Xerox PHASER 8560MFP Service Documentation Download Page 27

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10/2006

2-1

Phaser 8510/8560MFP Multifunction Product

Error Messages and Codes

Initial Issue

2 Error Messages and Codes

Power On Self Tests .......................................................................................................

2-3

NVRAM Reset .................................................................................................................

2-5

Error Message Troubleshooting ......................................................................................

2-7

1,00X.4x 525-Sheet Feeder Faults .................................................................................

2-8

1,000.6x 525-Sheet Feeder Program Faults...................................................................

2-9

2,00X.xx I/O Board Errors ...............................................................................................

2-9

2,006.xx I/O Board Program Faults.................................................................................

2-10

2,0XX.6x Configuration Card Faults................................................................................

2-10

3,0XX.6x IPC Program Faults .........................................................................................

2-11

4,0xx.4x Process Control Errors .....................................................................................

2-11

4,024.42 Wiper Alignment Fault......................................................................................

2-12

4,025.46 Drum Transfix Fault..........................................................................................

2-12

4,0xx.6x Process Control Program Faults.......................................................................

2-13

5,0xx.4x Y-Axis Sub-System Faults ................................................................................

2-13

5,0xx.6x Y-Axis Sub-System Program Faults .................................................................

2-14

6,0xx.4x X-Axis Fault ......................................................................................................

2-15

6,0xx.6x X-Axis Program Faults......................................................................................

2-15

7,002.44 Process Drive Fault ..........................................................................................

2-16

7,006.4x Head Tilt Solenoid Fault ...................................................................................

2-16

7,007.49 Process Drive Fault ..........................................................................................

2-17

7,008.41 Printhead Tilt Fault ...........................................................................................

2-17

7,009.42 Printhead Restraint Fault .................................................................................

2-18

7,01X.4x Process Faults .................................................................................................

2-19

7,0xx.6x Program Faults .................................................................................................

2-20

8,0XX.4x Wiper or Media Drive Faults ............................................................................

2-21

8,0xx.6x Media Drive Program Faults .............................................................................

2-22

9,0XX.4x Ink Loader Faults.............................................................................................

2-22

9,009.44 and 9,00X.6x Ink Loader Program Faults ........................................................

2-23

11,0XX.xx Electronics Module Interface Faults...............................................................

2-24

11,100.60 Electronics Module Temperature Fault ..........................................................

2-25

12,000.60 Program Faults...............................................................................................

2-25

13,000.48 Printhead Thermal Fault.................................................................................

2-26

13,003.42 and 13,007.46 Thermal Faults .......................................................................

2-26

13,008.47 and 13,010.49 Drum Thermal Faults .............................................................

2-27

13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults .........................................

2-28

13,XXX.4x Preheater Thermal Faults .............................................................................

2-28

13,1XX.4x Left Jetstack Thermal Faults .........................................................................

2-29

13,2XX.4x Right Jetstack Thermal Faults .......................................................................

2-29

13,XXX.xx Printhead Reservoir Thermal Faults..............................................................

2-30

13,XXX.xx Ink Loader Thermal Faults ............................................................................

2-30

13,00x.6x Thermal Program Faults .................................................................................

2-31

19,0XX.4x Printhead Calibration Faults ..........................................................................

2-32

19,0XX.6x Waveform Program Faults.............................................................................

2-32

21,000.69 Diagnostic Firmware Version Mismatch .........................................................

2-33

22,0XX.6x Jam Fault.......................................................................................................

2-33

23,0XX.6x NVRAM Faults...............................................................................................

2-34

26,0XX.6x Printing Faults................................................................................................

2-34

27,0XX.6x Profile Library ................................................................................................

2-35

29,0XX.6x Jam Manager Faults ......................................................................................

2-35

31,001.40 Mechanical Initialization Jam..........................................................................

2-36

31,0XX.6x Program Faults ..............................................................................................

2-36

33,00X.4x Tray 1 Width Sensor Faults............................................................................

2-37

34,00X.4x Printhead NVRAM Faults ...............................................................................

2-37

36,000.40 Drum Maintenance Faults ..............................................................................

2-38

36,001.67 Drum Maintenance Drive Faults.....................................................................

2-38

36,002.44 Drum Maintenance Kit Fault...........................................................................

2-39

37,0XX.xx PEST Heater Faults .......................................................................................

2-39

37,01X.41 PEST Fan Faults............................................................................................

2-40

37,016.43 PEST 50 Volt Supply Fault.............................................................................

2-40

37,0XX.4x PEST Clutch/Solenoid Faults ........................................................................

2-41

37,024.48 PEST Tray 2 Lift Motor Fault..........................................................................

2-42

37,026.44 PEST Purge Pump Fault ................................................................................

2-42

37,02X.4x PEST Relay Board Faults ..............................................................................

2-43

37,03X.4x PEST X-Axis Motor Faults .............................................................................

2-43

37,035.44 and 37,036.45 PEST Y-Axis Motor Faults......................................................

2-44

37,037.46 and 37,038.47 PEST Media Drive Faults .......................................................

2-44

37,039.48 and 37,040.40 PEST Process Drive Faults....................................................

2-45

37,0XX.4x PEST Power Supply Faults ...........................................................................

2-45

39,002.40 and 39,003.41 Scanner Subsystem Test Faults ............................................

2-46

39,004.42 Scanhead Locked or Shipping Restraint Faults .............................................

2-47

39,005.43 Scanner Missing Fault....................................................................................

2-47

39,010.8 Document Feeder Disconnected or Missing ....................................................

2-48

39,011.40 and 39,012.40 DADF Subsystem Test Faults ................................................

2-49

39,013.42 Document Feeder Jam...................................................................................

2-49

39,014.43 Document Feeder Calibration Fault ...............................................................

2-50

Jam Codes ......................................................................................................................

2-50

Summary of Contents for PHASER 8560MFP

Page 1: ...701P01133 October 2006 Phaser 8560MFP Multifunction Product Service Documentation...

Page 2: ...ns screen displays looks etc Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale These...

Page 3: ...l iii Organization iii Power Safety iv Service Safety Summary iv Moving the System vi Symbology and Nomenclature vii Electrostatic Discharge Precautions ix Regulatory Specifications ix Phaser 8510 856...

Page 4: ...10 2006 iv Phaser 8510 8560MFP Multifunction Product Initial Issue Introduction...

Page 5: ...the diagnostic aids for troubleshooting that include Power On Self Test POST Built in Self Tests BIST and Fault Code error procedures Section 3 Image Quality This section contains the diagnostic aids...

Page 6: ...l Safety Use the Power Cord supplied with the system Plug the Power Cord directly into a properly grounded electrical outlet Do not use a ground adapter plug to connect the system to an electrical out...

Page 7: ...er person capable of rendering first aid or resuscitation is present Use care when servicing with power Dangerous voltages may exist at several points in this product To avoid personal injury do not t...

Page 8: ...or using a power strip with an on off switch Always secure the scanhead shipping restraint on the left side of the scanner to lock the scanhead before removing the scanner portion of the system Shippi...

Page 9: ...ment sur Marche ou avec le cordon d alimentation branch The following sections have additional specific warning information WARNING A Warning is used whenever an operating or maintenance procedure a p...

Page 10: ...e used in order to prevent additional damage when circuit boards are returned for repair The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General...

Page 11: ...o the direction of parts when mounting or inserting them on Printed Circuit Boards PCB s Regulatory Specifications Xerox has tested this product to electromagnetic emission and immunity standards Thes...

Page 12: ...Tray 2 provides 525 sheets of capacity The Output Tray holds 250 sheets facedown On most configurations an Automatic Document Feeder DADF is installed providing enhanced document handling functionalit...

Page 13: ...Mode and PIN entered values in Engine Control Board NVRAM are set 2 The Control Panel momentarily displays Metered Ink is now enabled then returns to Ready if no other errors 3 The First Time Tips pag...

Page 14: ...Tray 4 optional 2 Tray 3 optional 3 Tray 2 4 Tray 1 MPT 5 Output Tray 6 Exit Cover 7 Control Panel 8 Duplex Automatic Document Feeder DADF Front Cover 9 DADF 10 Interface Cover 11 Drum Maintenance Ki...

Page 15: ...ration Card 9 RJ 11 Fax Modem Connection Back View Electronics Module The system s main electronics and power supply are enclosed in a metal case called the Elec tronics Module The rear panel allows a...

Page 16: ...hics or text only for copy or scan jobs 3 Output Quality selects the output quality mode for copies fast color standard enhanced or high resolution photo 4 2 Sided selects either one or 2 sided for th...

Page 17: ...print copy scan or fax Yellow indicates a warning condition The system continues the operation Red indicates a startup or operational error condition Blinking indicates a warm up or busy condition Co...

Page 18: ...Time Color and Monochrome 12 minutes from Power On Table 2 Memory Specifications Characteristic Specifications Minimum RAM 512 MB Maximum RAM 1 GB Supported RAM Supports up to 1 GB of DDR2 memory usi...

Page 19: ...ending image data through the scanner board to the image proces sor board in the electronics module Copies per Minute DADF 20 ppm simplex 10 ppm duplex Memory 2 MB 1M x 16 SDRAM Image Buffer 32 MB SDR...

Page 20: ...ial grades the wrapper s inner lining protects the paper Some specialty media is packaged inside sealed plastic bags Leave the media inside the bag until needed return unused media to the bag DADF Med...

Page 21: ...10 8560MFP Multifunction Product Service Call Procedures Initial Issue 1 Service Call Procedures Service Call Procedures 1 3 Initial Actions 1 4 Routine Maintenance Activities 1 5 Cleaning Procedures...

Page 22: ...10 2006 1 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Service Call Procedures...

Page 23: ...to find the root cause of the problem Use Service Diagnostics to check the system and optional components Use the Wiring Diagrams and Plug Jack Locator to locate test points Take voltage readings as...

Page 24: ...fic media specifications Look for any damage to the copies oil marks image quality defects or other indications of an unreported problem NOTE If a fault code is displayed while performing a diagnostic...

Page 25: ...eaning Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise in this manual Wipe with a dry lint free cloth if a moistened cloth is used 1 Feed...

Page 26: ...eck the supply of consumables Ensure that an adequate supply of consumables is available according to local operating procedures 3 Conduct any operator training that is needed Ensure the operator unde...

Page 27: ...mal Faults 2 28 13 1XX 4x Left Jetstack Thermal Faults 2 29 13 2XX 4x Right Jetstack Thermal Faults 2 29 13 XXX xx Printhead Reservoir Thermal Faults 2 30 13 XXX xx Ink Loader Thermal Faults 2 30 13 0...

Page 28: ...10 2006 2 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Error Messages and Codes...

Page 29: ...k code flashing on all three LEDs Control Panel LED PS LED and PE LED If initialization of the Control Panel fails POST errors will still report using the LED blink patterns The sum of the flashes equ...

Page 30: ...nly Soft Control Panel version mismatch 08 01 Flutter only Soft Control Panel failed to initialize 09 01 Flutter only Soft Control Panel data error 10 01 Flutter then 10 blinks Hard Power control link...

Page 31: ...Control panel Off No Copy Defaults Setup Color Mode Color No 2 Sided Copying 1 1 No Output Quality Enhanced No Document Type Mixed No Paper Supply Tray 2 No Color Balance Cyan Color Balance 0 No Color...

Page 32: ...No Custom Units Inches mm No Cleaning Page Source Highest No Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command Menu Parameter Default Required System Controls Startup Page On...

Page 33: ...tes a hardware problem The most common device faults troubleshooting procedures are docu mented in this section Program faults are indicated by a 6 in the tenths place of the fault code xx yyy 6x Unfo...

Page 34: ...erences Tray Feeder PL 3 0 Left Side Harness 1 2 Figure 4 Pick Assy and Retard Roller Kit PL 3 0 Left Side Harness PL 5 0 Left Side Wire Routing 1 2 P J204 Table 2 525 Sheet Troubleshooting Procedure...

Page 35: ...iring and Plug Jack References NVRAM PL 5 0 Table 2 525 Sheet Feeder Troubleshooting Procedure Step Questions or Actions Yes No 1 Reseat all Electronics Module connec tions Does the problem persist Go...

Page 36: ...rror 2 006 65 ROM read error 2 007 66 idiags entry point access error Table 1 2 006 xx Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References I O Board PL 5 0 13 NVRAM PL 5 0...

Page 37: ...1 Reseat all Electronics Module connec tions Does the problem persist Go to Step 2 Complete 2 Check ground integrity Are the system grounds connected Reset NVRAM If the error persists replace the NVRA...

Page 38: ...Go to Step 3 Go to Step 5 3 Check the Wiper drive and lock systems for ink obstructions or damage Is the Wiper drive function correctly Go to Step 4 Clear any ink or obstructions or replace any dam a...

Page 39: ...ity Are the system grounds connected Reset NVRAM If the error persists replace the NVRAM device REP 5 0 9 Reconnect the sys tem grounds Y Axis Sub System Faults 5 001 41 The Drum rotated once without...

Page 40: ...is Sub System Faults Troubleshooting Procedure Step Questions or Actions Yes No Y Axis Sub System Program Faults 5 001 63 Y Axis sub system general fault 5 005 67 Sub system not in homeless or idle st...

Page 41: ...ontrol Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the X Axis Motor wiring Is the wiring faulty Replace the wiring Go to Step 2 2 Test the X Axis Motor Run the Se...

Page 42: ...e is properly aligned ADJ 4 7 1 Is the Process Drive misaligned Perform ADJ 4 7 1 Go to Step 2 2 Test the Tilt Axis Drive Run the Service Diagnostics Tilt Axis Drive test Did the test pass Go to Step...

Page 43: ...e 8 Table 2 Process Drive Faults 7 007 49 Troubleshooting Procedure Step Questions or Actions Yes No 1 Check that the Process Drive is properly aligned ADJ 4 7 1 Is the Process Drive misaligned Perfor...

Page 44: ...lace the Wiper Drive Table 2 Head Tilt Solenoid Faults 7 008 41 Troubleshooting Procedure Step Questions or Actions Yes No Process Faults 7 009 42 Printhead is tilted back but not properly restrained...

Page 45: ...cess Faults 7 010 43 Printhead is stuck or is not tilting properly over the cam 7 011 44 Soft fault System continues to operate 7 012 45 Transfix Home Sensor does not indicate home position 7 014 47 T...

Page 46: ...rive operate correctly Replace the Exit Module REP 3 0 7 Repair the Wiper Drive 9 Test the maintenance drive Run the Service Diagnostics Load Mainte nance Clutch test Does the drive operate correctly...

Page 47: ...urrounding the Take Away Roller 2 Remove the Tray 1 Pick Solenoid REP 4 0 12 to view the meshing of the roller gears to the Media Drive Did this correct the problem Complete Go to Step 4 2 For an 8 00...

Page 48: ...Drive Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Reseat all Electronics Module connec tions Does the problem persist Go to Step 2 Complete 2 Check ground integrity Are...

Page 49: ...to Step 2 Remove any block age and or replace the ink stick Run clear ISC Fault test to clear the error This must be per formed following an ink loader replace ment 2 Test the appropriate Ink Melt Hea...

Page 50: ...018 46 Titan version mismatch Table 1 11 0xx 4x Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References I O Board PL 2 0 Right Side Harness I O Control Figure 8 Right Side Ha...

Page 51: ...troubleshooting procedure Troubleshooting Procedure Program Faults 11 100 60 The system reports an overheat condition Table 1 11 100 60 Troubleshooting Reference Table Applicable Parts Wiring and Plu...

Page 52: ...cedure Process Thermal Faults 13 000 48 A thermal fault was detected in the Printhead Table 1 13 0xx 4x Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Printhead PL 2...

Page 53: ...49 Troubleshooting Procedure Step Questions or Actions Yes No 1 Verify that the ambient temperature is within environmental specifications Is the room within operating parameters Go to Step 2 Advise...

Page 54: ...or PL 6 0 I O Board 2 2 Figure 10 Table 2 13 067 43 13 069 45 and 13 071 47 Troubleshooting Procedure Step Questions or Actions Yes No 1 Test the Drum Temperature Sensor Run the Service Diagnostics Dr...

Page 55: ...Procedure Step Questions or Actions Yes No 1 Verify that the ambient temperature of the room is within the system s specifications Is the room within operating parameters Go to Step 2 Advise the cust...

Page 56: ...m within operating parameters Go to Step 2 Advise the customer of operational requirements 2 Check ground integrity for the printer Does the error persist Go to Step 3 Complete 3 Test the Printhead Re...

Page 57: ...tronics Module REP 5 0 5 Go to Step 4 4 Check Ink Loader connections and wiring Are the connections secure and the wiring undamaged Replace the Ink Loader REP 2 0 1 Repair or replace the wiring If the...

Page 58: ...a Printhead operation without position data in NVRAM 19 003 48 Scale and offset voltage error too large Something is wrong with the Electron ics Module or Wave Amplifier 19 004 40 The Printhead and El...

Page 59: ...eshooting Procedure Locate the code in the Jam Codes listing and follow the procedure if available X Axis Program Faults 21 000 69 The diagnostics firmware doesn t match the engine firmware Table 1 6...

Page 60: ...ts follow the procedure below Troubleshooting Procedure Check the fault history and troubleshoot the error listed immediately prior to these codes Oth erwise reboot the system to clear these error con...

Page 61: ...lem persists follow the procedure below Primary Causes The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure Troubleshooting Procedure Profile Library Faults 27...

Page 62: ...e Parts Wiring and Plug Jack References Media Drive Assy PL 4 0 Left Side Harness 2 2 Figure 5 Table 2 X Axis Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Take...

Page 63: ...ay 1 Width Sensor Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Tray 1 Harness connection to the I O Board P J610 Is the connection secure and the harness undamaged Go...

Page 64: ...Maintenance Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check that system grounds are in place Are the grounds secure and undamaged Go to Step 2 Repair or replace the grounds...

Page 65: ...Is the installation correct Go to Step 2 Correct and retest 2 Replace the Drum Maintenance Kit Does the error persist Replace the Drum Maintenance Pivot Plate and Shaft REP 2 0 16 Complete PEST Heate...

Page 66: ...drawing less power than expected Table 1 37 01X 41 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Electronics Module Fan PL 4 0 Left Side Harness 2 2 Figure 5 Drum F...

Page 67: ...ect the Wave Amplifier Turn the system On Does the error persist Go to Step 8 Leave power on to ensure the problem is fixed 8 Reconnect the Printhead Turn the system On Does the error persist Replace...

Page 68: ...g Jack References Tray 2 Lift Motor PL 4 0 Left Side Harness 1 2 Figure 4 Electronics Module PL 4 0 Left Side Harness 1 2 Figure 4 Table 2 PEST Tray 2 Lift Motor Fault Troubleshooting Procedure Step Q...

Page 69: ...ronics Module PL 5 0 Electronics Module Power Figure 7 Table 2 PEST Relay Board Faults 37 02X 4x Troubleshooting Procedure Step Questions or Actions Yes No 1 Test the Relay Board Run the Service Diagn...

Page 70: ...m Assembly PL 2 0 Electronics Module PL 5 0 Electronics Module Power Figure 7 Table 2 PEST Y Axis Motor Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Drum rotation Does...

Page 71: ...the Process Drive Motor Run the Service Diagnostics Process Motor test Does the motor operate correctly Replace the Elec tronics Module REP 5 0 5 Go to Step 3 3 Check wiring to the motor Is the wirin...

Page 72: ...g Procedure Step Questions or Actions Yes No 1 Test the Power Supply Run the Service Diagnostics Voltages test Does the Power Supply operate correctly Go to Step 2 Replace the Elec tronics Module REP...

Page 73: ...iring and Plug Jack References Scanner Assembly PL 1 0 Table 2 Scanhead Locked Troubleshooting Procedure Step Questions or Actions Yes No 1 Cycle system power and retest Does this correct the problem...

Page 74: ...he Status LED light Replace the Scanner Assembly REP 1 0 11 Replace the Exit Module Control Board REP 5 0 1 If the error persists replace the Scanner Power Supply REP 5 0 2 If the Status LED remains O...

Page 75: ...ooting procedure Troubleshooting Procedure DADF Subsystem Faults 39 011 40 The DADF DRAM Test failed 39 012 40 The DADF Optical Test failed Table 1 39 011 40 and 39 012 40 Troubleshooting Reference Ta...

Page 76: ...References DADF PL 1 0 Table 2 Scanhead Locked Troubleshooting Procedure Step Questions or Actions Yes No 1 Cycle system power and retest Does this correct the problem Complete Replace the DADF REP 1...

Page 77: ...18 Table 2 Jam Code Troubleshooting Code Description Procedure A3R Deskew sensor time out during movement from exit roller to deskew roller when duplexing print 1 Ensure the media is appropriate for...

Page 78: ...rollers are present and installed correctly they should be the same for all 5 rollers 2 Verify the metal bar is installed on top of the Exit Guide Table 2 Jam Code Troubleshooting Code Description Pr...

Page 79: ...ng Code Description Procedure M2C M4A M4B M4C M4D M4E M4F M4G M4H M4J M4K M4L M4M M4N M4P M4Q M4R M4S M4T Media Drive motor had an unexpected event during mechanical recovery Media Drive motor stalled...

Page 80: ...Check system grounds 3 Run the Check Drum Y Axis Encoder test 4 Remove the Preheater REP 2 0 17 and check the Preheater flag for ink or paper interference 5 Replace the Preheater REP 2 0 17 Table 2 Ja...

Page 81: ...correctly 3 Run the Monitor Sensors test using Service Diagnostics 4 Check the Paper Size Switch Replace if necessary REP 6 0 7 5 Replace the Pivot Arm Table 2 Jam Code Troubleshooting Code Descriptio...

Page 82: ...um imaging Tray 4 Paper Size Switch activated during paper exit 1 Check system grounds 2 Check that the media guides are adjusted correctly 3 Run the Monitor Sensors test to test the Tray 4 Paper Size...

Page 83: ...Stripes 3 10 IQ15 Smudges or Smears 3 11 IQ16 Printed Image is Too Light or Too Dark 3 11 IQ17 No Image is Printed 3 12 IQ18 Color is Uneven or Color is Wrong 3 12 IQ19 Streaks or Lines Down the Prin...

Page 84: ...10 2006 3 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Image Quality...

Page 85: ...nt quality problem is not resolved using the image quality troubleshooting procedures see Analyzing Service Test Prints NOTE The Troubleshooting Print Quality page includes instructions for printing t...

Page 86: ...ribs rollers and separator pad Does the problem persist Go to Step 2 Complete 2 Check the CVT Window for ink build up Clean the CVT Window Does the problem persist Go to Step 3 Complete Advise the cu...

Page 87: ...to Step 3 Complete 3 Perform the DADF to Scanner Calibration adjustment procedure ADJ 1 15 1 Does the problem persist Replace the DADF REP 1 0 15 Complete Table 1 IQ6 Fuzzy Text or Image Step Questio...

Page 88: ...y combination of these set tings for a particular original might require several attempts In some cases these controls may not completely compensate for artifacts introduced in the scanning process Pr...

Page 89: ...the DADF Input Tray 3 Check that image skew exceeds specifications 4 Reseat all DADF connections Procedure Table 1 IQ8 Dark Streaks on Copied Image Step Questions and Actions Yes No 1 Check the CVT Wi...

Page 90: ...ity page and evaluate the Output Quality and Color Settings section 2 Use the Lighten Darken Output Quality adjustment to attempt to correct the problem 3 Check that the print mode is not set to Draft...

Page 91: ...ore you would print the yellow solid fill Figure 2 Discolored Jets on the Light Stripes Page Table 1 IQ12 Fuzzy Text or Image Step Questions and Actions Yes No 1 Print the Graphics Demo page for fuzzy...

Page 92: ...o clear obstructed jets Does the problem persist Go to Step 2 Complete 2 Clean the Print Engine exit path and wipe the Stripper Blade with a lint free cloth Does the problem persist Go to Step 3 Compl...

Page 93: ...the Drum Maintenance Kit and wipe the clear plastic blade with a lint free cloth Does the problem persist Replace the Drum Maintenance Kit If the problem per sists go to Step 5 Complete 5 Clean the ro...

Page 94: ...lor results Initial Actions 1 Check that supported media is being used 2 Run the Eliminate Light Stripes routine from the Control Panel Procedure Table 1 IQ17 No Image is Printed Step Questions and Ac...

Page 95: ...eck the Drum Fan Does the fan operate correctly Go to Step 5 Replace the Drum Fan REP 4 0 6 5 Check that the Drum Temperature Sensor contacts the Drum Clean or replace the Drum Temperature Sen sor REP...

Page 96: ...page for the affected color Does the problem persist Go to Step 7 Complete 7 Check the X Axis Drive If the X Axis Drive does not move the Print head smoothly vertical lines appear on the output Verify...

Page 97: ...5 Check for debris on the Preheater Run the Service Diagnostics Remove Print Smears routine Does the problem persist Go to Step 6 Complete 6 Force a sheet of thick 65 to 85 lb paper through the Prehe...

Page 98: ...mmed media in the exit path 3 Run the Remove Print Smears routine from the Control Panel Procedure 4 Check the thermal regulation of the Drum Run the Service Diagnostics temperature tests Replace the...

Page 99: ...agnostics temperature tests Replace the Drum Temperature Sensor REP 6 0 4 if necessary Does the problem persist Go to Step 5 Complete 5 Check Y Axis motion Run the Service Diagnostics Y Axis Encoder t...

Page 100: ...lem persist Replace the X Axis Motor REP 4 0 5 If the problem per sists replace the Electronics Mod ule REP 5 0 5 Complete 4 Try the procedure listed under the Solid Fill test prints Does the problem...

Page 101: ...Step 5 Complete 5 Check these Drum maintenance system parts for damage or defects Drum Maintenance Pivot Plate Drum Maintenance Cam Shaft Is there any damage Replace any dam aged parts If the problem...

Page 102: ...Yes No 1 Check and clean the Drum Maintenance Kit Wiper Blade Does the problem persist Replace the Drum Maintenance Kit If the problem per sists go to Step 2 Complete 2 Check X Axis motion Verify that...

Page 103: ...the Service Diagnostics Drum Mainte nance tests Does the problem persist Replace any defective parts found Complete Table 1 IQ27 Oil Streaks on Print Step Questions and Actions Yes No Table 1 IQ28 Inc...

Page 104: ...amaged parts found Does the problem persist Go to Step 6 Complete 6 Check the Preheater temperature Run the Service Diagnostics Preheater tests Does the problem persist Replace the Trans fix Load Modu...

Page 105: ...Pinstripes on Output Initial Actions 1 Check that supported media is being used 2 Print several solid fill test prints as a sample Procedure Table 1 IQ30 Repeating Print Defects Step Questions and Act...

Page 106: ...ars as a result of a mismatch between the application and the driver Initial Actions 1 Check that supported media is being used 2 Print an Information page from the Control Panel 3 Check the applicati...

Page 107: ...ake them more visible Figure 1 Test Print 1 Weak or Missing Jet Look for No interlacing is used in this print expect light dark variation between jets Use Look for much lighter colored vertical bands...

Page 108: ...egibility in the lines of 6 point text particularly in the primary colors If the letters are closed or badly plugged with ink the printhead is laying down too much ink A good quality print shows five...

Page 109: ...wn the length of the page are caused by a defective transfix roller The roller has a soft spot that is not pushing the ink into the paper as well as the rest of the roller If you observe variations in...

Page 110: ...nly Head to Drum Check These prints indicate if the gap between the printhead and the drum is correct Lines The horizontal lines of the print are made up of long and short dashes Inspect the first and...

Page 111: ...most visible on duplex solid fills Skew and Margins This print is used to gauge skew and margin on 2 sided prints For Skew The measurement between the edge of the paper and the magenta frame should be...

Page 112: ...ineering Y Dot Position This print is used by Manufacturing and Engineering Chase Pages A blank piece of paper is used to remove contamination from the Drum Transfix Roller and media path Oil Bar Chas...

Page 113: ...3 Scroll to Print Quality Problems and then press OK 4 Select Eliminate Light Stripes 5 Select Jet Substitution Mode and enter the color and number of the affected jet To substi tute the jet a Scroll...

Page 114: ...10 2006 3 32 Phaser 8510 8560MFP Multifunction Product Jet Substitution Mode Initial Issue Image Quality...

Page 115: ...plex Guide and Solenoid 4 40 REP 3 0 6 Outer Duplex Guide 4 41 REP 3 0 7 Exit Module 4 42 REP 3 0 14 System Stabilizer 4 43 REP 3 0 18 Pick and Retard Rollers 4 44 REP 4 0 3 Scanner Power Supply Fan 4...

Page 116: ...10 2006 4 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Repairs and Adjustments...

Page 117: ...emoval and replacement procedures may not match the names that appear in the Parts List For example a part called the Registration Chute Assembly in a removal procedure may appear on the Parts List as...

Page 118: ...mbly by releasing the left hinge pin from the frame and sliding the door to the right to remove it Table 1 Recommended Service Tools Description Detail Torx Drivers Bits T5 T8 T10 T15 T20 Phillips Dri...

Page 119: ...s and Adjustments Initial Issue REP 1 0 6 Output Tray Parts List on PL 1 0 Removal 1 Open the Front Cover Figure 1 Output Paper Tray Retaining Tabs 2 Spread the left and right sides of the Output Tray...

Page 120: ...cover to release it from the frame Replacement Insert the 3 tabs along the bottom edge of the cover into the slots in the frame before snapping the cover into place REP 1 0 8 Scanner Hinges Parts Lis...

Page 121: ...on PL 1 0 Removal 1 Open the Scanner Assembly 2 Remove 2 plastic T 20 screws that secure the Control Panel to the Scanner Assembly Figure 1 Removing the Control Panel 3 Release the tab at each end of...

Page 122: ...er Assembly from the system Figure 1 Unlocking the Scanner Assembly Hinges 4 Release the hinge latches using a screwdriver or pen 5 Slide the Scanner Assembly towards the back and then lift to remove...

Page 123: ...Cover to remove REP 1 0 15 Duplex Automatic Document Feeder Parts List on PL 1 0 Removal 1 Disconnect the DADF Cable from the Scanner Assembly 2 Lift the DADF to expose the locking mechanism 3 Release...

Page 124: ...each hinge to the DADF Figure 1 Removing the DADF Hinges Replacement NOTE Failure to adequately secure the DADF cable connection to the Scanner Assembly can result in sporadic DADF errors Seat the DAD...

Page 125: ...e Cover 5 Release the tab near the top of the cover using a flat blade screwdriver 6 Release the tabs along the front of the cover that secure it to the Exit Module 7 Pull outward at the front of the...

Page 126: ...ng the Document Cover Hinges REP 2 0 1 Ink Loader Assembly Parts List on PL 2 0 Removal CAUTION Allow adequate time for the Ink Melters to cool before servicing the Ink Loader 1 Remove the Scanner Ass...

Page 127: ...the right side and then discon nect the harness P J0150 from the Ink Loader to remove the Ink Loader Replacement Perform these steps while replacing the Ink Loader Assembly 1 Raise the Media Path Ele...

Page 128: ...s to cool before servicing the system The Roll Block that retains the Printhead Shaft remains hot longer than other nearby components CAUTION To prevent the Printhead from contacting the Drum while re...

Page 129: ...inthead Wiper Assembly 9 Move the Printhead Tilt Spring from its position on the Printhead and hook it behind itself as shown in Figure 3 Figure 3 Releasing the Printhead Tilt Spring 10 Pull the X Axi...

Page 130: ...as tic T 20 screw that secures each restraint and then shift the restraint inwards toward the Printhead while lifting toward the rear of the printer Figure 5 Removing the Printhead Restraint Screws NO...

Page 131: ...nd free the harness from the restraint Figure 8 Printhead Electrical Connections 15 Remove the 2 metal T 20 screws that secure the Ground Strap 16 Push the Air Hose into the chassis 17 Lift the Printh...

Page 132: ...e the Purge Pump Hose through the frame and connect it to the Purge Pump 7 Install the Roll Block on the left end of the Printhead Shaft Orient the Roll Black as shown on the label attached to the fra...

Page 133: ...the Right Side Cover REP 1 0 21 4 Remove the Left Side Cover REP 1 0 7 5 Remove the Ink Loader Assembly REP 2 0 1 6 Park the Printhead using ADJ 2 2 1 7 Place the Printhead Wiper Blade in its home pos...

Page 134: ...he Drum Assembly on the pulley Allow the pulley to overhang the sur face and rest the assembly on its feet 19 Lift the Drum Assembly straight out of the chassis using the metal grips provided Replacem...

Page 135: ...ule Ground Strap and Preheater Lift Solenoid 10 Align the clevis on the Transfix Load Arms with the holes in the mounting ears on the Drum Assembly The Transfix Load Arms should point in the opposite...

Page 136: ...Assembly harnesses 18 Connect the Drum Heater harness P J200 to the Relay Board 19 Connect the Drum Encoder harness P J120 to the Right Side Harness 20 Connect the Drum Thermal Sensor to the I O Board...

Page 137: ...procedure ADJ 2 2 1 36 Perform the Head Tilt Gear Homing procedure ADJ 4 13 1 37 Perform the Process Drive Homing Procedure ADJ 4 7 1 38 Turn system power On and print a Configuration page to test op...

Page 138: ...This lowers the left end of the wiper producing slack in the Wiper Belt Remove the Wiper Belt from the Wiper Clip to release the Wiper Blade Replacement 1 When reinstalling the belt into the wiper cli...

Page 139: ...ead restraints If the restraints are released tension from the Printhead Tilt Spring will force the Printhead toward the Drum Gradually release the spring tension when unlocking the Print head restrai...

Page 140: ...Blade 9 Hold the Printhead away from the Drum and push down on the left and right Printhead Restraint Arms to release the Printhead Tilt Spring tension Figure 3 Releasing the Printhead Tilt Spring 10...

Page 141: ...1 plastic T 20 screw that secures each Printhead Restraint and then shift the restraint inwards toward the Printhead while lifting toward the rear of the printer Figure 5 Removing the Printhead Restra...

Page 142: ...2 0 1 2 Remove the Media Drive Assembly REP 4 0 14 3 Remove the Exit Module REP 3 0 7 4 Remove the Duplex Roller REP 3 0 4 5 Remove the Upper Duplex Guide and Solenoid REP 3 0 5 6 Insert a T 20 Torx...

Page 143: ...the camshaft to the right release the bushing by carefully prying it from the ground plate Move the left end of the camshaft towards the rear of the printer move the camshaft to the right then lift t...

Page 144: ...wards the rear to release it from the ground strap and then downward to position it out of the way 9 Loosen 1 plastic T 20 screw that secures an I O Board ground strap and the Transfix Roller Shaft Re...

Page 145: ...n downward to position it out of the way 9 Loosen 1 plastic T 20 screw that secures an I O Board ground strap and the Transfix Roller Shaft Restraint then remove the restraint Figure 1 Removing the Tr...

Page 146: ...move the Front Door REP 1 0 1 3 Remove the Ink Loader REP 2 0 1 4 Remove the Preheater REP 2 0 17 5 Remove the Outer Duplex Guide REP 3 0 6 6 Remove the Media Drive Assembly REP 4 0 14 7 Remove the Ex...

Page 147: ...emoving the Transfix Load Arm Clevis Pins 12 Disconnect the Preheater Lift Solenoid P J202 from the harness 13 Remove the screw that secures the Preheater Lift Solenoid to the Transfix Load Module Fig...

Page 148: ...tal T 20 screws 2 at each end that secure the Transfix Load Module to the chassis Figure 5 Transfix Load Module Fasteners 16 Rotate the top of the Transfix Load Module forward and spread the chassis s...

Page 149: ...amage the Drum while servicing the Pivot Plate Feed a sheet of paper between the Transfix Roller and Drum to protect the Drum surface during this procedure 1 Remove the Front Door REP 1 0 1 2 Remove t...

Page 150: ...following installation of the Drum Fan Perform the Head Tilt Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjustments before restoring system power REP 2 0 17 Preheater and Deskew Assembly Pa...

Page 151: ...ainer in place followed by the right Make sure the sensors are properly positioned when completing the installation REP 2 0 21 X Axis Bias Spring Parts List on PL 2 0 Removal The X Axis Bias Spring is...

Page 152: ...EP 3 0 6 7 Disconnect the Preheater Solenoid P J202 8 Remove the screw that secures the solenoid to the Transfix Load Module Figure 1 Removing the Preheater Solenoid REP 3 0 1 Inner Simplex Guide Part...

Page 153: ...e Front Door REP 1 0 1 2 Remove the Scanner Assembly with attached DADF REP 1 0 11 3 Remove the Output Tray REP 1 0 6 4 Remove the Right Side Cover REP 1 0 21 5 Remove the Left Side Cover REP 1 0 7 6...

Page 154: ...left to release the right end from the chassis and lift the right end upward to clear the top of the frame at the right Figure 1 Removing the Duplex Roller REP 3 0 5 Upper Duplex Guide and Solenoid Pa...

Page 155: ...ges of the Exit Module frame Check that the Stripper Solenoid actuator engages the hole in the Stripper Carriage Assembly REP 3 0 6 Outer Duplex Guide Parts List on PL 3 0 Removal 1 Remove the Output...

Page 156: ...odule Right Side Fasteners c Remove the plastic T 20 screw connecting the Exit Module and Back Frame 7 Remove these components from the left side Figure 2 Exit Module Left Side Fasteners a Loosen the...

Page 157: ...nnections 9 Lift the Exit Module from the chassis Replacement Transfer the Front Exit Module Harness to the replacement part and Perform ADJ 2 5 1 after replacing the Exit Module REP 3 0 14 System Sta...

Page 158: ...2 2 Release the Pick Roller catch and pull downward to remove the roller Figure 1 Replacing the Pick Roller 3 Lift the Retard Roller to vertical then pull the roller from the shaft in the tray See Fi...

Page 159: ...t secure the fan to the frame Figure 1 Removing the Scanner Power Supply Fan Replacement NOTE Route the fan harness behind the mylar insulator as shown in Figure 1 REP 4 0 4 Head Maintenance Clutch Pa...

Page 160: ...lso slip the mounting plate behind the ground strap and replace the cable retainer on the lower right screw Perform the Head Tilt Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjustments befo...

Page 161: ...tion CAUTION Seat all 3 mounting screws before torquing the screws to final tightness 12 in lbs Tightening the screws individually before seating all three can put undue strain on the mounting bosses...

Page 162: ...ey to the replacement motor REP 4 0 9 Exit Elevator Motor Parts List on PL 4 0 Removal 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left...

Page 163: ...h Nut position the Push Nut so the fingers point away from the shaft Place a 3 8 in nut driver over the nut and press firmly to seat the nut on the shaft REP 4 0 11 Y Axis Motor Assembly Parts List on...

Page 164: ...Assembly Electrical Connections 10 Release the harness from the retainers in the chassis NOTE Observe the routing of the Y Axis Motor harness The harness exits the motor cav ity through the notch pro...

Page 165: ...id to the Media Drive Assembly Figure 1 Removing the Tray 1 Pick Solenoid Replacement Align the hole in the solenoid with the boss on the Media Drive Assembly before tightening the screw REP 4 0 13 Tr...

Page 166: ...move the Tray 1 Pick Solenoid screw A replacement solenoid is included with the new Media Drive Assembly Loosen the screw just enough to allow removal of the Media Drive Assembly 1 Remove the Scanner...

Page 167: ...cure the Media Drive Assembly to the frame Figure 2 Removing the Media Drive Assembly Replacement To replace the Media Drive Assembly remove Tray 2 Rotate the Pick Roller Shaft until the Pick Clutch s...

Page 168: ...Cover REP 1 0 7 4 Disconnect the fan P J207 from the Left Side Harness 5 Remove 2 plastic T 20 screws that secure the fan to the chassis Figure 1 Removing the Electronics Module Cooling Fan REP 4 0 16...

Page 169: ...Pull the cover right to release the left hook and position the cover out of the way Figure 3 Removing the Waste Tray Cover 9 Reach into the Waste Tray cavity and pull the gear and shaft from the chas...

Page 170: ...Gear Shaft 6 Perform the Head Tilt Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjustments before restoring system power REP 4 0 18 Fax Speaker Parts List on PL 4 0 Removal 1 Remove the Sca...

Page 171: ...Remove 1 plastic T 20 screw that secures the solenoid actuator to the frame and remove it from the frame 8 Release the hook to release the solenoid from the frame Figure 1 Removing the Head Tilt Sole...

Page 172: ...ws that secure the board to the Back Frame Figure 1 Removing the Exit Module Control Board REP 5 0 2 Scanner Power Supply Parts List on PL 5 0 Removal WARNING Disconnect the AC Power Cord before servi...

Page 173: ...d Tilt Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjustments before restoring system power REP 5 0 5 Electronics Module Parts List on PL 5 0 Removal CAUTION Touch the Electronics Module to...

Page 174: ...5 0 7 Hard Drive Parts List on PL 5 0 Removal 1 Loosen the thumbscrews on the back cover of the Electronics Module 2 Disconnect the Hard Drive from the Electronics Module Figure 1 Removing the Hard Dr...

Page 175: ...entation of the RAM device before removing it from the board 2 Disconnect the RAM module from the Electronics Module Figure 1 Removing RAM 3 Insert the replacement RAM and close the Back Cover REP 5 0...

Page 176: ...rner of the board behind the Ground Tab before installing the screws REP 5 0 19 Drum Heater Relay Board Parts List on PL 5 0 Removal WARNING Disconnect the AC Power Cord before servicing the system Th...

Page 177: ...0 20 6 Remove the Ink Loader REP 2 0 1 7 Remove the Scanner Power Supply Fan REP 4 0 3 8 Remove the Exit Module Board REP 5 0 1 9 Remove the Scanner Power Supply REP 5 0 2 and mylar insulator 10 Remov...

Page 178: ...he harnesses from the FDI board 5 Remove the 3 2 metal T 20 1 plastic T 20 screws that secure the board to the chassis Figure 1 Removing the FDI Board REP 6 0 1 Scanner Detect Sensor Parts List on PL...

Page 179: ...switch NOTE Replacement of the Front Door Interlock Switch does not require removal of the Outer Duplex Guide 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP...

Page 180: ...ce a couple sheets of paper between the Wiper Assembly and the Drum to protect the Drum while performing this procedure 1 Remove the Printhead REP 2 0 2 2 Remove the Waste Tray 3 Remove the X Axis Spr...

Page 181: ...Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjust ments before restoring system power REP 6 0 7 Paper Size Switch Parts List on PL 6 0 Removal 1 Remove the Scanner Assembly with attached D...

Page 182: ...eheater Assembly P J0720 and P J860 to make additional room to replace the sensor Release the lock on P J0720 to remove it from the Preheater Assembly REP 6 0 9 Paper Height Sensor Parts List on PL 6...

Page 183: ...ay Replace both boards when servicing this sensor 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left Side Cover REP 1 0 7 4 Remove the Rig...

Page 184: ...press the System Setup button 2 Select the Information menu 3 Select Troubleshooting and then press the Enter button 4 Select Calibrate Scanner and then press the Enter button 5 Place the Scanner Cali...

Page 185: ...n repeat Steps 1 and 2 until a successful result is achieved ADJ 2 2 1 Printhead Parking Purpose To place the Printhead in a parked position away from the Drum during service procedures or when the Co...

Page 186: ...2 1 Initial Issue Repairs and Adjustments Figure 1 Printhead Wiper Blade Drive 7 Rotate the Drum Maintenance Camshaft until the Printhead has moved to the parked position which is the furthest point f...

Page 187: ...he gear 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left Side Cover REP 1 0 7 4 Remove the Right Side Cover REP 1 0 21 5 Remove the KL C...

Page 188: ...e alignment points to verify proper gear alignment The holes in the Process Drive and gears must align as indicated in Figure 1 Figure 1 Process Drive Gear Alignment The hole in the Camshaft gear must...

Page 189: ...Product ADJ 4 13 1 Repairs and Adjustments Initial Issue Figure 1 Disengaging the Head Tilt Gear NOTE When the Head Tilt Gear is disengaged the two arrows on the left side of the printer align as show...

Page 190: ...ver as shown in Figure 3 If the Head Tilt Gear is engaged manually assist the movement of the Printhead There is an audible click when the Head Tilt Gear disengages Figure 3 Rotating the Drum Maintena...

Page 191: ...10 2006 4 77 Phaser 8510 8560MFP Multifunction Product ADJ 4 13 1 Repairs and Adjustments Initial Issue Figure 4 Head Tilt Gear Indicator...

Page 192: ...10 2006 4 78 Phaser 8510 8560MFP Multifunction Product ADJ 4 13 1 Initial Issue Repairs and Adjustments...

Page 193: ...ts List Parts List Overview 5 3 Serial Number Format 5 3 Parts Lists Covers PL 1 0 Covers 5 4 Imaging PL 2 0 Imaging 5 5 Paper Path PL 3 0 Paper Path 5 6 Drive PL 4 0 Drive 5 7 Electrical PL 5 0 Elect...

Page 194: ...10 2006 5 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Parts List...

Page 195: ...enclosed by a dashed line The notation with X Y following a part name indicates an assembly includes components X through Y For example 1 with 2 4 means part 1 consists of parts 2 3 and 4 The notation...

Page 196: ...2590 Scanner Assembly with 8 12 12 Upper Housing P O PL 1 0 Item 11 Includes Glass 13 DADF Front Cover P O PL 1 0 Item 15 14 DADF Upper Cover P O PL 1 0 Item 15 15 059K58460 DADF Assembly with 13 19 1...

Page 197: ...02160 Transfix Camshaft 12 041K06500 Stripper Carriage Assembly 13 022E32290 Transfix Roller 14 809E69920 Y Axis Tension Spring 15 137E24130 Transfix Load Module 16 020K15100 Drum Maintenance Pivot Pl...

Page 198: ...0 Exit Module Assembly with 10 11 20 8 809E78710 Spring Carriage 9 809E78700 Spring Carriage Roller 10 Pulley Exit Module P O PL 3 0 Item 7 11 Belt Exit Module P O PL 3 0 Item 7 12 059E05610 Roller Id...

Page 199: ...Motor Assembly 6 127E16010 Drum Fan 7 005K12670 Process Drive Assembly 8 127K56300 Exit Motor 9 059K58470 Elevator Motor Assembly 10 Lift Motor Gear Not Spared 11 127K56070 Y Axis Motor Assembly 12 12...

Page 200: ...M 9 237E23880 8 pin NVRAM 10 069E00400 Configuration Card 11 117E29790 Cable ZIF Wave Amp Drive 12 117E29820 Harness Right Side 13 960K22331 I O Board 14 117E29810 Cable Right Combined 15 117E29650 Ca...

Page 201: ...or Scanner Detect 2 110E20390 Front Door Interlock Switch 3 137E24280 Engine Exit Flag 4 130K75210 Drum Temperature Sensor Assembly 5 130K75220 Exit Module Sensor Assembly 6 130E12620 Waste Tray Senso...

Page 202: ...ay Kit B Port 650K26700 Control Panel Overlay Kit Russian 650K26710 Control Panel Overlay Kit Czech 650K26720 Control Panel Overlay Kit Danish 650K26730 Control Panel Overlay Kit Greek 650K27210 Contr...

Page 203: ...ng 6 36 DADF Malfunction 6 39 Scanner Malfunction 6 40 Control Panel Malfunction 6 40 Exit Module Malfunction 6 41 Media Path and Transport Problems 6 41 Operating System and Application Problems 6 42...

Page 204: ...10 2006 6 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Diagnostics...

Page 205: ...rol Panel dis plays status messages as each sub test is performed This test takes about 8 seconds All LEDs are off during the test If POST diagnostics pass the Control Panel displays the Xerox logo an...

Page 206: ...8510 8560MFP Multifunction Product System Power On Process Initial Issue Diagnostics Mechanical Engine Initialization Diagram Figure 1 Mechanical Engine Initialization 1 2 Figure 2 Mechanical Engine...

Page 207: ...History Displays available information regarding the last 15 faults reported by a test and or the print engine Jam History Displays available information regarding the last 20 jams reported by a test...

Page 208: ...general idea of the current test activity When the test completes the display changes to display the results In some menus the subsystems are identified as follows FP Control Panel Module subsystem EM...

Page 209: ...e Times 77 Clear PE NVRAM 121 Test FAX Modem Sub system 34 Paper Trail Edge Times 78 Set PE NVRAM To Defaults 122 Reset FAX Subsystem 35 Paper Sensor Bounce Times 79 Print DMU Blot 123 Report FP FW Ve...

Page 210: ...10 2006 6 8 Phaser 8510 8560MFP Multifunction Product Service Diagnostics Initial Issue Diagnostics Figure 1 Service Diagnostics Menu 1 3 Figure 2 Service Diagnostics Menu 2 3...

Page 211: ...may then be observed See the exercise menu table for a description of the individual test functions and results Check Menu A submenu containing a set of extensive manufacturing tests that return measu...

Page 212: ...ystem This test forces a hardware reset of the Exit Module Scanner DADF and FAX modules Table 3 Service Diagnostics Menu Definitions Menu Item Description Doc Handler Menu Report FW Version Reports th...

Page 213: ...ning with the upper right most LED and moves from top to bottom and left to right until all LEDs have been activated The pattern repeats As each LED is activated the LED name is displayed After termin...

Page 214: ...xis Motor Purge Pump Motor Drum Fan Motor Electronics Fan Motor Media Path Motor Shafts Transfix Cam Shaft Drum Maintenance Cam Shaft Deskew Shaft Wiper Shaft Tray 1 Pick Shaft Tray 2 Pick Shaft Tray...

Page 215: ...se conditions consistently If a test result differs significantly from the typical values defined in the following tables check the entire subsystem containing the problem component Each test included...

Page 216: ...possibly due to heating during the test A change in heating behavior could indicate a problem with cooling or the thermal conductivity through the mounting Deviations from typical average values coul...

Page 217: ...or unexpected resistance Shafts Menu Runs the selected shaft in both directions to determine shaft characteristics steady state drive requirements bearing status etc The objective of these tests is to...

Page 218: ...roller causing a lump 5 CCW Off fe settling time sec N A Reports the time it takes the Media Drive Motor servo system to settle down after the sudden release of the deskew shaft load A larger value c...

Page 219: ...ia Drive Assembly servo system to react to the sudden addition of the wiper shaft load Larger values may indicate a slipping or slow to engage clutch 7 CW On peak fe N A Reports the peak effort requir...

Page 220: ...could indicate extra friction between the cams and the lift plate followers wear contamination etc as well as high lift plate spring ten sion or higher shaft bearing drag Also if the pick shaft gear...

Page 221: ...between the activation of the Tray Motor and the detection of the raised lift plate Out of range values may indicate a problem with the lifting mecha nism which could effect the following friction me...

Page 222: ...Reports the peak temperature following the end of the heating interval 7 Peak Temperature Time ms N A Reports the time following the applica tion of power to the specified heater until the peak temper...

Page 223: ...temperature at a fixed time following the peak temperature time Table 20 Drum Heater Nominal Values R Characteristic Typical Value Result 0 AC Line Voltage volts N A Reports the baseline AC voltage p...

Page 224: ...ts average of the power over the exit interval for all trays for Simplex oper ations only Duplex Operations Only 7 Duplex Turnaround Average Power N A Reports average of the power over the duplex turn...

Page 225: ...efined No Tray 2 value 3 not used undefined No Tray 2 value Tray 1 Source Tray 2 not used undefined No Tray 1 value 3 not used undefined No Tray 1 value 4 Deskew Trailing Edge Interval Time N A Report...

Page 226: ...ance could indicate something block ing the normal Printhead range of motion either inside of outside the right side frame or some significant binding loose cables foreign object Printhead not in the...

Page 227: ...per Assembly Printhead latching mechanism Head Maintenance Clutch and related parts This test assumes that the tilt drive and the Wiper Assembly mecha nisms are functioning correctly Run the Tilt Driv...

Page 228: ...l it stalls against the upper stop If the tray is empty the normal situation the No Paper Sensor is not activated but the Paper Height Sensor is If the tray contains 1 sheet of media additional media...

Page 229: ...the roller is installed and is hanging down correctly 5 Lift Time sec N A Reports the interval from the motor start time until the Paper Height Sensor is activated This value indicates that the sensor...

Page 230: ...frequency of the most pow erful FFT frequency not including the drum or motor 6 FFT Power Ratio 2 none N A Reports the ratio of the FFT power amplitude of the second most powerful FFT frequency not i...

Page 231: ...ing error during the roller down portion of the transfix operation Table 37 Y Axis Drive Belt Tension Nominal Values R Characteristic Typical Value Result 0 Min Resonant Frequency hz N A Reports the m...

Page 232: ...one revolution 7 Releasing Amplitude mpts N A Reports the magnitude of the reaction of the Drum to the withdrawal of the blade See R3 Table 39 Drum Maintenance Contact Nominal Values R Characteristic...

Page 233: ...ge average value of the recording interval 4 Motor drive power ripple watts N A Reports variation of the motor drive power over the recording interval 5 Motor drive power average watts N A Reports the...

Page 234: ...ull of ink or not properly biased Head Tilt Spring missing or defective Also the trip lever could require extra effort to lift flat spring stronger than usual rough or warped engage surface with gear...

Page 235: ...dby position Next the X axis is moved to the right until the insulation makes contact with the right side frame and the drive cone unloads from the Printhead The X axis is then moved left for a fixed...

Page 236: ...nfirms diagnostic test results and subsequent repairs Component Checks Located under the Print Engine Exercise menu of Service Diagnostics is an extensive suite of component level tests that exercise...

Page 237: ...quence is indeterminate As is the case with simultaneous events In these cases a U is appended to the event to indicate an unknown sequence While event sequence can be important in determin ing cause...

Page 238: ...specified sequence generally pro vides better test coverage than performing tests in a different order If either the Scanner turns on or the Exit Module initializes the Scanner Power Supply is oper a...

Page 239: ...age to circuits within the Electronics Module may occur if the power supply capaci tors are not allowed to fully c Connect the Power Control cable to the I O Board connector J800 This connects the I...

Page 240: ...d contacts with isopropyl alcohol reinstall and then retest 5 Exchange the Configuration Card for a known working card to test operation System Power Supply The power supply is divided into two sectio...

Page 241: ...there power to the Exit Module The Exit Module elevator should cycle up and down after the Scanner Assembly is raised and lowered The Exit Module Control Board receives power from the Scanner Power Su...

Page 242: ...g 4 Reseat the Scanner Assembly connection to the Electronics Module 5 With Power Cord connected touch the Electronics Module to discharge any static ESD damage may occur if static electricity is disc...

Page 243: ...the correct media tray The paper guides indicate to the system the size of media being used Ensure the media guides are set correctly Inspect the paper for bent torn or folded corners Check to ensure...

Page 244: ...he system frame Operating System and Application Problems Print an internal test print from the system s control panel to ensure the problem is not system related There is additional help available at...

Page 245: ...from another computer 5 If the error returns turn On the PostScript error handler through the Control Panel Post Script Error Info in the Support menu or CentreWare IS and print the document again Tak...

Page 246: ...g network functions The logs contain TCP IP NetWare and AppleTalk initialization events The logs can also be accessed remotely via Cen treWare The logs list events chronologically The log is limited i...

Page 247: ...did not detect a dial tone when attempting to send a Fax Fax operations are not completely blocked by this error Outgoing faxes can queue Fax subsystem parameters are adjustable and jobs received befo...

Page 248: ...ission Report In addition to the Results codes the Job Details section includes Mode and Job Type codes Definitions of all these codes appears on each report Table 1 Common Fax Communication Commands...

Page 249: ...bled and configured properly for the local phone line Check the target Fax number If the number is in memory is it saved correctly Call the target Fax number from a desk phone and confirm a Fax tone r...

Page 250: ...oblem or an unusual or low quality ring signal A high Answer Delay setting Junk Fax Prevention or Fax Receive settings might impede inbound calls Troubleshooting Procedure Table 1 Remote Fax Answers t...

Page 251: ...rocedure for troubleshooting Printhead problems Complete this checklist as part of the Printhead replacement process Phaser 8510 8560MFP Printhead Troubleshooting Checklist Figure 1 Printhead Checklis...

Page 252: ...10 2006 6 50 Phaser 8510 8560MFP Multifunction Product Printhead Troubleshooting Checklist Initial Issue Diagnostics Figure 2 Printhead Checklist Page 2 Figure 3 Printhead Checklist Page 3...

Page 253: ...e pump sole noid opens 5 The Printhead tilts forward against the Wiper Blade and the purge and wipe cycle begins 6 The Control Panel indicates the system is performing the cleaning process 7 The Print...

Page 254: ...10 2006 6 52 Phaser 8510 8560MFP Multifunction Product Printhead Troubleshooting Checklist Printhead Initial Issue Diagnostics...

Page 255: ...10 2006 7 1 Phaser 8510 8560MFP Multifunction Product Wiring Data Initial Issue 7 Wiring Data How to use the Plug Jack Location List 7 3 Plug Jack Locations 7 4 Wire Routing 7 10 Wiring Diagrams 7 13...

Page 256: ...10 2006 7 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Wiring Data...

Page 257: ...e Tray Detect Sensor to the I O Board 118 Figure 2 C 107 Connects the Drum Fan to the Right Side Harness 120 Figure 2 C 107 Connects the Drum Encoder to the Right Side Harness 125 Figure 6 Connects th...

Page 258: ...e I O Board 870 Figure 9 G 106 Connects the Drum Temp Sensor to the I O Board 910 Figure 9 C 109 Connects the Ink Loader Sensors to the I O Board CN1 Figure 7 G 107 Connects the Exit Module Control Bo...

Page 259: ...10 2006 7 5 Phaser 8510 8560MFP Multifunction Product Plug Jack Locations Wiring Data Initial Issue Figure 2 Right Side P J Locations Figure 3 Front Side P J Locations...

Page 260: ...2006 7 6 Phaser 8510 8560MFP Multifunction Product Plug Jack Locations Initial Issue Wiring Data Figure 4 Right Side Electronics Module P J Locations Figure 5 Left Side Electronics Module P J Locatio...

Page 261: ...10 2006 7 7 Phaser 8510 8560MFP Multifunction Product Plug Jack Locations Wiring Data Initial Issue Figure 6 Top Electronics Module P J Locations Figure 7 Exit Module Control Board P J Locations...

Page 262: ...10 2006 7 8 Phaser 8510 8560MFP Multifunction Product Plug Jack Locations Initial Issue Wiring Data Figure 8 Scanner Power Supply P J Locations Figure 9 I O Board P J Locations...

Page 263: ...2006 7 9 Phaser 8510 8560MFP Multifunction Product Plug Jack Locations Wiring Data Initial Issue Figure 10 Drum Heater Relay Board P J Locations Figure 11 Underside of the Preheater Board P J Locatio...

Page 264: ...10 2006 7 10 Phaser 8510 8560MFP Multifunction Product Wire Routing Initial Issue Wiring Data Wire Routing Figure 1 Back Frame Wire Routing Figure 2 Right Side Wire Routing 1 2...

Page 265: ...10 2006 7 11 Phaser 8510 8560MFP Multifunction Product Wire Routing Wiring Data Initial Issue Figure 3 Right Side Wire Routing 2 2 Figure 4 Left Side Wire Routing 1 2...

Page 266: ...10 2006 7 12 Phaser 8510 8560MFP Multifunction Product Wire Routing Initial Issue Wiring Data Figure 5 Left Side Wire Routing 2 2 Figure 6 Front Wire Routing...

Page 267: ...10 2006 7 13 Phaser 8510 8560MFP Multifunction Product Wire Routing Wiring Diagrams Wiring Data Initial Issue Figure 7 Top Wire Routing 1 2 Wiring Diagrams Figure 1 Scanner DADF Block Diagram...

Page 268: ...10 2006 7 14 Phaser 8510 8560MFP Multifunction Product Wiring Diagrams Initial Issue Wiring Data Figure 2 System Block Diagram 1 2 Figure 3 System Block Diagram 2 2...

Page 269: ...10 2006 7 15 Phaser 8510 8560MFP Multifunction Product Wiring Diagrams Wiring Data Initial Issue Figure 4 Left Side Harness 1 2 Figure 5 Left Side Harness 2 2...

Page 270: ...10 2006 7 16 Phaser 8510 8560MFP Multifunction Product Wiring Diagrams Initial Issue Wiring Data Figure 6 Electronics Module Figure 7 Electronics Module Power...

Page 271: ...10 2006 7 17 Phaser 8510 8560MFP Multifunction Product Wiring Diagrams Wiring Data Initial Issue Figure 8 Right Side Harness I O Control Figure 9 I O Board...

Page 272: ...10 2006 7 18 Phaser 8510 8560MFP Multifunction Product Wiring Diagrams Initial Issue Wiring Data Figure 10 I O Board 2 Figure 11 Exit Module Control Board...

Page 273: ...2006 8 1 Phaser 8510 8560MFP Multifunction Product Theory of Operation Initial Issue 8 Theory of Operation System Overview 8 3 Image Input Terminal 8 3 System Electronics 8 6 Image Output Terminal 8...

Page 274: ...10 2006 8 2 Phaser 8510 8560MFP Multifunction Product Initial Issue Theory of Operation...

Page 275: ...ssemblies and subassembly interactions for this system This section is broken down into the following The Image Input Terminal IIT DADF and paper path The Scanner Assembly with Control Panel System El...

Page 276: ...predetermined staged point When the scanner detects this point it starts collecting data from the Charge Cou pled Device CCD DADF Cover Open Sensor This optical sensor detects the status of the DADF a...

Page 277: ...chieves a predetermined image quality and stability 5 Scanhead moves toward platen glass to confirm motion control 6 Scanhead moves back to the home position under the CVT window Manual Calibration Ma...

Page 278: ...ntrol Panel receives power from the power supply contained in the Electronics Module Electronics Module The Electronics Module includes the main board image processing board the power control board an...

Page 279: ...lated 12 V and 5 V from unregulated 15 V power Electronics Module Components Power Supply There are no field adjustments necessary on the power supply In gen eral the power supply has two main yet int...

Page 280: ...Supply Wiring Diagram Image Output Terminal The Image Output Terminal commonly referred to as the print engine is made up of nine major subsystems The Process Drive The Media Path Drive The Ink Loader...

Page 281: ...dlock mecha nism through a gear train and solenoid on the exit module Ink Loader Melts the solid ink as ink is required by the Printhead The melted ink drops into the ink reservoirs of the Printhead u...

Page 282: ...rom the tray and staged in the paper path while the system is printing previous pages The deskew process uses a reverse buckle deskew for all three paper paths The paper is first driven against non ro...

Page 283: ...of sensors track the progress of the paper along the paper path and detects if a paper jam occurs Other sensors detect the presence of the Ink Sticks stop system activity if a door is open interlock...

Page 284: ...nsors consist of a LED in one arm of a U shaped holder and a photo transistor in the other arm When the sensing area is vacant nothing is between the arms of the sensor light falls on the photo recept...

Page 285: ...he opposite direction the upper gears are engaged Since the system is open loop special attention to the home position of the Process Drive gears and the mating camshaft gears is critical The Process...

Page 286: ...o print the Drum starts rotating at a speed dependent upon print resolution As the Drum reaches the correct speed the jets begin to fire to deposit the image on the oiled portion of the Drum As the je...

Page 287: ...e Control Panel reports an Ink Jam error Figure 10 Ink Loading Printhead The Printhead is the heart of the system spanning nearly the length of the drum Using its 1236 jet nozzles 309 jets for each pr...

Page 288: ...screw system The Printhead mounted to the X Axis shaft moves laterally across the surface of the drum To find the Printhead home position the X Axis system drives the Printhead in an open loop The Pri...

Page 289: ...d are spring loaded to normally be unlocked 2 The Printhead is restrained at the X Axis shafts by the right and left head restraints that limit motion at both ends of the Printhead 3 The Printhead is...

Page 290: ...into more detail on the transfix sys tem In operation the image to be printed on paper is first printed on the rapidly rotating drum The paper Preheater heats a sheet of paper or transparency film to...

Page 291: ...Never attempt to adjust or increase the transfix pressure on the springs Figure 18 Transfix System Drum Maintenance System The drum maintenance system creates a thin intermediate liquid transfer surfa...

Page 292: ...drive governs wiper movement when it engages a clutch on the exit shaft of the system The purge pump applies pressure to the ink reservoir for approximately 2 5 sec onds Valves in the reservoir seal...

Page 293: ...om the paper Pre heater exit sensor the transfix roller lowers onto the leading edge of the media in the nip Tim ing is based on the sensor ensuring the image is perfectly aligned for transfix to the...

Page 294: ...iage back to its ready position The deskew rollers are not driven during transfixing The media path drive rotates the exit roll ers in the correct direction to pull the paper out with the deskew clutc...

Page 295: ...oint Paper Media inches per second Fast Color Standard Enhanced Hi Res Photo Peak transfix speed Simplex 20 ips 17 ips 13 ips 7 ips Peak transfix speed Duplex 5 ips 5 ips 5 ips 5 ips Peak Transfix Spe...

Page 296: ...set Identifier 128 truncated from 256 IP Host Name 64 IP Domain Name 256 IP Network Mask 4 IP IP Address 4 IP Default Gateway 4 IP BOOTP DHCP 1 IP DDNS 1 IP SMTP Server 256 IP IP Source 1 IP TCP IP 1...

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Xerox PHASER 8560MFP, Service Documentation

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Summary of Contents for PHASER 8560MFP

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