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Xerox Phaser 8500, Service Manual

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

xiii

Contents

Jam Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Jam Code Definition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

4 General Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hidden Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Service Diagnostics Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Check Menu Definition Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Check / Activators Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Check Shafts Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Check Paper Path Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Check Drive Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Check Drum Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Check Motors Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Check Misc Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Electronics Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Printer Power-Up Sequence  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Miscellaneous Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Verifying Power Supply Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Measuring AC Power Supply Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Measuring DC Power Supply Voltages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Ensuring Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Testing Motor and Solenoid Resistances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Paper Path and Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Pick Errors - Trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Paper-Pick Errors - Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Preheater and Transfix Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Checking the Process and Media Path Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Media Skews Passing Through the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Testing Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Obtaining Serial Back Channel Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Obtaining a Back Channel Trace with USB to Serial Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 4-74

Summary of Contents for Phaser 8500

Page 1: ...Service Manual Phaser 8400 8500 8550 8560 701P27910 Color Printer...

Page 2: ......

Page 3: ...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 instructi...

Page 4: ...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 Maci...

Page 5: ...esults 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 e...

Page 6: ...cessary 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...

Page 7: ...remove the wrist strap before applying power to the unit under test to avoid potential shock After removing a static sensitive assembly from its anti static bag place it on a grounded conductive surf...

Page 8: ...ts 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 comp...

Page 9: ...arning 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 Seve...

Page 10: ...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 equ...

Page 11: ...23 EEC as amended by 93 68 EEC January 1 1996 Electromagnetic Compatibility Directive 89 336 EEC March 9 1999 Radio Telecommunications Terminal Equipment Directive 1999 5 EC This product if used prop...

Page 12: ...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 Te...

Page 13: ...th Printer Interfaces 1 7 Rear View 1 8 Routine Maintenance Items and Consumables 1 9 Printer Specifications 1 10 Physical Dimensions and Clearances 1 10 Functional Specifications 1 12 Electrical Spec...

Page 14: ...Faults 3 14 7 0XX 4x Errors Process Motor Gearbox Faults 3 15 7 0XX 4x Errors Printhead Tilt Faults 3 16 7 0XX 6x Errors Program Faults 3 20 8 0XX xx Errors Wiper Media Drive Faults 3 21 8 0XX 6x Erro...

Page 15: ...p Sequence 4 51 Miscellaneous Electrical Troubleshooting 4 56 Verifying Power Supply Operation 4 64 Measuring AC Power Supply Voltages 4 64 Measuring DC Power Supply Voltages 4 65 Ensuring Ground Inte...

Page 16: ...Offset or Cut Off 5 33 Poor Ink Adhesion Poor Image Durability 5 33 Analyzing Service Test Prints 5 34 Weak Missing Jet 5 34 X Axis Motion 8400 Only 5 35 Color Bands RGBK Dither 5 36 Reverse Text 5 3...

Page 17: ...19 8 16 Wiper Assembly PL2 0 17 8 17 Stripper Carriage PL2 0 12 and Transfix Roller PL2 0 13 8 19 Preheater PL2 0 17 8 20 Duplex Roller PL3 0 8 8 21 Transfix Load Module PL2 0 15 8 22 Transfix Camsha...

Page 18: ...s 9 12 PL 6 0 Sensors and Flags Actuators 9 14 Xerox Supplies 9 16 10 Wiring Diagrams Main Wiring Diagram 10 2 Main Wiring Diagram Continued 10 3 Right Side Wiring Diagram 10 4 Right Side Wiring Diagr...

Page 19: ...r General Information In this chapter Printer Introduction and Overview Printer Configurations Control Panel Configuration Parts of the Printer Routine Maintenance Items and Consumables Printer Specif...

Page 20: ...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 comp...

Page 21: ...No No Optional Optional Optional Job Pipelining No Yes No Yes Yes Automatic 2 Sided Printing No Standard No Standard Standard 100 Sheet Tray 1 Standard Standard Standard Standard Standard 525 Sheet T...

Page 22: ...ction 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 Prin...

Page 23: ...print Yellow Warning condition printer continues to print Red Startup sequence or error condition Blinking Printer is busy or warming up 5 Up Arrow button Scrolls upward through the menus 2 Graphic di...

Page 24: ...er 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...

Page 25: ...25 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 8 Exit Cover 9 Ink Loader top cover 10 Legal A4 outp...

Page 26: ...llows 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...

Page 27: ...els 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 no...

Page 28: ...in Height 132 mm 5 2 in Weight 5 4 kg 12 lb 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 w...

Page 29: ...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 resulti...

Page 30: ...00x450 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 Tim...

Page 31: ...abels Phaser Color Printing Labels l l Special Phaser Professional Solid Ink Business Cards l l Phaser Professional Solid Ink High Resolution Photo Paper l l Phaser Premium Postcards l l Phaser Weathe...

Page 32: ...l l l Tray 1 Only 5 1 2 Baronial 4 375 x 5 75 in 6 3 4 3 625 x 6 5 in Monarch 3 87 x 7 5 in Brochure 6 x 9 in A7 5 25 x 7 25 in Choukei 3 Gou 120 x 235 mm Choukei 4 Gou 90 x 205 mm l l l l l l l l l...

Page 33: ...2 Chapter Theory of Operation In this chapter Main Printer Subsystems Print Process Printer Self Maintenance Configuration Card Personality Parameters...

Page 34: ...e 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...

Page 35: ...the media The Purge System Uses air pressure and a wiper blade to remove any debris or air bubbles that may be obstructing the Printhead nozzles The Drum Assembly and Transfix System Form the key port...

Page 36: ...tion 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 the pro...

Page 37: ...ich 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 sw...

Page 38: ...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 C...

Page 39: ...th 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 T...

Page 40: ...s 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 c...

Page 41: ...ross 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 the...

Page 42: ...inter 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...

Page 43: ...he 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...

Page 44: ...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 driv...

Page 45: ...ller 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...

Page 46: ...plies 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 pres...

Page 47: ...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 s8500 018 Purge...

Page 48: ...the Drum to about 60o C 140o 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 heat...

Page 49: ...losed 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...

Page 50: ...s 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 Pr...

Page 51: ...emory For Phaser 8400 printers the main board supports two PC 133 compatible SO DIMM SDRAM memory modules 128 to 256 MB Phaser 8500 8550 8560 printers support SIMMs instead of DIMMs Supported sizes ar...

Page 52: ...the end of this chapter for a detailed list of shadowed personality parameters Power Control Board The power control board distributes drive voltages to operate the printer s various motors solenoids...

Page 53: ...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 T...

Page 54: ...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 indica...

Page 55: ...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 sys...

Page 56: ...ution 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 i...

Page 57: ...s 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 K...

Page 58: ...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...

Page 59: ...ransfer 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 strippe...

Page 60: ...50 8560 Color Printer Service Manual Theory of Operation s8500 026 Drum Transfix Cam Transfix Load Arm Transfix Load Module Transfer Roller Transfix Load Spring Transfix Cam Process Drive Transfix Rol...

Page 61: ...Phaser 8400 8500 8550 8560 Color Printer Service Manual 2 29 Theory of Operation Exit Sensor Preheat Sensor Transfix Roller Paper Preheater Strip Sensor Release Blade Strip Solenoid s8500 027...

Page 62: ...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...

Page 63: ...k Transfix Speed Legal 20 ips 17 ips 13 ips 7 ips Peak Transfix Speed Tray 1 13 ips 7 ips 7 ips 7 ips First Sheet Transfix Speed 7 ips 7 ips 7 ips 7 ips Setpoint OHP Media Peak Transfix Speed 5 ips Ap...

Page 64: ...per minute ppm 8 5 sides per minute spm Standard 300 x 450 dpi 9 ppm 7 spm Enhanced 525 x 450 dpi 6 ppm 5 spm High Res Photo 525 x 2400 dpi 3 5 ppm 3 spm PCL 600 x 300 Mode PCL 600 x 600 Mode 6 5 ppm...

Page 65: ...a Printhead jet to malfunction Three basic actions take place during a cleaning cycle Purging Wiping Printing the Cleaning Page There is one basic type of cleaning cycle performed by the purge system...

Page 66: ...r 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 th...

Page 67: ...ated 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 AutoIP 1 IP DHCP Vend...

Page 68: ...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...

Page 69: ...r 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 Ja...

Page 70: ...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 er...

Page 71: ...s Electrical Troubleshooting on page 56 and check the power supply fuses On Solid dimly On Solid dimly Initialization failure The printer is held in reset mode This can be caused by an Electronics Mod...

Page 72: ...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...

Page 73: ...n 11 blinks Hard EEPROM re read failure 1 Check EEPROM orientation 2 Replace EEPROM 12 3 11 04 Flutter then 11 blinks Hard EEPROM data failure mismatch error 1 Check EEPROM orientation 2 Replace EEPRO...

Page 74: ...ious assertion 19 13 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 c...

Page 75: ...rint engine copy count when the error occurred 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...

Page 76: ...Sheet Feeder Step Questions or Actions Yes No 1 1 Unplug all connectors to the feeder 2 Remove the feeder and inspect the connector 3 Replace any damaged connectors either on the feeder or engine 4 R...

Page 77: ...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...

Page 78: ...e 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 co...

Page 79: ...t Did the test fail Go to Step 4 Go to Step 6 4 Inspect the wiper drive and wiper lock system Look for ink in the belts Is the wipe system operating correctly Go to Step 5 Replace the problem componen...

Page 80: ...o Step 4 4 1 Check the Process Drive for damage 2 Ensure the gears are correctly aligned see Homing the Process Drive Train on page 6 8 Is the Process Drive damaged Replace the Process Drive Go to Ste...

Page 81: ...ide of the deadband area Software fault a Reset NVRAM and retest b Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 c Replace the EEPROM chip d Reboot the printer Tro...

Page 82: ...home parameters 6 025 66 An attempt was made to home with the X Axis uninitialized 6 032 68 Could not find a solution to the described home motion profile 6 033 60 Could not allocate memory for X Axis...

Page 83: ...bstructions in the Process Drive 2 Ensure the Process Drive gears are correctly aligned Are the gears damaged Replace the Process Drive Go to Step 4 4 Use Service Diagnostics to run the Process Motor...

Page 84: ...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 The black plastic shr...

Page 85: ...r 7 008 Error Code Step Questions and Actions Yes No 1 Reboot the printer Did this correct the problem Go to Step 2 Complete 2 1 Check the printer for ink spills on the HeadTilt Gear and the drive tra...

Page 86: ...s aligned correctly see Wiper Alignment Procedure on page 6 2 Complete Go to Step 3 3 1 Check the Printhead wire routing 2 Remove the Printhead and clean around the Printhead tilt gears Did this corre...

Page 87: ...Restraints 3 1 Has ink spilled ink around the Printhead that prevents the Printhead from moving to its center position You should be able to push the Printhead right to left Clean the Printhead area...

Page 88: ...fail Replace the Exit Module Go to Step 10 10 1 Use Service Diagnostics to run the Load Maintenance Clutch test Did the test fail Inspect the maintenance drive system replace any defective parts Go t...

Page 89: ...n the Wiper Assembly path Is the Wiper Assembly obstructed by the Printhead or wiring Clear any obstructions Go to Step 2 2 For an 8 005 48 error 1 Check for paper in the paper path that is adding dra...

Page 90: ...per 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...

Page 91: ...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 ea...

Page 92: ...ted 11 005 42 Power control broken serial link detected 11 005 44 Power control broken serial link detected 3 Test the Ink Count Sensor by running the Monitor Sensors test in Service Diagnostics Inser...

Page 93: ...ting 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 c...

Page 94: ...46 13 008 47 The Drum heater is too hot 13 010 49 The Drum heater took too long to reach its setpoint Troubleshooting Procedures for Error Code 13 000 Printhead Step Questions and Actions Yes No 1 Ens...

Page 95: ...ciated with an overheat condition Go to Step 4 Go to Step 6 4 Verify clearance for adequate air flow Are any of the vents blocked Advise customer Go to Step 5 5 Using Service Diagnostics run the Drum...

Page 96: ...istor circuit is shorted 13 199 49 The Printhead left jetstack thermistor returned a bad reading or the reading was corrupted by ESD Troubleshooting Procedure for 13 067 to 13 071 Error Code Drum Ther...

Page 97: ...vironmental Specifications on page 1 12 Is the room too cold or too hot Advise customer Go to Step 2 2 Ensure ground integrity see Ensuring Ground Integrity on page 4 65 Are all components grounded pr...

Page 98: ...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...

Page 99: ...ceived an unexpected message a Reset NVRAM and retest b Ensure ground integrity for the printer see Ensuring Ground Integrity on page 4 65 Troubleshooting Procedure for 13 326 to 13 583 Error Code Ink...

Page 100: ...d 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 Mod...

Page 101: ...n the main board remove the 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...

Page 102: ...eshooting Procedure for Mechanical Unit Jam Step Questions and Actions Yes No 1 Check that all the main tray paper path sensor wires are clear of the Take Away Rollers Are any wires damaged Replace th...

Page 103: ...rinthead 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 N...

Page 104: ...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 Printhead jet stack 37 002 47 or 37 003 48...

Page 105: ...is not drawing the expected power from the supply 37 03 48 PEST Printhead Right jetstack disconnect The right jetstack is not drawing the expected power from the supply 37 004 40 PEST Printhead Reser...

Page 106: ...03 48 Right Jetstack Heater 37 004 40 37 005 41 Reservoir Heaters Did the test pass Replace the Printhead 3 Run the appropriate diagnostic test 37 006 42 Drum Heater Did the test pass Replace the Drum...

Page 107: ...o Step 2 2 Check the wiring for the problem fan Is the wiring damaged Replace the harness Replace the fan 8400 PEST Description 8500 8550 8560 PEST description 37 016 43 PEST 50 V power supply test Fo...

Page 108: ...l to I O board J800 gray ribbon cable on right side Power Control right J400 16 wire multi color Printhead data interface J130 gray ribbon cable on top side Wave amp signal J790 short gray ribbon cabl...

Page 109: ...inthead Apply power and retest Complete 8400 PEST Description 8500 8550 8560 PEST description 37 017 44 Deskew Clutch Disconnect The Deskew Clutch is not drawing the expected power Head Maintenance Cl...

Page 110: ...id 37 020 47 8400 Strip Solenoid 37 021 48 8500 8550 8560 Strip Solenoid 37 022 40 8400 Preheat Solenoid 37 023 41 8500 8550 8560 Head Tilt Solenoid Did the test pass Go to Step 3 Go to Step 2 2 Check...

Page 111: ...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 Did the test...

Page 112: ...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 dr...

Page 113: ...e the Electronics Module Go to Step 4 4 Check the wiring for damage Replace the Y Axis motor 8400 8500 8550 8560 PEST Description 37 034 43 37 037 46 Media Drive motor disconnect The Media Drive is no...

Page 114: ...supply 1 8 volt under limit 37 043 43 Power supply 2 5 volt over limit Power supply 2 5 volt over limit 37 044 44 Power supply 2 5 volt under limit Power supply 2 5 volt under limit 37 045 45 Power s...

Page 115: ...wer supply 5 volt under limit 37 063 45 Vpp measurement too low The Printhead power cable may be disconnected NOTE Later version Printheads feature a lock connector on the printhead data cable Power s...

Page 116: ...n 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 The tray number...

Page 117: ...y 1 Media Present F Front Door Event G Exit Cover H Tray 3 Media Sensor J Tray 4 Paper Sensor M Paper Path Motor N Y Axis Motor P Process Motor Q DMU Missing T Exit Cover Event U Pipeline Resource V T...

Page 118: ...er 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 Ve...

Page 119: ...edly while picking paper from Tray 2 B2N The preheat flag tripped unexpectedly while picking paper from Tray 3 B2P The preheat flag tripped unexpectedly while picking paper from Tray 4 B2Q The preheat...

Page 120: ...The strip flag timed out waiting for the paper picked from Tray 4 C3Q The strip flag timed out waiting for the paper picked from Tray 1 C3T NOTE After replacing the Process Drive Drum Maintenance Pivo...

Page 121: ...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 su...

Page 122: ...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 th...

Page 123: ...un 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 ground integrity of t...

Page 124: ...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...

Page 125: ...and load arms if necessary 7 Run the Tilt Drive test replace if necessary 8 Replace the Process Drive T2A The Exit Cover open flag unexpectedly tripped while the printer was performing an abnormal sh...

Page 126: ...nsure 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 duri...

Page 127: ...pectedly activated while print Drum maintenance cycle being performed W2W Tray 3 media size sensor unexpectedly activated during printer imaging W2S Tray 3 media size sensor unexpectedly activated whi...

Page 128: ...ity 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 Tra...

Page 129: ...pectedly activated while picking from Tray 4 Y2Q Tray 4 media size sensor unexpectedly activated while picking from Tray 1 Y2R Tray 4 media size sensor unexpectedly activated while duplexing Y2S Tray...

Page 130: ...lag sensor timed out during normal shutdown Z3D Tray 4 pick flag sensor timed out during warm up Z3E Tray 4 pick flag sensor timed out during wile printer ready Z3F Tray 4 pick flag sensor timed out w...

Page 131: ...ing 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 S...

Page 132: ...rinter is supposed to function Hidden Service Menu The Hidden Service Menu provides access to a large group of information pages and functions usable for diagnosing and correcting printer malfunctions...

Page 133: ...0 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 th...

Page 134: ...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 135: ...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 Button Function Back Returns to the prior higher le...

Page 136: ...Check Activator menu items Monitor Menu Functions for monitoring mechanical measurements Sensors Monitors all mechanically activated sensors except for the Control Panel buttons Whenever a state chan...

Page 137: ...kew Clutch Cycles the activator repeatedly Pre heater Solenoid 8500 8550 8560 Cycles the Preheater Solenoid Strip Solenoid Cycles the activator repeatedly Tilt Solenoid 8500 8550 8560 Cycles the Head...

Page 138: ...ting 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 all heaters Off Toggle...

Page 139: ...istory 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 Provides read write access to select...

Page 140: ...f 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 values defined in...

Page 141: ...5 3 1 5 to 3 0 Reports the average power Tray 1 Pick Solenoid R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions 0 Peak Power watts 20 0 to 30 20 to 25 Reports the max power value 1...

Page 142: ...ower Purge Vent Solenoid R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions 0 Peak Power watts 0 5 to 1 2 12 to 1 2 Reports the max power value 1 Average Power watts 0 4 to 1 2 15 to...

Page 143: ...atts Reports the average power following power on Deskew Shaft R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions 0 Time to CCW On peak fe sec 0 01 to 0 04 01 to 04 Reports how long...

Page 144: ...rger value could indicate particles in the gears or non uniform contamination of a roller causing a lump 5 CCW Off fe settling time sec 0 010 to 0 20 0 to 5 Reports the time it takes the MP motor serv...

Page 145: ...umber 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...

Page 146: ...or slow to engage clutch 1 CCW On peak fe 25 to 100 015 to 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...

Page 147: ...slow to release clutch 6 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 ma...

Page 148: ...ffective diameter of a roller 10 CW On fe ripple 20 to 75 0 to 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 par...

Page 149: ...verage MP fe 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 lif...

Page 150: ...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 6 Final average MP fe mpts 900...

Page 151: ...n of effort required to rotate the Tray 2 pick shaft in the pick direction at a constant velocity A larger value could indicate particles in the gears or non uniform contamination of a roller causing...

Page 152: ...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 Paper Drive P...

Page 153: ...nterval 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 4 Tray 3 Transport Interval us Reports the interv...

Page 154: ...e time the engine software is commanded to start the transfix process until the Strip sensor activates part way through the paper transfix motion 7 Exit Interval us Reports the interval from the time...

Page 155: ...mmon 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...

Page 156: ...Value 8400 Typical Value 8500 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 Interval us Repo...

Page 157: ...during which the Strip sensor bounces following the passage of the paper trailing edge 7 Exit Bounce Interval us Reports the interval during which the exit sensor bounces following the passage of the...

Page 158: ...ime the engine software is commanded to start the duplex pick process until the Deskew sensor activates 10 Duplex Stage Interval us Reports the interval from the time the engine software is commanded...

Page 159: ...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...

Page 160: ...nterval during which the Exit sensor bounces following the passage of the paper trailing edge during duplex turnaround 8 Duplex Deskew Bounce Interval us Reports the interval during which the Deskew s...

Page 161: ...the distance up from the lower limit of travel at which the head lock latch is encountered 4 Lock Engage Distance uin 350 to 700 2500 to 4500 Reports the distance up from the lower limit of travel at...

Page 162: ...ite direction Paper Path Drive R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions 0 Forward Drive Power Level watts 1 0 to 4 0 Reports the average drive power level in the foreword d...

Page 163: ...5 Reports the average power required to move the printhead 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...

Page 164: ...Axis following error ripple mpts 75 to 1200 150 to 1100 Reports the difference between the max and min Y Axis following errors during the Roll With Transfix Roller Down interval 3 Time to last contac...

Page 165: ...average Y Axis following error mpts 160 to 50 800 to 100 Reports the average Y Axis following error during the Roll With Blade Loaded interval 8 Blade loaded Y Axis following error ripple mpts 0 001...

Page 166: ...0 Tray Configuration Reports the tray status present plate not lifted etc See Paper Path Status test for a description of the configuration encoding 1 Start Peak Power watts Reports the highest peak...

Page 167: ...5000 24000 to 52000 Reports the max variation in the reported delta position between samples over the revolution 4 Sin max delta position 3 to 5 3 to 5 Reports the max value of the diference between t...

Page 168: ...eports the ration of the FFT power amplitude of the motor frequency to the FFT power amplitude of the drum frequency 3 Motor Frequency hz 44 to 48 Reports the current motor frequency 4 FFT Power Ratio...

Page 169: ...4000 Reports average following error during the last half of the second period 3 HAHVN CW Fe Ripple mpts 80 to 380 75 to 350 Reports following error ripple during the last half of the second period 4...

Page 170: ...Peak Y Axis FE mpts 0 to 11000 1100 to 7500 Reports the amplitude of the maximum Y Axis FE peak after the first 2 Average Y Axis FE mpts 0 to 4000 2200 to 3500 Reports the average of the Y Axis follow...

Page 171: ...other potential factor could be the solenoid range of travel or engagement force solenoid solenoid drive strength or return spring strength 1 Engage Time sec 0030 to 0035 0 to 05 Reports time between...

Page 172: ...to withdraw from the drum see R2 6 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...

Page 173: ...ltage 4 Motor drive power ripple watts 0 25 to 1 8 06 to 13 Reports variation of motor drive power 5 Motor drive power average watts 1 25 to 2 6 1 3 to 2 5 Reports average value of motor drive power X...

Page 174: ...ge average value 4 Motor drive power ripple watts 1 03 to 3 6 7 to 2 0 Reports amount of variation of the motor drive power 5 Motor drive power average watts 1 5 to 3 5 1 2 to 2 75 Reports the motor d...

Page 175: ...60 Actions 0 Motor Peak Power watts 1 to 2 5 Reports max amount of power 1 Motor Average Power watts 25 to 55 Reports the average motor drive power over the last half of the run interval 2 Brake Avera...

Page 176: ...least significant bit 1 an item that needs to be corrected 0 normal Paper Path Status R Definition Typical Value 8400 Typical Value 8500 8550 8560 Actions 0 Upper Paper Path 6 31 Not used always 0 0 5...

Page 177: ...ater Temp 62o 70 Reports the current temperature 4 Drum Temp 60o 60o Reports the current temperature 5 Ink Melt 1 Temp 50o 50o Yellow usually off 6 Ink Melt 2 Temp 50o 50o Cyan usually off 7 Ink Melt...

Page 178: ...e setting of the pressure relief valve 4 Pumping Time To Max sec Reports the time from pump on until the pressure relief valve opens May indicate the conditions discussed in R3 as well as the system v...

Page 179: ...ed12 Volts volts 20 20 5 2 5 Volts volts 2 5 2 5 6 unregulated Negative 12 Volts volts 20 20 Control Board Voltages 7 DC Power watts 8 50 Volts 47 to 52 47 to 52 9 Negative 50 Volts 47 to 52 47 to 52...

Page 180: ...l Value 8500 8550 8560 Actions 0 DM Initial FE Peak pm motor counts Reports the height of the initial peak when starting rotation of the dm drive gear 1 DM Initial FE Peak Time sec Reports the time si...

Page 181: ...ial port 5 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 display...

Page 182: ...S Xa State HOMELESS Is the head tilt Cam engaged head tilted Home the CAP wiper without disengaging the Head Tilt Cam 8005 8007 8008 8009 YES NO Values in the NVRAM are used to determine if printhead...

Page 183: ...e XA to Tilt Position 6000 Move Head to the Home Print position 7010 7006 Start YA Slew 5003 Rehome XA 6000 RECOVERY ROUTINE Try to recover from Process Motor Stall Home XA 6000 Move XA to Left Side H...

Page 184: ...ilt CAM will be engaged when the printhead is in the PARKED restrained position The RED numbers indicate errors that may be displayed at that point in the process Yes No Home XA 6000 Did the Process M...

Page 185: ...The purge pump begins the pressure purge after about 2 seconds the purge pump solenoid opens 5 The printhead tilts forward against the wiper assembly wipe position and the purge and wipe cycle begins...

Page 186: ...lay 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 fo...

Page 187: ...circuit on 3 3 V power supply within the I O board a REQURIED Follow all procedures from Step 3 before proceeding with these steps The I O board needs to be isolated from other systems in the printer...

Page 188: ...rt 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...

Page 189: ...onal otherwise continue debugging d 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 discha...

Page 190: ...en 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 s...

Page 191: ...per mating Optional Features Not Available 1 Printer configuration incorrect a Verify proper configuration of printer using Control Panel 2 Computer print driver configured incorrectly a Examine print...

Page 192: ...discharge f Unplug Power Cord and remove printer s covers g Unplug the following Electronics Module connectors Power Control to I O Board J800 Power Control right J400 Printhead data J130 Wave Amp si...

Page 193: ...edures until all I O board connectors are plugged back in f 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...

Page 194: ...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 procedu...

Page 195: ...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 disc...

Page 196: ...l Troubleshooting Key Ground Connections The following illustration shows the grounding points in the printer s8500 032 Transfix Roller Ground Springs I O Board Ground DM Ground Clip X Axis Motor X Ax...

Page 197: ...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 brus...

Page 198: ...d Ensure that the media guides in the tray are set correctly 6 Inspect the paper for bent torn or folded corners 7 Check to ensure no small pieces of paper are in the paper path 8 Run the paper path s...

Page 199: ...ng 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 solenoi...

Page 200: ...he tray especially with envelopes 4 Check to see if the media is excessively curled Curled media can get mistracked in the paper path 5 Examine the paper path ensure it is clear of obstructions 6 Ensu...

Page 201: ...hernet 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...

Page 202: ...enu so the printer is Ready To Print 4 Reset the printer to cause AutoIP 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...

Page 203: ...nnections Use the menu path Troubleshooting Network Problems Network Diagnostics To troubleshoot network problems select the standard Network Log Pages or Network Diagnostics Network Diagnostics take...

Page 204: ...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...

Page 205: ...e 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 tra...

Page 206: ...4 76 Phaser 8400 8500 8550 8560 Color Printer Service Manual General Troubleshooting...

Page 207: ...5 Chapter Print Quality Troubleshooting In this chapter Print Quality Problems Overview Analyzing Service Test Prints...

Page 208: ...f it is repeating or random The visible surfaces of all rollers should be inspected for obvious defects Diagnosing Print Quality Problems The Troubleshooting Print Quality page provides a good overvie...

Page 209: ...ion 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 2 It may be necessary to repeat Step...

Page 210: ...Step 5 5 For the 8400 Download the latest Jet Fix snippet from the Customer Support Site and follow the readme instructions For the 8500 8550 8560 Select Advanced You are prompted to choose the color...

Page 211: ...ages on the reverse This reduces Preheater temperatures to prevent partial melting of the preprinted image Initial Actions Check that the media used is supported Run the Remove Print Smears routine fr...

Page 212: ...Did this correct the problem Go to Step 3 Complete 3 1 Repeat Step 2 up to 3 times if the smears persist 2 Open a fresh ream of supported paper and reprint the test page Did this correct the problem...

Page 213: ...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 2 Adjust the print mode or Color settings D...

Page 214: ...ntrol Panel Troubleshooting Reference Applicable Parts Example Print Electronics Module Printhead Wave Amp Blank Prints Troubleshooting Procedure Step Questions and Actions Yes No 1 Check the area aro...

Page 215: ...Fan Drum Heater Relay Board Drum Temperature Sensor Electronics Module Drum Assembly Color is Uneven or Wrong Troubleshooting Procedure Step Questions and Actions Yes No 1 To remove discolored jets in...

Page 216: ...ate range Go to Step 4 Go to Step 5 4 Check the Drum Fan for correct installation and operation Go to Step 5 Replace the Drum Fan 5 Check that the Drum Temperature Sensor is in contact with the Drum C...

Page 217: ...dule Drum Assembly Streaks or Lines Down the Print Troubleshooting Procedure Step Questions and Actions Yes No 1 Check for and remove any media jammed paper or debris found in the exit path Did this c...

Page 218: ...Red Green Blue Cyan Magenta and Yellow Solid Fills on page 5 42 Did this correct the problem Complete Go to Step 7 7 Check X Axis drive motion If the X Axis drive does not move the Printhead smoothly...

Page 219: ...ck the media used is supported by this printer Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade Drum Maintenance Kit Prehe...

Page 220: ...Go to Step 4 4 1 If there is no scratching on the 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 D...

Page 221: ...is problem Initial Actions Check the media used is supported by this printer Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Bl...

Page 222: ...em thermal characteristics using 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 c...

Page 223: ...ebris Troubleshooting Reference Applicable Parts Example Print Drum Temperature Sensor Y Axis Encoder X Axis Motor Printhead Fuzzy Text Troubleshooting Procedure Step Questions and Actions Yes No 1 Tr...

Page 224: ...to Step 5 5 1 Test the Y Axis Encoder 2 Run the Service Diagnostics Y axis Encoder test Is the Y axis encoder working properly Go to Step 6 Clean the encoder or replace the Drum Assembly 6 Check X Axi...

Page 225: ...lor Did this correct the problem Complete Go to Step 2 2 1 Test the Y Axis Encoder 2 Run the Service Diagnostics Y axis Encoder test Is the Y axis encoder working properly Go to Step 3 Clean the Drum...

Page 226: ...ng Reference Applicable Parts Example Print Drum Maintenenace Kit Drum Maintenance Pivot Plate Drum Maintenenace Camshaft Drum Temperature Sensor Ghosting Troubleshooting Procedure Step Questions and...

Page 227: ...um 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...

Page 228: ...Poor Small Text Resolution Troubleshooting Procedure Step Questions and Actions Yes No 1 Try using a higher quality print mode Did this correct the problem Complete Go to Step 2 2 1 Test the Drum Tem...

Page 229: ...xis Encoder Drum Maintenance Pivot Plate Drum Maintenance Camshaft Wavy Vertical Lines Troubleshooting Procedure Step Questions and Actions Yes No 1 Check and clean the Drum Maintenance Kit wiper blad...

Page 230: ...g 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 Replace the pivot plate or Drum...

Page 231: ...e Go to Step 4 4 Clean the Stripper Blade and exit guides Did this correct the problem Complete Go to Step 5 5 Test Drum maintenance operation 1 Run service diagnostics to verify the Drum maintenance...

Page 232: ...ence Applicable Parts Example Print Drum Temperature Sensor Drum Maintenance Kit Drum Maintenance Pivot Plate Drum Maintenance Camshaft Incomplete Image Transfer Troubleshooting Procedure Step Questio...

Page 233: ...ep 6 6 Is the incomplete image on the left and right sides but fine through the center This indicates incomplete transfix cam rotation Check for a damaged Transfix Camshaft or a malfunction of the Pro...

Page 234: ...inter Check that the paper path is clean and clear of debris Troubleshooting Reference Applicable Parts Example Print Stripper Blade Preheater Ink Smears on First Printed Side of Duplex Print Troubles...

Page 235: ...eheater operate within the normal operating range Replace the Preheater if necessary Did this correct the problem Replace in the following order Preheater Electronics Module Troubleshooting Reference...

Page 236: ...he print Initial Actions Check the media used is supported by this printer Check that the Printhead is free to move in the horizontal direction 2 A single repeating defect that has a different Y posit...

Page 237: ...ong grain White Stripes Troubleshooting Procedure Step Questions and Actions Yes No 1 Print the Solid Fills test print to reveal an X axis problem See Primary Solid Fills 10x on page 5 40 for more inf...

Page 238: ...heavier media type from an unopened fresh ream of paper Did this correct the problem Complete Go to Step 2 2 Increase the margin size of the image Wrinkling generally occurs in solid fills near the pr...

Page 239: ...ty 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...

Page 240: ...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 Look for No interlacing is used in this print expect light dark variation...

Page 241: ...text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print This is a text print...

Page 242: ...f 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 caus...

Page 243: ...pqrstuvwxyz1234567890 4 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 10 point Times Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 8 point Tim...

Page 244: ...overhead transparencies 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 p...

Page 245: ...ht 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 r...

Page 246: ...even 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...

Page 247: ...ad are not equal Text Examine each end of the band of text Look for fuzziness or differences between the quality of the characters on the left and right ends of the print A difference indicates the Pr...

Page 248: ...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 cont...

Page 249: ...is 5 1 4 9 0 2 mm Skew tolerances are All sizes except envelopes and custom sizes 0 0 0 89 mm Envelopes 0 0 1 04 mm Custom media evaluate with the following formula Skew Spec mm 998 4 width 12 5 1 02...

Page 250: ...h 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 Other Test and Specialty Pr...

Page 251: ...6 Chapter Adjustments and Calibrations In this chapter Printer Component Homing Positions and Indicators Jet Substitution Mode Jet Substitution Mode...

Page 252: ...tments 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 cl...

Page 253: ...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 4 Replace the left drive g...

Page 254: ...d forward and disengaged from tilt gear 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 Camshaf...

Page 255: ...d 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 po...

Page 256: ...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 Pr...

Page 257: ...60 Color Printer Service Manual 6 7 Adjustments and Calibrations Note When the tilt gear is disengaged the two arrows on the left side of the printer are pointing at each other s8500 063 Tilt Gear Eng...

Page 258: ...lign with the hole on the frame When installing or homing the Process Drive engage the Drum Maintenance Pivot Plate to the Drum Maintenance Camshaft by pushing the Drum Maintenance Kit to the left tow...

Page 259: ...y 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 t...

Page 260: ...sed on the frame Note When properly aligned the hole in the camshaft gear points to the 6 00 or 5 30 position If the hole does not point at the arrow while the Drum Maintenance Kit is being pressed ag...

Page 261: ...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 t...

Page 262: ...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 Elimi...

Page 263: ...s 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 Select Jet Substitu...

Page 264: ...and then press the OK button 3 Select Eliminate Light Stripes and then press the OK button 4 Select Turn Jet Substitution Mode Off and then press the OK button 5 Print the Eliminate Light Stripes tes...

Page 265: ...7 Chapter Cleaning and Maintenance In this chapter Maintenance Inspection Cleaning...

Page 266: ...used 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 Cleaning Caution...

Page 267: ...heck the maintenance kit for ink and paper dust build up on the wiper blade Oil Drum fluid on top edge of print Select the automated procedure Remove Print Smears from the Control Panel Media Jams Not...

Page 268: ...then remove it 6 Replace the roller 7 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 C...

Page 269: ...ion 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 pro...

Page 270: ...re 3 rubber belts in the printer Inspect the belts for wear Look for these problems Loose rubber particles below the belts indicate a worn belt Missing teeth in the belts Cracking or moderate fraying...

Page 271: ...8 Chapter Service Parts Disassembly In this chapter Overview General Notes on Disassembly Covers Imaging Paper Path Motors Gears Solenoids Clutches and Fans Electronics...

Page 272: ...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...

Page 273: ...m over tightening the screws into plastic parts Always use the correct type and size screw coarse thread brass colored screws into plastic and fine thread silver colored screws into metal Using the wr...

Page 274: ...ft 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 Carefu...

Page 275: ...move 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...

Page 276: ...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 pri...

Page 277: ...e disconnects directly from the Ink Loader 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 Disconnect the 2 connectors...

Page 278: ...pulling the end of the spring arm toward the front of the printer using your fingers 3 Slide the belt off the pulley 4 Using a spring hook or pliers remove the Y Axis Tension Spring from the chassis...

Page 279: ...m 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 torqu...

Page 280: ...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 3 Rotate the gears to lower the Wiper all the way down Caution To pr...

Page 281: ...ice 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 6 Disconnect the air ho...

Page 282: ...ead then lift up and slightly toward the rear to remove 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...

Page 283: ...nthead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame 11 Disconnect the data cable from the Printhead s8500 077 Heater Cable Data Cable E...

Page 284: ...t 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 i...

Page 285: ...ft side disconnect the Head Tilt Solenoid P J208 4 Remove 1 screw from the Head Tilt Solenoid then swing the unit out to the left until the solenoid is free from the chassis Replacement Note To ensure...

Page 286: ...ose proximity to the Drum Use care not to damage the Drum with the removal tools or the spring 1 Remove the Printhead page 8 10 2 Using your hands a spring hook or pliers remove the X Axis Bias Spring...

Page 287: ...the way up 3 On the left side remove the KL clip and gear as shown below 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...

Page 288: ...dure on page 6 2 2 When reinstalling the belt into the wiper clip in 8500 8550 8560 models place the belt partly on the clip and then press the center of the clip with a small needle nose plier until...

Page 289: ...fix Roller Shaft Restraint as a lever to pry the shaft Doing so can bend the restraint 1 Remove the Right Side Cover page 8 5 2 Disconnect P J250 from the I O Board 3 Remove the Control Panel Cover pa...

Page 290: ...ide page 8 33 4 Unplug the AC and sensor flag connectors from the bottom of the Preheater Note Release the lock on the back of the AC connector 5 Slide the latches in and forward to latch in their slo...

Page 291: ...ler PL3 0 8 1 Open the Front Door 2 Remove the Outer Duplex Guide page 8 34 3 Remove the Upper Duplex Guide page 8 34 4 Remove the Lower Inner Duplex Guide page 8 33 5 Remove the Duplex Roller by remo...

Page 292: ...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 8 Insert a T 20 Torxbit through the slotted hole in the Transfix Loa...

Page 293: ...he clevis pins securing the Transfix Load Arms to the chassis and remove the Transfix Load Arms and Transfix Roller 10 Remove the Transfix Camshaft page 8 25 11 Remove the grounding springs from the T...

Page 294: ...rd Note The Transfix Load Module is a very tight fit remove carefully Replacement Note Place a small amount of Rheolube 768 grease P N 070E00890 in the groove on the end of each Transfix Load Arm befo...

Page 295: ...m 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 Pivo...

Page 296: ...L clip on the right end of the Pivot Plate Shaft 6 Remove the Pivot Plate Shaft 7 Disconnect the connector from the I O Board black white 8 Feed the cable into the printer while sliding the Drum Maint...

Page 297: ...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 Note Ensure that you lever the sp...

Page 298: ...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...

Page 299: ...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 r...

Page 300: ...onnecting the spring hooks to the Transfix Load Arms Repeat for the other side 14 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 m...

Page 301: ...age 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 Replacement Note Screws in plastic are torqued to 12 in lb...

Page 302: ...a Drive and let the motor hang 3 Disconnect 3 connectors two on the right I O Board J680 and J870 and one on the left 4 Remove the 4 screws holding the Exit Module to the printer chassis and remove th...

Page 303: ...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 gu...

Page 304: ...Seat the guide on the chassis Torque the 4 screws to 12 in lbs 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...

Page 305: ...isassembly 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...

Page 306: ...to the left side to release it from the right side frame rotate the shaft forward and remove it to the right Note Pressure from the idler rollers makes it difficult to move the Take Away Roller shaft...

Page 307: ...d 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 3 Pull down t...

Page 308: ...8 38 Phaser 8400 8500 8550 8560 Color Printer Service Manual Service Parts Disassembly Retard Roller Repalcement s8500 102 1 2 2 1 s8500 103...

Page 309: ...ve 2 screws holding the Tray Lift Motor to the printer frame 7 Remove the Tray Lift Motor from the outside of the printer Replacement Note Check that the two tabs of the bushing are seated in the chas...

Page 310: ...y 1 Pick Solenoid harnesses 4 Remove the 6 screws securing the Media Drive Replacement Note Remove the tray then rotate the Pick Roller Shaft until the clutch seats Working upwards rotate the Take Awa...

Page 311: ...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 Replacement Note Align the hole on the solenoid with the boss on...

Page 312: ...2 connectors and remove the Exit Module page 8 32 4 Remove the Outer and Upper Duplex Guides page 8 34 The Preheater Lift Solenoid is now visible on the top of the Transfix Load Module 5 Disconnect t...

Page 313: ...Train on page 6 8 Torque the Process Drive screws to 12 in lbs Irreversible damage can result if these screws are over tightened 1 Remove the Right Side Cover page 8 5 2 Disconnect the drum heater har...

Page 314: ...l 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 Mainten...

Page 315: ...Cover without disconnecting the Waste Tray Detect Sensor harness 4 Reach in to the Waste Tray cavity and remove the Head Tilt Gear Replacement Note On reassembly the leaf spring on the back side of t...

Page 316: ...ector 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...

Page 317: ...screws Caution Route the ribbon cables carefully through the slots 4 Remove the Wave Amp through the back of the printer Replacement Note Insert the ribbon cables fully and squarely into the flex con...

Page 318: ...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 Replacement Note Locate the corner of the board behind the ground tab on reass...

Page 319: ...rd before starting this procedure 1 Remove the Right Side Cover page 8 5 2 Disconnect all connections to the board 3 Remove 2 screws securing the board to the chassis 4 Remove the Drum Heater Relay Bo...

Page 320: ...lectronics 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 it s socket in the Electronics Module 3 Inser...

Page 321: ...rted 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...

Page 322: ...ip are vulnerable to damage by Electrostatic Discharge ESD 1 Remove the Back Cover from the Electronics Module 2 Disconnect the 2 connectors from inside the Electronics Module 3 Pull out and replace t...

Page 323: ...9 Chapter Parts Lists In this chapter Serial Number Format Using the Parts List Xerox Supplies...

Page 324: ...e 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 ident...

Page 325: ...em 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 exam...

Page 326: ...9 4 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 1 0 Covers s8500 117 9 13 5 6 7 8 12 11 10 4 1 3 2 3 4 14 2...

Page 327: ...8500 8550 8560 6 Control Panel with Bezel 1 657012880 8400 802K93650 8500 8550 8560 7 Exit Cover Assembly Exit Cover with Badge 1 200469380 8400 802K93590 8500 802K88420 8550 848K12760 8560 8 Ink Load...

Page 328: ...9 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 2 0 Imaging 8500 118 1 2 3 7 12 13 14 15 16 17 8 11 10 9 4 19 20 21 18 18 5 6...

Page 329: ...ressure Pump 1 094E02790 8 Left Printhead Restraint 1 120E29160 9 Right Printhead Restraint 1 120E29150 10 Transfix Camshaft Assembly 1 384187480 8400 008K02160 8500 8550 8560 11 Drum Maintenance Cams...

Page 330: ...9 8 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 3 0 Paper Path s8500 119 4 5 3 11 10 9 12 6 8 2 1 7 13...

Page 331: ...ocks 1 032K04640 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...

Page 332: ...9 10 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 4 0 Motors Gears Solenoids Clutches and Fans 13 14 6 3 9 12 11 10 7 8 5 2 s8500 120 1 15 4...

Page 333: ...50 8560 6 Tray Lift Motor Kit and Gear plus item 10 1 604K31810 7 Paper Path Cooling fan 1 119650580 8400 No longer orderable refer to service bulletin 655 8 Electronics Module System Fan 1 119642680...

Page 334: ...9 12 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 5 0 Circuit Boards 7 8 9 10 6 3 11 5 12 15 14 16 18 4 2 1 s8500 121 17 13 19...

Page 335: ...AM 1 156483700 8400 156466300 8400 237E23890 8500 8550 8560 237E23640 8500 8550 8560 237E23650 8550 8560 9 8 pin NVRAM 1 856476800 10 Configuration Card B Configuration Card BD Configuration Card N Co...

Page 336: ...9 14 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists PL 6 0 Sensors and Flags Actuators s8500 122 3 6 1 4 8 7 2 5...

Page 337: ...ription 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...

Page 338: ...w yellow 2 ea 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...

Page 339: ...apter with UK Power Converter 220V 097S03742 Recommended Tools Description Part Number Torque Screwdriver 003082700 T20 Screwdriver Tip 003086600 Mechanical Parts Kit 650429700 Flashlight Grease 070E0...

Page 340: ...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 108R...

Page 341: ...er 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...

Page 342: ...9 20 Phaser 8400 8500 8550 8560 Color Printer Service Manual Parts Lists...

Page 343: ...Chapter Wiring Diagrams In this chapter Main Wiring Diagram Right Side Wiring Diagram Left Side Wiring Diagram Inside Front Wiring Diagram Inside Top Wiring Diagram Inside Top Printhead Wiring Diagra...

Page 344: ...ator plate motor Printhead tilt solenoid Main tray pick clutch MPT solenoid Deskew clutch Pick sense opto Paper out sense opto Pick clutch Transport motor Elevator plate motor USB Mode Switch Parallel...

Page 345: ...opto Process home optional Process motor with encoder Drum fan Y axis pos encoder ECB I O color coding Black input Magenta output Red temp Printhead AC Resv heaters 2 AC Jetstack heaters 2 Drum Heater...

Page 346: ...Wiring Harness Pass Through Wiring Harness Pass Through 37016 4x 50V PS J680 13067 4x J870 13067 4x J860 Maintenance Kit Missing J400 Drum Heater J600 Add Paper Tray J250 37020 4x Strip Solenoid J110...

Page 347: ...ows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel 13387 4x 37027 4x X Motor Ribbon Cable Routed in Middle of Channel Routes to Top o...

Page 348: ...e which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel s8500 127 37023 4x Purge Valve 37022 4x Purge Motor 37013 4x Electric Fan J280 37032 4x Y Mot...

Page 349: ...indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel s8500 128 37015 4x MP Fan 8400 Only 37034 3x MP Motor 370xx 4x Preheater Lift Solenoi...

Page 350: ...Wiring Diagram The arrows indicate which connectors you should look at for the PEST codes The PEST codes are displayed on the Control Panel s8500 129 37036 4x Process Motor 37008 4x Preheat Power AC...

Page 351: ...tors you should look at for the PEST codes The PEST codes are displayed on the Control Panel 37010 4x Ink 1 Heater J130 34062 4x Data Cable J1AC 37009 4x Ink Load Power J2AC 37002 4x JSL Heater s8500...

Page 352: ...l 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 8400 Only s8500 131 Heater Cable Cabl...

Page 353: ...ppendix 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 8...

Page 354: ...Pages Supplies Info Configuration Page Connection Setup TCP IP DHCP BOOTP AutoIP TCP IP Address TCP IP Network Mask TCP IP Gateway Port 9100 LPR IPP SLP SSDP CentreWare IS Connection Setup Page Networ...

Page 355: ...c Mode Service Usage Profile Email Service Report Reset NVRAM NetWare Start Log NetWare Runtime Log TCP IP Start Log TCP IP Runtime Log AppleTalk Start Log AppleTalk Runtime Log Front Panel Language F...

Page 356: ...Paper Type Paper Handling Setup Networked printer Duplex Unit Hard Drive Requires Graphics Demonstration Office Demonstration 2 Sided Demonstration Print Mode Demonstration CMYK Sampler Pages RGB Samp...

Page 357: ...es PostScript Error Info Print Quality Mode TekColor Correction Image Smoothing User Defined Screens Reset PostScript Setup Font Number Pitch Point Size Symbol Set Orientation Form Length Line Termina...

Page 358: ...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 2...

Page 359: ...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...

Page 360: ...Troubleshooting Summary Follow the checklist below and fill in spaces as they apply as you complete the troubleshooting procedures Check List Items to Complete Value or Result What to look for Step 1...

Page 361: ...3b 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 per...

Page 362: ...isually check the printhead faceplate Is the faceplate contaminated YES NO Circle one Are there streaks smudges or a scum of wax in the jet area outlined in red of the printhead If YES replace the wip...

Page 363: ..._ ____________________________________________________________________________ A completed checklist and sample prints must be returned with each printhead Xerox reserves the right to refuse reimburse...

Page 364: ...r x Provide the customer with the Diagnosis Form and Onsite Failure notification letters x Once payment has been authorized or assured replace the printhead and included ink per normal procedures x Ch...

Page 365: ...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 Items to Complete...

Page 366: ...tory replace the electronics module continue to 3b 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...

Page 367: ...Step 8 Visually check the printhead faceplate Is the faceplate contaminated YES NO Circle one Are there streaks smudges or a scum of wax in the jet area outlined in red of the printhead If YES replac...

Page 368: ...lid fill pages of cyan If the bands vary in intensity and or location over the 10 prints the customer is experiencing stagnant ink discoloration Continue to print solid fills of the offending color un...

Page 369: ...clutch 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 d...

Page 370: ...gear 8 45 head tilt solenoid 8 15 I O board 8 48 ink loader assembly 8 7 media release blade and roller 8 19 NVRAM 8 50 pick assembly 8 37 pick solenoid 8 41 preheater and deskew assembly 8 20 preheat...

Page 371: ...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...

Page 372: ...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 PO...

Page 373: ...vironmental 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 1...

Page 374: ...I 6 Phaser 8400 8500 8550 8560 Color Printer Service Manual Index Notes Reference Description...

Page 375: ......

Page 376: ...701P27910...

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