overhead projector Some print artifacts visible on the print do not show when projected Likewise some defects do not show until projected Causes The ink drops from the jets are traveling in incorrect trajectories The printhead is incorrectly mounted or its pr...

Page 192: ...d drum for correct thermal regulation Also check the printhead to drum gap Ensure the drum fan is running properly A vertical band 1 5 of a page wide running the length of the page is caused by a stuck heating plate in the paper preheater Run the front panel cleaning procedure Clean Ink Smears which raises the temperature of the paper preheater and may free the stuck heating plate Additionally you...

Page 193: ...To test for wrinkling print the YMCKRGB prints in duplex mode at the Standard resolution Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media Replace the drum maintenance drawer to correct streaking Check the drum temperature sensor for debris build up on the sensor Check to see if the sensor is in improper contact with the drum Refer to the R...

Page 194: ...0 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 5 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78...

Page 195: ...for text that is fuzzy or text that differs in quality from one side of the print to the other Either condition indicates that the printhead to drum gap is incorrect Perform the procedure Printhead to drum spacing adjustment Phaser 840 printer on page 102 Generally the Phaser 850 printer should never require this adjustment 12 Manuf x axis scanner This print is used for manufacturing and engineeri...

Page 196: ... in Transfix roller pressure spring adjustment on page 110 As a last resort replace the drum transfix assembly 14 Red Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media R...

Page 197: ... described in Transfix roller pressure spring adjustment on page 110 As a last resort replace the drum transfix assembly 16 Blue Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different pr...

Page 198: ...n Transfix roller pressure spring adjustment on page 110 As a last resort replace the drum transfix assembly 18 Magenta Solid Fill This prints shows uniformity of fill Look for Even uniform fills throughout the print There should be no wrinkling or deformity of the paper throughout the print Causes Weak jets or uneven drum heating may cause uneven fills To solve wrinkling try different print media...

Page 199: ...streaking Check the drum temperature sensor for debris build up on the sensor Or the sensor is in improper contact with the drum Refer to the test print Reverse Text The transfix pressure may be incorrect Perform the transfix spring adjustment described in Transfix roller pressure spring adjustment on page 110 As a last resort replace the drum transfix assembly 20 OHP Color Bands This print consis...

Page 200: ...olid fill prints then 10 yellow solid fill prints and then 10 black solid fill prints 22 Manuf Skew Margins Phaser 850 printer only This print consists of an image used by manufacturing to gauge skew on 2 sided prints 23 Manuf Banding Phaser 850 printer only This print consists of an imaged used by manufacturing to gauge banding ...

Page 201: ...190 Phaser 840 and 850 Color Printers ...

Page 202: ...A A4 Empty Tray present Process Gear Position Sensor Drumhome sensor Phaser 840 only Drum encoder sensor Upper feed roller clutch Drum maintenance cam clutch Pick clutch Preheater exit sensor Left I O board Handfeed sensor A size sensor A4 size sensor Preheat entry left edge sensor J 140 J 180 J 150 4 3 6 3 4 2 2 2 Drum temperature sensor 2 2 2 2 3 J 990 J 970 J 170 Right I O board Tray present se...

Page 203: ...ssing printer wiring Incorrect wiring dressing can result in wires pinched by cabinet panels or damaged by moving parts of the printer Wire routing on the right side of the printer near right I O board Bundle vacuum hose through Tie wrap wiring harness cable restraint Tie wrap hose and wiring to corner of fan ...

Page 204: ... Wire dressing above the x axis drive The power wiring harness for the ink loader is routed through a cable strap located behind the vacuum pump module Vacuum pump Paper path motor X axis motor Drum fan Right I O board ...

Page 205: ...each tie wrap s knot should be oriented inward so that it does not rub against the printer cabinet panel Do not pinch shut the vacuum hose Vacuum hose dressing Orient knots in ties inward Bundle cap wipe purge wiring with hose Tie wrap cap wipe purge wiring harness to both ends of metal vacuum hose ...

Page 206: ...t side of the printer Wrap drum position sensor wiring harness around drum temperature sensor wiring harness Tie wrap to frame Tie wrap to bracket Main fan Process motor encoder Process motor Y axis motor High capacity paper tray Left I O board ...

Page 207: ...196 Phaser 840 and 850 Color Printers Wire dressing behind the printhead Printhead cable restraints Printhead ground lugs built into frame Maintenance tray counter sensor wiring harness restraint ...

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