Tektronix Phaser 840 Service Manual

PHASER® 840 COLOR LASER PRINTER

Service Quick Reference Guide

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 operating instructions unless you are qualified to do so.

This printing: May 1998 071-0388-00

Copyright © 1998 by Tektronix, Inc., Wilsonville, Oregon. Printed in the United States of America. All rights reserved. Contents of this publication may not be reproduced in any form without permission of Tektronix, Inc.

Tektronix

, Phaser®, and Made for Each Other® are registered trademarks of Tektronix, Inc. TekColor™, PhaserShare™, PhaserMatch™, PhaserLink™, Finepoint™ and PhaserPrint™ are trademarks of Tektronix, Inc. RealSUPPORT

and TekColor CareSM are service marks of Tektronix, Inc.

Other marks are trademarks or registered trademarks of the companies with which they are associated.

November 1998. First printing

December 1998. Changed pages: 41, 60, 76, 84, 85, 108, 126, 133

May 1999. Changed pages: 5, 61, 62, 68, 74, 112, 118, 124, 126, 127, 147, 149

TE/mq/mm

User safety summary

Terms in manual

CAUTION Conditions that can result in damage to the product.

WARNING Conditions that can result in personal injury or loss of life.

Power source:

between the supply conductors or between either supply conductor and ground. Use only the speciﬁed power cord and connector. For 220 VAC printers, do not apply more than 250 volts RMS between the supply conductors or between either supply conductor and ground. Use only the speciﬁed power cord and connector. Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

technician to replace fuses inside the product. Do not operate without the covers and panels properly installed. Do not operate in an atmosphere of explosive gases.

WARNING Turning the power off using the On/Off switch does not de-

Safety instructions:

product into a power source.

For 110 VAC printers, Do not apply more than 130 volts RMS

Avoid electric shock by contacting a qualiﬁed service

energize the printer. You must remove the power cord to disconnect the printer from the mains. Keep the power cord accessible for removal in case of an emergency.

Read all installation instructions carefully before you plug the

Terms on product

CAUTION A personal injury hazard exists that may not be apparent.

For example, a panel may cover the hazardous area. Also applies to a hazard to property including the product itself.

DANGER A personal injury hazard exists in the area where you see the

sign.

Care of product:

Disconnect the power plug if the power cord or plug is frayed or otherwise damaged, if you spill anything into the case, if product is exposed to any excess moisture, if product is dropped or damaged, if you suspect that the product needs servicing or repair, and whenever you clean the product.

Ground the product:

grounded AC outlets only. If necessary, contact a licensed electrician to install a properly grounded outlet.

Disconnect the power plug by pulling the plug, not the cord.

Plug the three-wire power cord (with grounding prong) into

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

Use caution. Refer to the manual(s) for information:

WARNING:

controls (and other conductive parts) can cause an electrical shock. Electrical product may be hazardous if misused.

If the product loses the ground connection, usage of knobs and

Service safety summary

For qualiﬁed service personnel only:

Summary.

Do not service alone:

unless another person capable of rendering ﬁrst aid or resuscitation is present.

Use care when servicing with power on:

points in this product. To avoid personal injury, do not touch exposed connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or replacing components.

Do not wear jewelry:

other metallic objects could come into contact with dangerous voltages and currents.

Power source:

not apply more than 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Do not perform internal service or adjustment of this product

Remove jewelry prior to servicing. Rings, necklaces, and

This product is intended to operate from a power source that will

Refer also to the preceding Users Safety

Dangerous voltages may exist at several

Contents

General Information 1

Phaser 840 printer overview 2 Solid inks 3

About RAM upgrades 3 Memory considerations 4 Print engine assemblies 6 The main board 14

Combination sensors and their meanings 15

Media tray type sensing 15

Front panel 16 Rear panel 18

Regulatory specifications 24

Error Codes and Messages 25

Rear panel LEDs error codes 25 Error messages 28

Troubleshooting 37

System power-up sequence 37

Verifying main board CPU operation 39 Verifying print engine operation by printing its startup page 39 Verifying power supply operation 39

Measuring power supply voltages 40

Inspecting the power supply fuses 40 Testing for shorted drivers 41 Testing for a shorted motor 42 Testing motor and solenoid resistances 42 Media jams and the paper path 43

Media-based problems 43 Paper-pick errors 43 Print transfer jams 44 Checking the process motor and drive train 45 Media skews passing through the paper path 45

Printing and print quality problems 46

Streaks or lines across the print 46 Streaks or lines down the print 46 Missing ink or light colored ink band running length of print 47 Scratches parallel to the long axis of printing, particularly with film 48 White portion of print is colored 48 Color is uneven 49 Not printing 49

Service Guide

Printing too light or too dark 49 Fuzzy text 50 Poor primary color fills 50 Poor small text resolution 51 Ghosting 51 Variation of density on second side of print 52 Ghost of first side image on second side of print 52 Vertical line appear wavy 52 Oil streaks on print 53 Poor ink adhesion, poor image durability 53 Incomplete image transfer to paper 54 Ink smears of first side of duplex print 55 Repeating print defects on print 55 Banding parallel to long edge of print 56 Wrinkling 56 Image is offset or cut off 57 Oil streaks on top of print 57

Macintosh printing problems 57

Image never prints 57 Image prints in black-and-white 58 Image is rotated 90 degrees 58 Printer isn’t in the Chooser 58

Windows printing problems 58

Image never prints 58

Adjustments 59

Bypass mode (manufacturing mode) 59 Cool down mode 59 Hidden service menu 60

Bypassing a “short menu” 60 Printing service test prints 61 Printing the Configuration Page 61 Selecting Duplex Oil Chase 61

Adjustments 62

Process belt tension adjustment 62 Exit roller drive belt tension adjustment 63 Y-axis belts tension adjustment 64 Printhead-to-drum spacing adjustment 66 Cap/wipe/purge assembly belt adjustments 68 Drum position encoder gap 70 Transfix roller pressure spring adjustment 72 X-axis scale adjustment 74

Vacuum check 75

Phaser 840 Color Printer

Cleaning and Maintenance 77

Cleaning 78

Cleaning Page 79 Vacuum 79 Drum temperature sensor 79

Maintenance 80

Maintenance roller 80

Waste tray 80 Lubrication 81 Inspection 82

Resetting NVRAM 83

Key FRU Removal and Replacement 87

Main board 88

Power supply 89

Power control board 90

Paper/drum heater 91

Upper feed roller assembly 92

Drum/transfix assembly 94

Drum position sensor assembly 99

Printhead 101

X-axis motor and drive assembly 104

Y-axis belt drive assembly 105

Cap/wipe/purge assembly 106 Locking the printhead 108

FRU List 109

High-capacity Paper Tray Assembly 126 Service tools 128 Supplies and accessories 128

Test Prints 133

Wiring Diagrams 145

Service Guide

vii

Figures

The Phaser 840 printer (shown with optional High-capacity Paper Tray Assembly) 1

Internal features of the print engine 6 Circuit boards of the print engine (right front view) 7 Circuit boards of the print engine (left-rear view) 8 The printer’s I Printhead maintenance system of the print engine 10 Sensors and switches on the right side of the print engine 11 Sensors and switches on the left side of the printer 12 Solenoids and clutches on the print engine 13 Features of the main board 14 Printer front panel 17 Printer rear panel 19 Attaching the service load connector to J250 41 Setting process belt tension 62 Setting exit roller drive belt tension 63 Setting the Y-axis belt tension 65 Attaching the digital gap indicator 66 Spacing the printhead to the drum 67 Aligning (timing) the cap/wipe/purge assembly drive belts 69 Setting the drum position encoder gap 71 Adjusting the transfix roller pressure springs 73 Adjusting the x-axis scale adjustment 74 Connecting the vacuum gauge to the printer 75 Resetting print engine NVRAM menu item 84 Clearing PostScript NVRAM menu item 85 Removing the main board 88 Removing the power supply 89 Removing the power control board 90 Removing the paper/drum heater 91 Remove the upper feed roller assembly (left side) 92 Removing the upper feed roller assembly (front) 93 Removing the drum transfix assembly (left side) 95 Removing the drum/transfix assembly (right side) 97 Marking the drum home flag sensor alignment 99 Removing the drum position sensor assembly 100 Plugging the reservoir holes 101 Removing the printhead 103 Removing the x-axis motor and drive assembly 104

C bus 9

viii

Phaser 840 Color Printer

Removing the Y-axis belt drive assembly 105 Removing the cap/wipe/purge assembly 107 Cabinet FRUs 111 Imaging FRUs 113 Paper path FRUs 115 Motors and fans FRUs 117 Circuit boards FRUs 119 Solenoids and clutches FRUs 121 Gears and belts FRUs 123 Sensors and flags FRUs 125 High-capacity Paper Tray 127 Print engine wiring diagram 145 Wire routing on the right side of the printer near right I/O board 146 Wire dressing above the x-axis drive 147 Vacuum hose dressing 148 Routing wiring on the left side of the printer 149 Wire dressing behind the printhead 150

Service Guide

Tables

Installed RAM and printer capabilities 4 Tray switch sensor combinations 15 Rear panel DIP switch settings 19 Physical dimensions 20 Printer installation clearances 20 Functional specifications 21 Electrical specifications 22 Environmental specifications 23 Main board power-up self-test error codes 25 Front panel and fault history log error codes and messages 28 Motor and solenoid resistances 42 Hidden Service Menu 60 Cabinet FRUs 110 Imaging FRUs 112 Paper path FRUs 114 Motors and fans FRUs 116 Circuit board FRUs 118 Solenoid and clutches FRUs 120 Gears and belts FRUs 122 Sensors and flags FRUs 124 High-capacity Paper tray FRUs 126 Service tools 128 Supplies and accessories 128

Phaser 840 Color Printer

General Information

This service guide contains information useful to verify operation, troubleshoot, repair, adjust, and maintain a Tektronix Phaser® 840 Color Printer. This guide includes a Field Replacement Unit list.

Topics such as printer theory of operation, detailed removal/replacement procedures, conﬁguration page details, and verifying printer operation are located on the companion

To ensure complete understanding of the product, we recommend participation in Phaser 840 printer service training, if available.

Color Printer Service & Support Resources CD-ROM

0388-01

The Phaser 840 printer (shown with optional High-capacity Paper Tray Assembly)

Service Guide

Phaser 840 printer overview

The Phaser 840 Color Printer is an Adobe PostScript Level 3 (Version 3010) color, solid ink-jet printer. It also supports color PCL 5C at 600 x 600 dots-per-inch resolution. The Phaser 840 printer prints at a number of resolutions: A 10 pageper-minute (ppm) Fast Color Mode, a standard 5.7 ppm mode, an Enhanced mode of 491 x 982 dpi at 3.3 ppm and a High-Resolution/Photo mode of 600 x 1200 dpi at 2.2 ppm.

All printer models but the standard version feature built-in auto-duplex printing.

Standard Phaser 840 printer .

and is equipped with 32 Mbytes of RAM. It can be upgraded to as much as 128 MBytes of RAM using any combination of two 16-, 32-, and 64-Mbyte RAM DIMMs.

The Phaser 840 Plus printer.

printer to 64 Mbytes of RAM. It include a SCSI port daughter card to support an external SCSI disk for additional font storage as well as a scanner. Special circuitry on the SCSI port daughter card enables additional features like duplex printing, job pipelining and Check Print mode. With job pipelining, the printer can print one image and process the data for the next image at the same time. Check Print mode prints the ﬁrst page of a multiple page print job while holding the remainder of the job pending front panel approval.

The Phaser 840 Extended printer.

of the Phaser 840 Plus printer but includes additional RAM to bring the printer to 128 Mbytes of RAM. It also includes a High-capacity Paper Tray and an internal IDE hard drive.

All printers support four available paper trays: Two A and A4 trays are meant for paper and low volumes of transparencies; two other A and A4 trays are meant for label stock and high-volume transparencies. The optional 500-sheet Highcapacity Paper Tray Assemblies gives the printer a two-tray capability. With the addition of a second High-capacity Paper Tray, the printer has a three tray capability. (The High-capacity Paper Tray Assembly is sometimes referred to as a lower feeder; it only supports paper printing.) The printer can also print six sizes of handfed envelopes in low volumes.

A 133-MHz PowerPC processor oversees print engine operations and PostScript image processing. The printer features an integral bi-directional parallel port (IEEE 1284C with ECP mode) and a 10baseT Ethernet port (with support for EtherTalk, Novell NetWare/NDS, TCP/IP, DHCP and Windows Peer-to-Peer). A USB high-speed serial port is also provided. A rear panel slot allows customers to install one “smart card” PhaserShare Series B Network Card. One card provides a LocalTalk port. A second, alternative card offers a 10BaseT/ 100BaseT/10Base2 Ethernet board providing standard protocol support for EtherTalk, Novell NetWare/NDS, TCP/IP and DHCP. When installed, this card disables the standard 10baseT port. A third card provides a Token Ring board providing protocol support for TokenTalk, Novell NetWare/NDS and TCP/IP. When inserted, this card also disables the standard 10baseT port.

The base Phaser 840 printer features 136 built-in fonts,

The Phaser 840 Plus printer option upgrades the

The Extended Features option has all the features

A second rear panel slot accommodates an internal IDE hard drive for print job collation, job accounting, font storage and PDF direct printing.

Phaser 840 Color Printer

The printer features Job Accounting, which maintains from 50 to 5000 records of processed print jobs, depending on memory options and hard drive options. The record contains information such as time and duration of the print and the percentage of color coverage on the print. The log of records can be retrieved using PhaserLink or PhaserShare.

Solid inks

Solid inks, sometimes called phase-change inks, are solid at room temperature and are liquid at the higher temperature used during printing. The inks solidify almost instantly after being jetted onto the printer’s drum. Because Tektronix' proprietary solid inks bleed much less than ordinary liquid inks, they allow the printer to print brilliant colors on plain paper. Each Tektronix solid-ink printer inks are especially formulated for that printer; the inks are not interchangeable.

Note

Turning the printer off and allowing it to cool causes it to perform a printhead cleaning and purge cycle upon power-up. The printer's purge cycle consumes a signiﬁcant amount of ink. During normal use and servicing, turn the printer off and allow it to cool only when necessary.

About RAM upgrades

The printer features two DIMM connectors which accept both 32-, or 64-Mbytes RAM DIMMs (16-Mbyte RAM DIMMs work but are not offered). The printer can use SDRAM DIMMs meeting these speciﬁcations:

■

168-pin DIMM

■

Synchronous DRAM

■

3.3 volts

■

10 nsec speed

■

Valid on-board Serial Presence Detect ROM

■

Unbuffered

■

Latency of 2

■

9 address columns

■

Maximum of 2.8 cm (1.1 in.) in height. SDRAM DIMMs from other Phaser printers, such as the Phaser 740 and Phaser 780 color printers may be too tall to ﬁt inside a Phaser 840 printer.

Upon power-up, the image processor interrogates the 256 byte Serial Presence Detect ROM, which describes the DIMM in great detail, such as data width, clock delay, number of address columns and row, refresh rate and more. If the DIMM does not meet the required speciﬁcations, it will be ignored; no error message will be reported.

Service Guide

Memory considerations

With more memory the printer dual frame buffers for printing one image while processing a second image (which gives greater printing throughput). With additional RAM memory, and the SCSI daughter card installed (the Plus and Extended conﬁgurations), the printer’s capabilities increase as detailed in the following table:

Installed RAM and printer capabilities

Feature Base (32 Mbytes) Plus conﬁguration

Fast Color (draft) printing

Standard Printing yes yes yes Enhanced Printing yes yes yes High-Resolution/

Photo Printing Duplex printing no yes. The printer

Color PCL 5C yes yes yes Pipelining no yes yes Check Print no yes yes Collation (requires

hard drive) PDF printing.

Requires hard drive Job accounting 50 records 500 records. 5000

Frame buffer (lower print resolutions can provide additional frame buffer space)

yes yes yes

no yes yes

no Standard. Standard.

1 Letter size image 1 Letter-size image 2 Letter-size images

(64 Mbytes)

requires at least 80 Mbytes of RAM to print duplexed, highresolution, 1200 x 600 dpi prints

records with optional hard drive

Extended conﬁguration (128 MBytes)

yes

5000 records with included hard drive

Phaser 840 Color Printer

Print the Conﬁguration Page and check the item “Installed RAM” to see what type of RAM is installed.

For example:

Installed RAM: 64 Mbytes Mem slot 1: SDRAM/parity/64 MB/KMM366S823BTL-G0 Mem slot 2: empty

This is a list of SDRAM DIMMs that are branded for use by Tektronix in this printer at the time this guide was published:

Size

32 Mbytes Samsung KMM366S403CTL-G0

32 Mbytes Micron MT166LSDT464Ag-66ZXX

64 Mbytes Samsung KMM366S823BTL-G0

64 Mbytes Micron/Crucial CT8M64S4D10-MBTBGLP

Maker Part Number

Service Guide

Print engine assemblies

Cap/wipe/purge assembly

Drum

Transfix roller

rocess

otor

Paper/ drum heater

Y-axis motor

Printhead

Paper feed motor

Ink load assembly

X-axis drive and motor

0388-0

Internal features of the print engine

Phaser 840 Color Printer

Six circuit boards support the printer’s electronics. Two boards, called I/ O boards, support the front panel, solenoids and sensors. The main board contains the printer’s CPU processor, RAM and ROM. The power control board distributes power supply voltages to the other printer boards as well as drive many printer motors. The front panel provides a user interface to the printer. The printhead drive board, a part of the printhead, manages the signals and voltages of the printhead’s printing elements and sensors. The optional network card and internal hard drive could be considered a seventh and eighth circuit boards.

Front panel

Circuit boards of the print engine (right front view)

I/O board right

Service Guide

0388-03

Printhead drive board

Internal hard drive

Network card

Power supply

Main board

Circuit boards of the print engine (left-rear view)

Drum Maintenance counter EEPROM

Power control board

I/O board left

0388-04

Phaser 840 Color Printer

An internal data bus, called the I2C bus, connects all I/O boards to the main board. Through this single bus, the main board can “poll” the I/O boards for the state of the printer’s sensors as well as actuate the printer’s solenoids. This data bus greatly simpliﬁes the wiring that would otherwise be required for monitoring numerous sensors and solenoids. The I

C bus also extends down to the High-

capacity Paper Trays.

High capacity Paper T ray connection

The printer’s I2C bus

Service Guide

I2C bus

0388-05

The printer features a printhead maintenance system used to clean the printhead faceplate and clear clogs from the printhead nozzles. The system consists of a vacuum pump assembly, the cap/wipe/purge assembly and the cap/wipe/ purge carriage drive.

Cap/wipe/purge carriage drive

Cap/wipe/purge assembly

Printhead maintenance system of the print engine

Phaser 840 Color Printer

Vacuum pump assembly

0388-06

Sensors in the printer provide information to the main board to determine the state of the printer. The printer monitors the positions of some of the movable assemblies, such as the drum, as well as the temperature of many other assemblies, such as the printhead, paper preheater and the drum.

Ink load cover sensor

Top cover switch

Front cover switch

Preheater entry/left edge sensor

Ink-sticklow sensor

Ink-stickout sensor

Exit / tray-full sensor

A4-size media sensor

A-size media sensor

Cap/wipe/purge home sensor

Maintenance blade position sensor

Hand-feed sensor

Paper-pick sensor

Tray type sensors

Paper-empty sensor

Sensors and switches on the right side of the print engine

Service Guide

0388-07

Transfix exit sensor

Drum temperature sensor

Duplex paper sensor

Drum-homeposition sensor

Drum encoder sensor

Process gear position sensor

Preheater exit sensor

Transfix roller

Preheater exit sensor located on inside wall of drum/transfix frame

Drum

Sensors and switches on the left side of the printer

Phaser 840 Color Printer

Preheater

0388-34

Caution

Electric clutches and solenoids are used by the printer to engage rollers as needed to move paper through the printer as well as start some print processes.

The actual position of some printer assemblies, such as the printhead or the cap/wipe/purge assembly, cannot be ascertained at all times. The printer records, in NVRAM, where it last positioned such assemblies each time it moves them. If, after power-down or a power interruption, the assemblies are manually repositioned, the printer erroneously assumes that the assemblies are in the position it last left them. This assumption can result in damage to the printer when it tries to position the assemblies. For example, the printhead could be tilted forward and crash into the raised cap/wipe/purge assembly.

Before turning on the printer, ensure the printhead is tilted forward, centered in front of the drum and the cap/wipe/purge assembly is in the retracted, home position. The tilt cam gear should be disengaged from the gear drive train.

Upper feed roller clutch

Pick clutch

Drum maintenance cam clutch

Cap/wipe/purge clutch

Air valve solenoid

Transfix solenoid

Solenoids and clutches on the print engine

Service Guide

0388-0

The main board

The main board features the printer’s PowerPC processor that controls the engine and the PostScript processing. Prominent on the main board is the ROM code DIMM and the RAM DIMM plug-in modules. The code ROM DIMM also contains the printer’s on-board fonts. Variations of the ROM code DIMM contain alternate language fonts such as Kanji or Hangul.

Network connection is provided through a built-in 10baseT port. A plug-in SCSI interface adaptor board provides a SCSI port for an external hard drive or scanner.

The printer stores unique printer status and PostScript values in its NVRAM module. The printer’s Ethernet address, unique to each printer, is stored in the printer ID chip, an 8-pin socketed IC. All these socketed components should be transferred to a replacement main board to maintain customer-unique settings.

SCSI riser board

Boot ROM/ Printer ID

Features of the main board

RAM DIMMs

NV RAM/ Real Time Clock

Code ROM DIMM

0388-09

Phaser 840 Color Printer

Combination sensors and their meanings

Combinations of sensors are used by the printer to determine the type of standard (or upper) media tray installed in the printer.

Media tray type sensing

The combinations of the three tray sensors inform the print engine what type of media tray is installed. (The print engine does not detect the type of media installed in the tray; it only detects the particular tray being used by the presence of sensor ﬂags on the side of the tray.) The tray sensors are located on the right-side interior of the paper tray slot, mounted on I/O board right. There are four tray types:

■

Letter (A-size).

low-volumes of A-size transparency ﬁlm.

■

Metric Letter (A4-size).

paper as well as low-volumes of A4-size transparency ﬁlm.

■

High-volume Transparency/Label (A).

volumes of U.S.-size transparency ﬁlm as well as laser quality, adhesive label stock.

■

High-volume Transparency/Label (A4).

volumes of Metric-size transparency ﬁlm as well as laser quality, adhesive label stock.

Table 1 Tray switch sensor combinations

This tray is sized for 8.5 x 11-inch (U.S.) paper as well as

This tray is used for 210 x 297 mm (Metric)

This tray supports high

Tray type A Paper A4 Paper A Transparency A4 Transparency

Top switch Closed Open Closed Open Middle switch Open Closed Open Closed Bottom switc

h Open Open Closed Closed

Service Guide

Front panel

These front panel features are found on the printer:

■

128 x 64 pixel backlit graphic display

■

Two push buttons and four arrow buttons

■

Two LEDs

LCD.

The backlit LCD serves two purposes: displaying current image processor and print engine status information and displaying an interactive menu. Status information includes image processor status such as

Receiving data Out of paper, Paper Jam, Add ink

Customers can review and modify certain NVRAM, I/O ports and peripheral parameters. Using the front panel to review and change parameters is discussed in the topic, “Adjustments” on page 59.

and

Printing

. Print engine status includes messages such as

as well as error messages.

Ready to print

Buttons.

other two buttons are used as Select and Help.

In addition, when in the troubleshooting menu, pressing the

Select

Pressing and holding the immediately to the language selection menu.

Holding the correctly parked by ﬂashing both front panel LEDs.

Turning the printer on with the rear panel DIP 2 in the “down” position, allows access to the front panel during the warm-up cycle.

Four of the six buttons are arranged as a diamond-shaped keypad. The

button enters the hidden service support menu.

Left arrow

Right arrow

while turning off the printer will conﬁrm the printhead is

and the

Select

button proceeds

Left arrow

and the

Phaser 840 Color Printer

The topic “Resetting NVRAM” on page 83 explains how to use the front panel buttons to reset the NVRAM to its factory-default values.

Navigation buttons

Power

READY TO PRINT

Error

Printer front panel

Help button

Select button

0388-10

Service Guide

Rear panel

Connectors

The rear panel of the printer features the host interface connectors to the printer; it includes the following connectors:

■

Standard parallel (high-density connector), IEEE 1284C

■

Twisted Pair (10BaseT) Ethernet connector

■

A Universal Serial Bus port

■

Optional SCSI high-density connector (hard disk drive or Tektronix approved scanner).

■

A special 5-pin connector accommodates a service RS-232 cable from a PC or Macintosh computer running PC-based diagnostics.

The rear panel also includes two option slots. With the addition of a PhaserShare network card in one slot, the printer can feature either of these connector combinations:

■

LocalTalk connector

■

ThinNet (10Base2) and Twisted Pair (100BaseT) Ethernet or Token Ring connectors.

Note

When an Ethernet or TokenRing PhaserShare card is installed, the printer’s built-in 10BaseT Ethernet port is disabled.

The second slot accommodates an internal IDE hard drive for print job collation, job accounting, font storage and PDF direct printing.

Health LEDs

Two health LEDs indicate the status of the printer’s CPU functions: PostScript processing and print engine control.

■

Blinking

: The printer is operating normally. Both LEDs blink

irregularly during diagnostics.

If a soft error occurs, image processing occurs, but in a reduced capacity. Soft failures include failure of expansion memory DIMMs or any of the interface ports. When a soft error occurs, the printer automatically prints a startup page listing the error.

■

Off, or blinking a coded error indication

: A hard error condition has occurred that would keep the image processor board from operating. Refer to the topic “Error Codes and Messages” on page 25 for the meaning of a coded indication.

Phaser 840 Color Printer

Switches

Four DIP switches allow you to reset the printer or place the printer in different operating modes.

Table 2 Rear panel DIP switch settings

Function Switch 1 Switch 2 Switch 3 Switch 4

Normal operating mode UP UP UP UP Service mode DOWN UP UP UP Reset printer UP UP UP DOWN Manufacturing mode (Bypass

UP DOWN UP UP

mode) Development mode (engineering

DOWN DOWN DOWN UP

use only) Recovery mode (engineering use

DOWN UP DOWN UP

only)

The following ﬁgure illustrates the rear panel of the printer.

IDE hard drive

Network card

PostScript

PhaserShare

Series B

Ethernet Card

health

100 Mbs

TP LINK

10/100Base-TX

10Base2

light

Engine health light

SCSI

Service

RS-232

Printer rear panel

Ethernet

10BaseT

Parallel

USB

DIP

switches

Service Guide

0388-11

Physical dimensions

Dimensions Value

Height: 38.7 cm. (15.25 ins.)

Width: 40 cm (17.25 ins.) Depth: 57.8 cm (22.75 ins.) Weight: Approximately 36 kgs (79 lbs). Print engine weight only;

51.4 cm (20.25 ins.) with one High-capacity Paper Tray Assembly

64.1 cm (25.25 ins.) with two High-capacity Paper Tray Assemblies

add 9 kgs (20 lbs.) for each optional High-capacity Paper Tray Assembly.

Printer installation clearances

Clearances Value

Top: 45.7 cm (18 ins.) Left: 10.2 cm (4 ins.) Right: 10.2 cm (4 ins.) Front: Unrestricted to replace trays and clear paper jams Rear: 10.2 cm (4 ins.) Bottom: No obstruction under printer that could block its cooling

vents.

Mounting surface ﬂatness:

Phaser 840 Color Printer

Within 3 degrees of horizontal with all four feet in contact with the surface.

Functional speciﬁcations

Characteristic Speciﬁcation

Printing process Solid ink-jet onto plain paper. Color medium Cyan, magenta, yellow and black ink sticks, each shape-

coded. The printer uses the subtractive color system to produce the colors red, green, and blue.

Addressability Selectable 273 x 300, 409 x 409, 491 x 982 or 600 x 1200

dots-per-inch (horizontal and vertical).

Engine printing speed (single-sided)

The time it takes from loading to ejecting: Fast Color 273 x 300 dot per inch:

on A- or A4-size: ≈ 6 seconds per print

Standard 409 x 409 dpi:

on A- or A4-size: ≈ 10.5 seconds per print

Enhanced 491 x 982 dpi:

on A- or A4-size: ≈ 18 seconds per print

Photo 600 x 1200 dpi:

on A- or A4-size: ≈ 24 seconds per print

Fast Transparency ﬁlm (273 x 300 dpi):

on A- or A4-size: ≈ 12 seconds per print

Standard Transparency ﬁlm 409 x 409 dpi):

on A- or A4-size: ≈ 22 seconds per print

Print times do not include image processing time, which varies, due to image complexity. 25 mm (1 in.) margins assumed with 35% ink coverage.

Minimum printing

All sides: 5 mm (0.2 in.)

margins Maximum print area A-size: 8.1 x 10.6 in.

A4-size: 200 x 283 mm

Usable paper weights

Tray fed: 16 - 32 lb. Bond (60 - 120 g/m 65 lb. (176 g/m

) Cover stock (main tray only) Manual fed: 16 - 32 lb. Bond (60 - 120 g/m 50 - 80 lb. Cover (135 - 220 g/m 110 lb (216 g/m

) Index stock

)

) -single-sided

Usable envelopes #10 (U.S.)

#6 3/4 (U.S.) C5 (Metric) DL (Metric) Choukei 3 Gou Choukei 4 Gou

Do not use envelopes with endﬂaps, plastic windows or metal clasps; they can damage the printer.

Label A/A4 laser quality sheet stock only, Recommended Avery™

white laser labels: U.S.: 5160, 5960 Metric: L7162

Service Guide

Electrical speciﬁcations

Characteristic Speciﬁcation

Primary line voltages 87 to 132 VAC (115 VAC nominal)

174 to 264 VAC (220 VAC nominal) Input voltage range is auto-sensed.

Primary voltage

47 to 63 Hz

frequency range Power consumption 200 watts standby; 300 watts at idle; 600 watts during

printing. Maximum power consumption 1000 watts during warm-up.

Current rating 115 VAC conﬁguration – 8 amp max./1 amp min.

220 VAC conﬁguration – 4 amp max./1 amp min.

Fusing F1: DC switcher - 6.3 amp slo-blo

F2: Drum heater 1, reservoir heater 1, ink melt chambers, cap/wipe/purge unit - 10 amp slo-blo F3: Jet stack left and right, paper pre-heaters, reservoir heaters 2,3,and 4 10 amp slo blo Fuses are not user-accessible.

Secondary voltages +5

V ± 2.5%

+12 V ± 5%

-12 V ± 5% +40 V -5%, +12%

-52 V ± 10% +54 V ± 10%

RF emissions Both 115 and 220 VAC-conﬁgured instruments pass these

standards: EC EN60950:1992 Safety of Information Technology Equipment including Business Equipment EC EN55022:1992 Limits and methods of measurement of radio interference characteristic of Information Technology Equipment EC EN50082-1:1997 The Generic Immunity Standard Residential, Commercial, and Light Industry EN61000-4-3:1995-02 RF Field Immunity EN61000-4-2:1995-01 ESD (Electo-Static Discharge) EN61000-4-4:1995-01 Fast Burst Transient EN61000-4-5:1995-02 Line Surge EN61000-4-6:1996-03 RF conducted Immunity EN61000-4-11:1994-06 Voltage Dips and Interruptions EN61000-3-3:1994-12 Flicker 73/23/EEC Low Voltage Directive 89/336/EEC Electromagnetic Compatibility Directive 89/392/EEC Machinery Directive

Phaser 840 Color Printer

Environmental speciﬁcations

Characteristic Speciﬁcation

Temperature Operating Storage and shipping

Humidity Operating Non-operating

Altitude Operating Non-operating

Vibration/shock Non-Operating (vibration) Non-operating (shock)

Operating (shock)

10 to 32 C

-30 to 60

(50 to 90° F)

C (-22 to 140° F)

10 to 80% relative humidity, non-condensing 10 to 95% relative humidity, non-condensing

0 to 2400 m (8,000 ft.) at 25

0 to 15000 m (50,000 ft.)

Will withstand 0.15 G excitation, 5 to 200 Hz, 3 axes for up to 7 minutes with no impairment or subsequent damage.

0.5 g, 25 minute sweep, 5-200-5 Hz, 100-200 sec/sweep cycles

The printer may have any corner raised and dropped 1.5 cm (0.6 in.) while printing is in progress, without impairment of operation that cannot be recovered by a printhead purge cycle. The printer may have any corner raised and dropped 6 cm (2.4 in.) while idle without subsequent impairment of operation.

Service Guide

Regulatory speciﬁcations

The Phaser 840 Color Printer is in conformance with the following regulatory standards:

■ FCC Part 15 Class B (for 115 VAC equipment)

■ EN55022 (CISPR 22) Class B

■ VCCI (CISPR 22) Class B

■ EN61000-3-2 Flicker on AC Mains Susceptibility

■ The packaged product meets National Safe Transit Committee Test

Procedures

Listed:

■ UL 1950 Information Technology Equipment

Certiﬁed to:

■ CSA C22.2 No. 950 Safety of Information Technology Equipment,

Including Electrical Business Equipment

GS licensed:

■ IEC 950 (1991) Second Edition; EN60950 Information Technology

Equipment

Phaser 840 Color Printer

Error Codes and Messages

Rear panel LEDs error codes

The rear panel LEDs are located on each side of the rear panel DIP switches.

left LED represents the operation of the PostScript ﬁrmware. The right LED represents operation of the main board’s print engine ﬁrmware.

LEDs toggle back and forth for each successful pass through each SDRAM test. A failure in the power on self tests is indicated by the left LED (the PS LED) ﬂashing in a speciﬁc pattern of long and/or short ﬂashes and repeated indeﬁnitely. A long ﬂash represents a 5, while a short ﬂash is a 1. For example, a long ﬂash followed by 4 short ﬂashes is 5 + 4 = 9. If the left LED repeatedly ﬂashes in the same sequence, then the PostScript processor has encountered an error and is looping. The possible LED-encoded error codes are listed in the following table. Other failures are indicated by the failure being printed on the Startup Page.

After successful power-up, the left LED ﬂashes at a regular “heartbeat” rate. The

Power

front panel cleared.

Table 3 Main board power-up self-test error codes

Left LED ﬂashes

Long ﬂash =5 Short ﬂash=1 2L+1S=11

1 2 SDRAM

light is turned on, the

Meaning Details

not used

SIMM Presence

This test veriﬁes for the presence of both SDRAM SIMMs. If both SDRAM SIMMs are missing the resultant error indication is 2 short ﬂashes from the left LED.

During the POST tests, the two

Error

light is ﬂashed, and the LCD is

The

3 SDRAM bank 0This test veriﬁes DRAM bank 0 in the DRAM DIMM

4 SDRAM bank 1This test veriﬁes DRAM bank 1 in the DRAM DIMM

5 SDRAM bank 2This test veriﬁes DRAM bank 0 in the DRAM DIMM

6 SDRAM bank 3This test veriﬁes DRAM bank 1 in the DRAM DIMM

7 not used 8

not used

located in Position 0 (closest to the rear panel)

located in Position 1 (farthest from the rear panel)

Service Guide

Table 3 Main board power-up self-test error codes

Left LED

Meaning Details

ﬂashes

Long ﬂash =5 Short ﬂash=1 2L+1S=11

9 NVRAM This test does a w alking 1s and a walking 0s test for

that last 4 bytes in the VxWorks section of the NVRAM.

10 EPROM This test reads in the ﬁrst 24 bytes from the EPROM

then veriﬁes that the Tektronix Ethernet address 0x08, 0x00, and 0x11 has been copied into three locations.

11 Mariner ASIC This test reads and veriﬁes the version level of the

Mariner ASIC.

12 Medusa ASIC This tests reads and veriﬁes the version level of the

Medusa ASIC.

13 Super Glue

ASIC

This tests reads and veriﬁes the version level of the Super Glue ASIC.

14 CL1284 IC This tests reads and veriﬁes the version level of the

parallel port controller CL1284 chip.

none

SCSI This test veriﬁes the functionality of the SCSI I/O

processor. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a failure is detected, the message “SCSI Option Card:” with one of the following messages will be sent to the Start Page.

■

Wrong values in script-set scratch registers. Script operation timed-out.

■

Script operation returns wrong exit code.

■

DMA transfer spills outside buffer. DMA transfer data mismatch.

■

none

10baseT This test veriﬁes the functionality of the Ethernet

LAN Controller chip. Any test failures with this component are treated as non-fatal errors with the error information written to the start page. If a failure is detected, the message “Ethernet:” with one of the following messages will be sent to the start page.

■

General Failure. MAC internal loopback failure.

■

MII internal loopback failure (currently disabled)

Phaser 840 Color Printer

Table 3 Main board power-up self-test error codes

Left LED ﬂashes

Long ﬂash =5 Short ﬂash=1 2L+1S=11

none

Meaning Details

Ethernet 100BaseT Option Card

This test veriﬁes the functionality of the Ethernet LAN Controller chip. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a f ailure is detected, the message “Ethernet Option Card: with one of the following messages will be sent to the Start Page.

General Failure.

■

MAC internal loopback failure. MII internal loopback failure.

■

Token Ring Option Card

This test veriﬁes the functionality of the processor chip. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page.If a failure is detected, the message “Token Ring Option Card:” with one of the following messages will be sent to the Start Page.

■

General error

■

Problem with EEPROM Error trying to Bring Up Diags

■

Error initializing device Command completion error

■

Interrupt error

■

Wrong vendor ID

■

Wrong microcode version Wrong version ID

■

LocalTalk Option Card

This test veriﬁes the functionality of the LocalTalk option card. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a failure is detected, the message

General Error

LocalTalk Option Card:

will be sent to the Start Page.

Service Guide

Error messages

Error codes indicate the following:

■

The failing system (XX,yyy.zz)

■

The failing subsystem (xx,

■

The actual problem (xx,yyy.ZZ).

■

The print engine copy count (xx,yyy.zz

Table 4 Front panel and fault history log error codes and messages

Error code Meaning 2,000: System fault I/O board...

YYY

.zz)

:123

) the error occurred on.

2,001.40: SY_DEV_FAULT_IO_ RIGHT

2,002.40: SY_DEV_FAULT_IO_ LEFT

4,000: PC (process control supervisor)....

4,001.40 (0x2401): PC_DEV_FAULT_HEAD _READ

4,002.41 (0x2402): PC_DEV_FAULT_HEAD _ZEROS

4,003.42 (0x2403): PC_DEV_FAULT_HEAD _ONES

4,004.43 (0x2404): PC_DEV_FAULT_HEAD _CHECKSUM

4,005.44 (0x2405): PC_DEV_FAULT_DM_ CAM_ERR

4,009.48 (0x2409) PC_DEV_FAULT_DM_ CAM_BEGIN

The engine can not detect the presence of the right I/O board. Ensure the connections are good.

The engine can not detect the presence of the left I/O board. Ensure the connections are good.

Failure reading printhead NVRAM data: chec k the wiring to the printhead, I2C bus and other hardware.

Printhead NVRAM data was all zeros: has this printhead been through normalization? If so, check wiring to printhead.

Printhead NVRAM data was all ones: has this printhead been through normalization? If so, check the wiring to the printhead.

Printhead NVRAM checksum failure: the data within the printhead NVRAM has been corrupted. Check the hardware and wiring. The printhead may need to be renormalized (a manufacturing function).

Failure positioning drum maintenance cam during a drum maintenance cycle: check drum maintenance cam solenoid, clutch, home sensor, and related hardware.

At the start of a drum maintenance cycle, when the drum maintenance cam position should have been at blade down, oil roller down, the drum maintenance cam home sensor should have been TRUE and was instead FALSE. Check the drum maintenance cam solenoid, clutch, home sensor, and related hardware.

Phaser 840 Color Printer

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

4,010.40 (0x240A) PC_DEV_FAULT_DM_ CAM_BU_WU

4,011.41 (0x240B) PC_DEV_FAULT_DM_ CAM_BU_WD

4,012.42 (0x240C) PC_DEV_FAULT_DM_ CAM_END

4,013.43 (0x240D) PC_DEV_FAULT_GEAR _GRIND

During the drum maintenance cycle, when the drum maintenance cam position should have been at blade up/oil roller up, the drum maintenance cam home sensor should have been FALSE and was instead TRUE. Check the drum maintenance cam solenoid, clutch, home sensor, and related hardware.

During the drum maintenance cycle, when the drum maintenance cam position should have been at blade up/oil roller down, the drum maintenance cam home sensor should have been FALSE and was instead TRUE. Check the drum maintenance cam solenoid, clutch, home sensor, and related hardware.

At the end of a drum maintenance cycle, when the drum maintenance cam position should have been at blade down/oil roller down, the drum maintenance cam home sensor should have been TRUE and was instead FALSE. Check the drum maintenance cam solenoid, clutch, home sensor, and related hardware.

During power-on initialization, the engine is unable to disengage the process motor. Prior to declaring this fault, the engine has attempted to move the process motor through enough revolutions to disengage the head tilt mechanism, but the motor stalled. The X-axis was then displaced to the right 3.8 mm (0.15 in.) and the disengage was repeated, but the motor stalled again. This fault is then declared. The head is unable to move on its tilt axis, perhaps because it is colliding with something (head restraint pin, cap, poorly installed ink loader, screwdriver.)

4,014.44 (0x240e) PC_DEV_FAULT_6x6DP I_CAL

4,015.45 (0x240F) PC_DEV_FAULT_HEAD _ ADJUST_TIMEOUT

4,016.46 (0x2410) PC_DEV_FAULT_HEAD _NV_FORMAT

4,016.68 Bad Message in main pc_ready message loop . The code

Calibration Failure: Deﬁned but not used.

The engine spent too much time in the printhead adjust-state. The engine declares a device f ault and shuts down, rather than leave a hot heater against a cold drum for an indeﬁnite period.

The printhead format number, stored in printhead NVRAM, is not understood by this version of engine ﬁrmware.

received an unexpected message while the printer was in ready state waiting for a command from PostScript. Typically this message is a PM_RESULT_OK message that is the result of a previous command to PM to tilt the head back. The odd behavior is that PC is not waiting for the operation to ﬁnish.

Service Guide

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

4,017.47 (0x2411) PC_DEV_FAULT_ AMBIENT_TOO_COLD

4,018.48 (0x2412) PC_DEV_FAULT_LATE_ CLEAN_REQUEST

4,019.40 (0x2413) PC_DEV_FAULT_ 193DPI_CAL

4,020.41 PC_DEV_FAULT_FTTR _HEADCAP

04,021.4x PC_DEV_FAULT_FTTR _DIRTYDRUM

4,023.66 Cannot tilt head forward. The engine was attempting to

5,000: Y axis (drum)

Ambient temperature has fallen to less than 10o C. Something may be wrong with a heater.

After the printer determined, at power-up, that the printhead was warm enough not to need cleaning, and while the printer was warming up, the printhead temperature dropped below the head-clean-needed threshold. Something may be wrong with a heater.

Calibration Failure: Target Volt-Sec Area of Fast Color mode could not be achieved. Check the hardware. The head may need to be renormalized.

Declared when the printer is booted and the head/cap contact ﬂag is set in NVRAM. The printer cannot run with the head and cap/wipe/purge unit in contact because it would be unwise to separate the two when the printhead is cold.

Declared when the printer is booted and the drum is dirty. Cleaning the drum when very cold could increase the chance of gluing media to the drum surface and creating a mess around the stripper ﬁngers.

do something that required the printhead to be in print position. The printhead was not in position and some condition was preventing the code from tilting it.

5,001.41 (0x2c01) YA_HOME_FAIL

5,002.41 (0x2b02): YA_STALL_FAIL

5,002.42 (0x2b03): YA_POS_FAIL

6,000: X axis

6,000.41 (0x3400): XA_FAULT_MCURRENT

7,000: Process motor

Phaser 840 Color Printer

Drum-home sensor failure: the drum turned one full revolution without seeing the drum home sensor activate . Check the drum-home sensor or I/O board 1.

The Y-axis (drum) motor stalled, possibly because the drum position sensor electronics have failed, or because the motor drive or drive belts have failed, or because something is physically blocking the motion of the drum.

Y-axis position failure, the drum is not where is should be, possibly because the drum position sensor electronics have f ailed, or because the motor drive or drive belts ha v e failed, or because something is physically blocking the motion of the drum.

X axis motor over/under current. Indicates motor coil(s) are open, or shorted, or the motor fuse has opened.

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

7,001.43 (0x3c01): PM_FAULT_AUXILIARY _ MOTOR_ERROR

7,002.44 (0x3c02): PM_FAULT_PROCESS_ MOTOR_STALL

7,003.45 (0x3c03): PM_FAULT_ COMPOUND_ GEAR_SENSOR_BAD

7,004.46 (0x3c04): PM_FAULT_DM_CAM_ SENSOR_BAD

8,000: Cap drive and web sensors

8,001.44 (0x4401): CAP_FAULT_HOME_ SENSOR

8,002.46 CAP_FAULT_ OVERCURRENT

9,000: Ink loader: ink melters and printhead ink level sensors.

9,001.45 (0x4c01): IL_FAULT_C_ TWANGER

The electronics report an error while operating the motor in the auxiliary feeder (the optional High-capacity paper Tray)

The process motor stalled during operation. This has several possible causes, depending on what the process motor was gear-connected to at the time of failure.

No transitions are observed of the compound gear sensor when the compound gear should be turning. P erhaps the sensor is failing, or the process motor to compound gear linkage is broken.

No transitions are observed of the drum maintenance cam sensor. The sensor may be failing or the drum maintenance cam may be jammed.

An expected transition of the cap-home sensor did not occur. The home sensor may be faulty, or the cap motor may not be operating, or the cap may be jammed and unable to move.

The cap/wipe/purge assembly stalled: Deﬁned but not used.

Malfunction of the ink-level sensor in the cyan reservoir. Replace the printhead.

9,002.46 (0x4c02): IL_FAULT_M_ TWANGER

9,003.47 (0x4c03): IL_FAULT_Y_ TWANGER

9,004.48 (0x4c04): IL_FAULT_K_ TWANGER

9,005.40 (0x4c05): IL_FAULT_C_JAM

Malfunction of the ink-level sensor in the magenta reservoir. Replace the printhead.

Malfunction of the ink-level sensor in the y ellow reservoir. Replace the printhead.

Malfunction of the ink-level sensor in the black reservoir. Replace the printhead.

The cyan ink-melt heater is on, but ink does not seem to be dripping. Check that the ink stick is able to advance in the chute. An ink stick jam will be reported three times before an ink-melter fault is declared.

Service Guide

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

9,006.41 (0x4c06): IL_FAULT_M_JAM

9,007.42 (0x4c07): IL_FAULT_Y_JAM

9,008.43 (0x4c08): IL_FAULT_K_JAM

11,000:DMC

11,011.61 DMC event parameter block not found. The DMC library

11,020.61 DMC event parameter block not found. The DMC library

13,000:Printhead thermals

13,001.40 (0x6c01): TCH_JS_LEFT_OPEN

13,002.41 (0x6c02): TCH_JS_LEFT_SHORT

The magenta ink-melt heater is on, but ink does not seem to be dripping. Check that the ink stic k is able to advance in the chute. An ink stic k jam will be reported three times before an ink-melter fault is declared.

The yellow ink-melt heater is on, but ink does not seem to be dripping. Check that the ink stick is able to advance in the chute. An ink stick jam will be reported three times before an ink-melter fault is declared.

The black ink-melt heater is on, but ink does not seem to be dripping. Check that the ink stick is able to advance in the chute. An ink stick jam will be reported three times before an ink-melter fault is declared.

was attempting to locate an event parameter block in its linked list. The block was not found.

was attempting to locate a timer parameter block in its linked list. The block was not found.

The thermistor in the left jet stack appears to be open. Replace the printhead.

The thermistor in the left jet stack appears to be shorted. Replace the printhead.

13,003.42 (0x6c03): TCH_JS_LEFT_HOT

13,004.43 (0x6c04): TCH_JS_LEFT_SLOW

13,017.47 (0x6c11): TCH_JS_RIGHT_OPEN

13,018.48 (0x6c12): TCH_JS_RIGHT_ SHORT

13,019.40 (0x6c13): TCH_JS_RIGHT_HOT

13,020.41 (0x6c14): TCH_JS_RIGHT_SLOW

13,033.45 (0x6c21): TCH_RESERVOIR_ OPEN

Phaser 840 Color Printer

The left jet stack heater is running away. Unplug the printer NOW!

The left jet stack heater is not heating at all, or is not heating as quickly as it should. Replace the printhead.

The thermistor in the right jet stack appears to be open. Replace the printhead.

The thermistor in the right jet stack appears to be shorted. Replace the printhead.

The right jet stack heater is running away. Unplug the printer NOW!

The right jet stack heater is not heating at all, or is not heating as quickly as it should.

The thermistor in the reservoir appears to be open. Replace the printhead.

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

13,034.46 (0x6c22): TCH_RESERVOIR_ SHORT

13,035.47 (0x6c23): TCH_RESERVOIR_HOT

13,036.48 (0x6c24): TCH_RESERVOIR_ SLOW

14,000: Cap/wipe/purge thermals

14,001.42 (0x7c01): TCC_THERMISTOR_ OPEN

14,002.43 (0x7c02): TCC_THERMISTOR_ SHORT

14,003.44 (0x7c03): TCC_THERMISTOR_ HOT

14,004.45 (0x7c04): TCC_THERMISTOR_ SLOW

15,000: Drum thermals

15,001.42 (0x7c01): TCD_THERMISTOR_ OPEN

The thermistor in the reservoir appears to be shorted. Replace the printhead.

The reservoir heater is running away. Unplug the printer NOW!

The reservoir heater is not heating at all, or is not heating as quickly as it should.

The cap/wipe/purge thermistor appears to be open. Replace the drum temperature sensor.

The cap/wipe/purge thermistor appears to be shorted. Replace the drum temperature sensor.

The cap/wipe/purge heater is running away. Unplug the printer NOW!

The cap/wipe/purge heater is not heating at all, or is not heating as quickly as it should. Check for an open connection or open thermistor in power supply.

The drum thermistor appears to be open. Replace the drum temperature sensor.

15,002.43 (0x7c02): TCD_THERMISTOR_ SHORT

15,003.44 (0x7c03): TCD_THERMISTOR_H OT

15,004.45 (0x7c04): TCD_THERMISTOR_ SLOW

15,005.4x TCD_F AN BLOCKED

16,000: Preheater thermals

16,001.43 (0x8401): TCP_THERMISTOR_ OPEN

The drum thermistor appears to be shorted. Replace the drum temperature sensor.

The drum heater is running away. Unplug the printer NOW! Verify that the vent on the right side of the printer is not blocked.

The drum heater is not heating at all, or is not heating as quickly as it should. Check for an open connection or open thermistor in power supply.

The drum fan is not rotating properly.

The preheater thermistor appears to be open. Replace the paper preheater.

Service Guide

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

16,002.44 (0x8402): TCP_THERMISTOR_ SHORT

16,003.45 (0x8403): TCP_THERMISTOR_ HOT

16,004.46 (0x8404): TCP_THERMISTOR_ SLOW

19,000 Head Calibration Fault

19,001.4X HC_DEV_FAULT (0x01)

19,002.4X HC_DEV_FAULT (0x02)

The preheater thermistor appears to be shorted. Replace the paper preheater.

The preheater heater is running away. Unplug the printer NOW!

The preheater heater is not heating at all, or is not heating as quickly as it should. Check for an open connection or open thermistor in power supply.

Occurs during the scales and offset calibration. If this process fails a fault is declared. Any part in the chain could be responsible for the incorrect reading including the print head electronics, the A/D electronics, the waveform generation electronics, power supply, Wave Ampliﬁer (on the power control board), print head interconnect cable, etc.

Occur when the printer is attempting to determine how many data taps the print head uses. If this process fails an fault is declared. Any part in the chain could be responsible for the incorrect reading including the print head electronics, the A/D electronics, the waveform generation electronics, power supply, Wave Ampliﬁer (on the power control board), print head interconnect cable, etc.

22,700: Media jams

22,703,0C DECLARED JAM

22,704,0C DECLARED JAM

22,705,0C DECLARED JAM

22,707,0C DECLARED JAM

22,708,0C DECLARED JAM

22,721,0C DECLARED JAM

22,722, 0C DECLARED JAM

Phaser 840 Color Printer

Stall event

Sensor failure

Media jam at exit tray

Media too long at exit tray

Media too short at exit tray

Media not staged at preheater entry in time for transﬁx

Media jam at stripper ﬁngers

Table 4 Front panel and fault history log error codes and messages

Error code Meaning

22,901,0C DOOR EVENT

22,902, 0C DOOR EVENT

22,LSS,TC: Media jams L

indicates the location of the jam 1 Bottom Hi-capacity

Paper Feeder

2 Middle Hi-capacity

Paper Feeder 3 Top standard tray 4 Handfeed 5 Front cover 6 Top cover 7 Y-axis jams (see

following error

codes) 9 Door opened jams

(see following error

codes)

indicates whether a timeout or an event occurred 0 = event 1 - timeout

indicates checksum

31,000 Motor Faults

The front access door is opened

The top, stripper, access door is opened

indicates sensor location: 00 Usually because of an opened door 01 Bottom High-Capacity tray sensors 02 Bottom High-Capacity pick sensors 03 Middle High-Capacity tray sensors 04 Middle High-Capacity pick sensors 05 Standard tray sensors 06 Standard tray pick sensors 07 Handfeed sensors 08 Preheat entry sensor 09 Width sensors 10 Width A sensor 11 Width A4 sensor 12 Preheat exit sensor 13 Stripper exit sensor 14 Media Exit sensor 15 <undeﬁned> 16 VE_DM CYCLE_DONE out of order 17 VE_TF_ROLLER_LIFTED out of order 18 Unknown reason

31,001.4x MP_FAULT_AUX_MOTO R_ERROR

31,002.4x MP_FAULT_PROCESS_ MOTOR_STALL

31,003.4x MP_FAULT_PREHEAT_ EXIT_SENSOR_BAD

Not used as a device fault condition.

Declared at boot time when a check is made to determine the condition of the preheat exit sensor. Declared when the sensors around the preheat exit sensor indicate the presence or absence of media contrary to that indicated by the preheat exit sensor.

Service Guide

Phaser 840 Color Printer

Troubleshooting

System power-up sequence

The following lists the chain of events that occur when you turn on a printer. You can follow this list as one means of determining if the printer is operating correctly. The exact chain of events depends upon where the printer “believes” the printhead is positioned. The printer records in NVRAM the last known position of the printhead and the cap/wipe/purge assembly.

Power switch turned on:

Low-level, power-on self-test (POST) diagnostics are performed. The two status LEDs at the rear panel should be blinking and the front panel LEDs are turned on.

If POST diagnostics pass, the front panel the LCD display is cleared.

If the printhead is in either the Standby or Print position:

If the printer is in its Standby mode, the cap/wipe/purge motor is run to ensure that the cap/wipe/purge assembly activates its home position sensor. If the printer is in Print mode, the printhead is moved to its X-axis home position and then centered.

The process motor is rotated to tilt the printhead forward (if not already forward), rotate all the rollers to their ready positions, disengage the transﬁx roller, and lower the maintenance drawer blade and wiper.

Error

LED is turned off and

Service Guide

If the printhead is in the cap/wipe/purge position:

The heaters in the printhead and cap/wipe/purge assembly are activated to melt the ink “gluing” them together.

The printhead is tilted back.

The ink is allowed to drain from the cap/wipe/purge assembly.

The cap/wipe/purge assembly is lowered to its home position.

A short wipe is performed and the cap/wipe/purge assembly is returned to its home position.

The printhead is moved to its X-axis home position and then centered.

If the printhead is in the print position but the cap/wipe/purge assembly is in some unknown intermediate position:

If the cap/wipe/purge assembly is not detected in its home position, then the heaters in the printhead and cap/wipe/purge assembly are activated in case the printhead and cap/wipe/purge may be “glued” together by cooled ink.

After waiting for the ink to melt, the cap/wipe/purge assembly is lowered to its home position.

The printhead is moved to its X-axis home position and then centered.

A short wipe is performed and the cap/wipe/purge assembly is returned to its home position.

The printhead is tilted back to the locked position.

The front panel displays a warm up message.

The heaters are enabled and the drum begins to rotate.

When the ink in the printhead is molten, the cap/wipe/purge assembly is positioned to the purge position.

The printhead tilts forward and a purge cycle begins.

A cleaning page is printed.

10.

The front panel displays a message that the printer is initializing and then ready.

The print engine is initialized.

Phaser 840 Color Printer

Verifying main board CPU operation

If the printer does not power up (rear fan is off and power-up diagnostics LEDs are off), go to the topic, “Verifying power supply operation” below.

Observe the rear panel LEDs located on each side of the rear panel DIP switches.

The right LED represents operation of the main board’s print engine ﬁrmware.

During the POST tests the two LEDs toggle back and forth for each successful pass through each DRAM test. A failure in the power on self tests is indicated by the left LED (the PS led) ﬂashing in a speciﬁc pattern of long and/or short ﬂashes and repeated indeﬁnitely. Other failures are indicated by the failure being printed on the Startup page.

After successful power-up, the left LED ﬂashes at a regular “heartbeat” rate. The front panel cleared.

The left LED represents the operation of the PostScript ﬁrmware.

Power

light is turned on, the

Error

light is ﬂashed, and the LCD is

Verifying print engine operation by printing its startup page

If not already on, turn on the printer. If the printer does not begin initializing, go to the topic, “Verifying power supply operation” below.

Once the

Ready to Print

Printer Conﬁguration menu item, press select the Startup Page.

Power

light is on (not blinking) and the front panel displays

, scroll to

Startup page

and press

menu item. The printer should print out a

Select.

Select,

Then scroll to the

and then scroll and

If the printer prints a startup page, then the print engine is working correctly. If the printer does not print a startup page, then a problem exists with the print engine.

Verifying power supply operation

Required tools

■

TORX T-20 screwdriver Digital multi-meter (DMM)

■

The power supply is divided into two sections: the AC section used for heaters and the DC section for control logic, printhead drivers and motors. Verifying the power supply involves three steps:

■

Checking for proper AC voltage.

■

Inspecting the power supply fuses.

■

Testing for a shorted motor or solenoid driver, which shuts down the power supply.

Service Guide

Measuring power supply voltages

Warning

Turn off the printer and unplug it from its power outlet.

AC Input:

power being supplied to the printer; it should measure between 87 to 128 VAC (115 VAC nominal) or 174 to 250 VAC (220 VAC nominal).

Proceed to the step, “Inspecting the power supply fuses” below.

If a heater shorts, F2 or F3 opens. The power supply does NOT shut down, however, a front panel.

AC line voltages are present on the power supply and possibly in the printer, via the heaters, while the printer is plugged into an AC outlet, even if the power switch is off.

With the DMM set to measure AC voltages, measure the

Service Required

error code is displayed on the

Inspecting the power supply fuses

Three fuses (F1 - F3) are mounted on the power supply.

Turn off the printer and remove the power cord.

Remove the screws securing the power supply. Disconnect the wiring harnesses plugged into the power supply and remove power supply.

With a DMM, determine that the fuses on the power supply are functional. Fuse F1 is the AC input fuses for the DC section of the power supply. If F1 opens, the power supply does not function and should be replaced.

Caution

If the fuses are functional, but the printer's power supply does not output DC voltages, proceed to the topic, “Testing for shorted drivers” on page 41.

Fuse F2 and F3 are used for the AC heaters within the printer; they protect the power supply from, most often, a shorted triac. If F2 or F3 blows, it is best to replace the power supply rather than the fuse. Otherwise, with the fuse replaced, but the triac shorted, AC power may be applied to the heater without the printer even being turned on, resulting in a thermal runaway condition.

Phaser 840 Color Printer

Testing for shorted drivers

Turn off the printer.

Disconnect the +40 DC loopback connector (the 4-pin connector with the two loopback wires) from J250 at the top of the power control board. (This isolates the Y-axis motor, process motor, X-axis motor, paper feed motor, vacuum pump, solenoids and clutches).

Attach the service load connector to J250 on the top of the power control board (behind the printhead) to simulate a load on the power supply. Attach the service load connector’s ground clip to the printer frame. Do not leave the service load connector in place and poweredup for longer than 5 minutes; it gets hot from the current load.

Warning: AC voltage hazard. Never attempt to plug service load connector here.

J 250

Service load connector

Attaching the service load connector to J250

Turn on the printer. If the rear panel LEDs illuminate (indicating power), the power control board or its loads are current-limiting the power supply. Go to Step 5. If no power is evident (no lit LEDs), replace the power supply.

Turn off the printer. Reconnect the +40 volt service connector to the power control board; then disconnect all load connectors from the power control board. Turn the printer on. If the rear panel LEDs still do not illuminate, the power control board has a shorted driver and must be replaced. If the LEDs do illuminate, isolate which motor or fan is overloading the power control board and power supply by turning off the printer and sequentially plugging each cable in one at a time and turning on the printer until the power supply is disabled. Replace the defective component. Also refer to the next topic “Testing for a shorted motor” on page 42.

Turn off the printer. Disconnect the two I2C bus cables from the power control board. (This isolates the I/O boards and their solenoid drivers.) If the rear panel LEDs illuminate, isolate which I/O board is shorting or which I

If the power supply still does not work, replace the power supply.

C cable is defective.

Service Guide

0388-66

Testing for a shorted motor

Reinstall the power supply if removed in the previous procedure.

Disconnect the process motor, the Y-axis motor, X-axis motor and the cap/wipe/purge assembly motor wiring harness.

Turn on the printer again to see if it does not overload now that the motors are disconnected from the power supply.

If the power supply is functional, move to the procedure, “Testing motor and solenoid resistances” on page 42.

If the motors and solenoids are not shorted, but the power supply still does not function, replace the power control board.

Testing motor and solenoid resistances

Turn off the printer and disconnect the power cord.

With a DMM set for measuring resistance, test each motor's windings for correct resistance (disconnected from the printer). Rotate the motor's drive shaft slightly while taking the measurement.

Table 5 Motor and solenoid resistances

Motor or solenoid Resistance (approximately)

Process motor 3 ohms Y-axis motor 2 ohms X-axis motor 60 ohms/phase Paper feed motor <1 ohms/phase Maintenance drawer camshaft electric

clutch Paper-pick electric clutch 10 ohms Transﬁx cam solenoid 45 ohms

10. ohms

Phaser 840 Color Printer

Media jams and the paper path

Required tools

■

TORX screwdriver and tips Digital multi-meter

■

Jams fall into the following four categories:

■

Media-based problems

■

Paper-pick errors

■

Paper-feeding errors

■

Paper-ejecting errors

Media-based problems

Check that the correct type of media is being used. Fanning the media eliminates its tendency to double-pick.

Inspect the paper for bent, torn or folded corners.

Check to ensure no small pieces of paper are in the paper path.

Ensure that the correct media is in the correct media tray. The tray switch actuators indicates the size and the type of media loaded in the tray; the printer does not directly sense the size or type of media.

Ensure the correct weight of paper is being used. Use 16 - 32 lb. Bond (60 - 120 g/m Bond (60 - 120 g/m

Ensure that envelopes are of the acceptable size and orientation with the side-ﬂap up.

) in the paper trays. For manual feeding use 16 - 32 lb.

) or 50 - 80 lb Cover (135 - 220 gm2).

Paper-pick errors

Paper-pick errors occur when the media in the media tray mispicks or the printer double-picks two or more sheets of paper.

Fan the media before inserting it in the media tray.

In humid environments, keep media sealed in packaging until it is needed for printing.

Ensure that the media ﬁts properly in the tray. With the left edge of the stack of paper ﬂush against the tray rail, there should be a small gap between the opposite edge of the stack of paper and the opposite side rail.

Clean the interior of the media tray. When installing paper, push the stack of paper down until the tray's lift-plate locks to the bottom of the tray. This prevents the top sheet of paper from being mispositioned as the tray is inserted in the printer.

Service Guide

Check that the pick roller is being rotated. In its starting position, the pick roller’s ﬂat side should face down; the ﬂat, keyed end on the left end of the pick roller shaft faces up. If it is not, go to the topic “Checking the process motor and drive train” on page 45. Otherwise, go to Step 6.

Clean the pick roller with alcohol and a lint-free cloth. Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of the tray. Also clean the transport rollers.

Use the PC-based diagnostic’s Verify Drive Current Requirement Test to check the operation of the paper-pick system.

Inspect the wiring harness leading to the paper transport clutch for nicks, cuts or crimped wiring. Ensure the connector is seated.

Inspect the paper-feed module for obstructions.

Print transfer jams

Using PC-diagnostics, test the paper preheater. If the test fails, replace the paper/drum heater assembly.

Check to see if the upper feed roller drive belt is broken or slipped off of its pulleys. In such a case, the upper feed roller does not rotate when the lower feed roller rotates.

Check that the feed rollers rotate smoothly and that the front cover is fully closed and seated.

Check the paper-eject path for obstructions. Ensure no small pieces of paper are trapped around the stripper ﬁngers.

If a piece of paper is trapped in the paper pre-heater, try pushing it out by inserting a stiff piece of cardstock into the paper preheater.

Ensure that the transfix roller rotates during the transﬁx process.

Test the sensors in the paper path. Look for damaged or non-operating sensor ﬂags.

Check the transﬁx solenoid and its cam. Ensure they operate correctly and are properly lubricated.

Phaser 840 Color Printer

Checking the process motor and drive train

Determine if the process motor runs. If it does not rotate, go to Step 2. If it does rotate, go to Step 5.

Measure to determine if +40 VDC is being supplied to the motor. If it is, go to Step 3. If it is not, inspect the process motor's wiring harness. If the harness is functional, then troubleshoot the power control board and power supply. Refer back to the topic, “Verifying power supply operation” on page 39.

Disconnect the motor's wiring harness. Measure the resistance of the motor's windings. The expected resistances are listed in Table 5 “Motor and solenoid resistances,” on page 42. If the windings are opened, shorted or far out of tolerance, replace the motor.

If the motor’s winding resistances are within speciﬁcation, inspect the wiring harness for nicks, crimps, opens or other problems. If the harness is functional, then replace the power control board.

Inspect the gear train on the inside of the printer frame; look for stripped gears or broken teeth. Be sure to inspect the inner teeth on the process motor gear.

Media skews passing through the paper path

Check to see if the media is excessively curled. Curled media can get mistracked in the paper path.

Examine the paper path; ensure it is clear of obstructions.

Ensure that the pick roller is clean so that it picks up a sheet of media smoothly and evenly.

Check the upper and lower feed rollers. Also make sure that the front door is properly closed.

Check the ﬂexible, white “paper deskew” springs on the inside of the front cover. Ensure none are bent, damaged, or missing.

The printer should be installed on a ﬂat, level surface.

Service Guide

Printing and print quality problems

Generally, print problems fall into the following six categories:

■ Streaks or lines in the prints

■ No printing

■ Printing too light or too dark

■ Poor quality printing

■ Image is offset or cut off

■ Wrinkling

Streaks or lines across the print

Check the Y-axis belt tension. If the Y-axis drive is not smoothly and consistently rotating the drum, horizontal bands or lines appear in the print.

Replace the Y-axis motor.

Replace the power control board.

Streaks or lines down the print

Clean the blade of the drum maintenance drawer.

Check for media in the exit path.

Phaser 840 Color Printer

0388-41

Possible missing or weak jet. Print the service test print Weak/Missing Jet to determine if a jet is not performing. Perform up to three printhead cleaning cycles to try to clean a clogged jet.

If necessary, turn off the printer and allow the printhead to cool for 4 hours.

Test the vacuum system for proper vacuum levels and operation.

Ensure that no wiring harnesses are interfering with the horizontal slewing of the printhead. In such a case, the streaks or lines should be parallel and evenly spaced.

The x-axis drive is not functioning correctly. If the X-axis drive does not slew the printhead smoothly and evenly during printing, vertical lines appear in the print. Print Service Test Print 1 “X-axis” to reveal an X-axis problem. Replace the X-axis drive, if indicated.

Replace the x-axis drive assembly.

Replace the power control board.

10.

If streaks are on the front side of a duplex print, the paper preheater may be scraping ink off the print. Clean the preheater using the front panel initiated cleaning process “Remove ink smears.”

11.

Smears on a duplex print can also be caused by the paper preheater operating at a too high temperature. Use the PC-diagnostics to check the paper preheater’s temperature. Replace, if necessary.

Missing ink or light colored ink band running length of print

Possible missing or weak jet.

Print the Service Test Print 2 “Weak Jet” to determine if a jet is not performing. Perform up to three printhead cleaning cycles to try to clean a clogged jet.

If necessary, turn off the printer and allow the printhead to cool for 6 hours.

0388-42

Ensure the printhead maintenance vacuum system operates correctly.

If weak or missing jet cannot be recovered, replace the printhead.

Service Guide

Scratches parallel to the long axis of printing, particularly with ﬁlm

Usually caused by foreign debris in the paper path.

Run a transparency through the

manual feed to see if the scratch appears on the print. If it does not, the scratch occurred in the paper pick and early transport of the transparency ﬁlm.

A scratch or smear caused by the paper preheater can be caused by debris built up on the heating surfaces. Run the front panel cleaning procedure Remove Ink smears. Additionally, you can manually force a sheet of thick 65 to 80 lb. paper through the paper preheater to “buff” the paper preheater heating surfaces. With the leading and trailing ends of the sheet of paper extending from the

0388-43

entry and exit of paper preheater, gently pull the sheet of paper back and forth several times and then remove the sheet of paper. Be careful of the paper sensor ﬂags.

White portion of print is colored

0388-44

Phaser 840 Color Printer

Color on a print where no color should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. An insufﬁcient amount of oil on the drum, provided by a dirty or defective or old maintenance drawer may be the problem.

Clean the wiper blade of the drum

maintenance drawer. If necessary, replace the maintenance kit.

Run diagnostics to ensure that printer temperatures are in tolerance. Ensure that the drum heater is properly positioned. Print using a smoother, laser quality paper. Some recycled paper brands may be too rough.

Dark rectangular marks on transparency ﬁlm can be caused by an accumulation of paper dust and oil on the feed rollers. Run 2 or 3 sheets of blank paper through the printer to clean the rollers or manually clean the rollers.

Replace the power control board.

Non-functioning printhead data cable. Replace the main board.

Replace the printhead.

Color is uneven

This may be due to poor thermal regulation in the printer, resulting in uneven heating of the printhead, which in turn results in uneven ink drop jetting.

Clean the wiper blade and the wick

of the drum maintenance drawer. Inspect the operation of the drum maintenance cam roller and the left and right cam actuators it pushes against.

Perform the procedure, “Printhead-to-drum spacing adjustment” on page 66 and “Transﬁx roller pressure spring adjustment” on page 72.

Replace the printhead.

0388-45

Not printing

The printer processes a sheet of paper, but no image is printed on it.

No drive voltages to the printhead. Check for a loose connector leading to the printhead.

Replace the power control board.

Replace the printhead.

Printing too light or too dark

Make sure the printer is correctly reading the type of tray installed and that the tray is correctly set for the media loaded in it. Printing on paper in transparency mode signiﬁcantly darkens a print. Try a different color correction setting.

Perform the procedure, “Printhead-to-drum spacing adjustment” on page 66.

Service Guide

Fuzzy text

Poor primary color ﬁlls

0388-46

Text appears indistinct and difﬁcult to read.

Head-to-drum gap is too great.

Verify the gap with the adjustment as explained in the topic “Printhead-to-drum spacing adjustment” on page 66.

Verify the drum temperature using PC-based diagnostics. Ensure the drum temperature sensor is properly positioned.

If the problem persists, replace the printhead.

Primary ﬁlls appear banded and inconsistent.

Phaser 840 Color Printer

0388-47

Head-to-drum gap is too small.

Verify the gap with the adjustment explained in the topic “Printheadto-drum spacing adjustment” on page 66.

Verify the drum temperature using PC-based diagnostics. Ensure the drum temperature sensor is properly positioned.

Verify the paper preheater

temperature using PC-based diagnostics.

If the problem persists, replace the printhead.

Poor small text resolution

Ghosting

0388-48

Small characters appear heavy and “plug up.”

Verify the drum temperature using

PC-based diagnostics. Ensure the drum temperature sensor is properly positioned.

Inspect and clean the drum temperature sensor.

Ensure that the X-axis drive system is correctly assembled and lubricated.

If the problem persists, replace the printhead.

Drum is too warm.

0388-49

Verify the drum temperature using

PC-based diagnostics. Ensure the drum temperature sensor is properly positioned.

Service Guide

Variation of density on second side of print

The transﬁx spring pressure is incorrect. Perform the procedure “Transﬁx roller pressure spring adjustment” on page 72.

Ghost of ﬁrst side image on second side of print

Incomplete image transfer is taking place on the ﬁrst side of the print.

Inspect the drum maintenance system. Does the drum maintenance roller contain sufﬁcient oil? Replace the drum maintenance roller (and counter chip), if necessary.

Is the drum maintenance cam roller and electric clutch operating correctly? Test them using PC-based diagnostics.

Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller.

Vertical line appear wavy

Straight vertical lines appear to be wavy and ill-formed.

Too much oil on the drum. Inspect

the drum maintenance drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.

Phaser 840 Color Printer

0388-50

Are the drum maintenance cam roller and electric clutch operating correctly? Test them using PCbased diagnostics.

Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller.

Oil streaks on print

Oil stains the edge of the print.

Inspect the drum maintenance

drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.

Are the drum maintenance cam roller and electric clutch operating correctly? Test them using PCbased diagnostics.

Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller.

0388-51

Poor ink adhesion, poor image durability

Verify the paper preheater temperature using PC-based diagnostics.

The drum is too cold. Verify the drum temperature using PC-based diagnostics. Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface.

Try a different paper, if a specialty coated paper is being used.

The transﬁx spring pressure is incorrect. Perform the procedure “Transﬁx roller pressure spring adjustment” on page 72.

Service Guide

Incomplete image transfer to paper

All of the image does not transfer to the paper. Part of the image remains on the drum to be picked up by a chase page or the next print, usually caused by insufﬁcient or non-uniform drum oiling.

Inspect the drum maintenance

drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.

Inspect the drum maintenance system. Does the drum maintenance roller contain sufﬁcient oil? Replace the drum maintenance roller, if necessary.

Are the drum maintenance cam roller and electric clutch operating correctly? Test them using PCbased diagnostics.

0388-52

Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller.

The drum may be too warm, verify the drum temperature using PCbased diagnostics. Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface.

Verify the paper preheater temperature using PC-based diagnostics.

Try a different paper, if a specialty coated paper is being used.

Phaser 840 Color Printer

Ink smears of ﬁrst side of duplex print

0388-53

Repeating print defects on print

Preheater temperature is too high.

Verify the paper preheater

temperature using PC-based diagnostics. Replace the paper preheater, if necessary.

The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect.

0388-54

Repeating defect 13.6 cm (5.34 in.)

are caused by the transﬁx roller.

White or dark lines parallel to the long edge of the print, spaced 1.4 mm (0.054 in) in solid ﬁlls, using Standard printing mode indicate the X-axis step accuracy is incorrect. Ensure the long spring mounted underneath the printhead is intact and not contaminated with ink; remove the maintenance drawer to access the underside of the printhead. Inspect the X-axis drive system; replace it if necessary.

Service Guide

Banding parallel to long edge of print

0388-55

Wrinkling

Fills are inconsistent with wide bands of variegated color.

The head-to-drum gap is too great.

Perform the adjustment detailed in the topic “Printhead-to-drum spacing adjustment” on page 66.

If the problem persists, replace the printhead.

Phaser 840 Color Printer

0388-56

Try different media from a sealed

package. In high-humidity environments, paper left exposed (unpacked) absorbs moisture and begins to warp.

Ensure the deskew ﬁngers inside the front cover are not damaged or missing.

Inspect the maintenance drawer wiper blade. Replace the maintenance drawer, if necessary.

The transﬁx spring pressure is incorrect. Perform the procedure “Transﬁx roller pressure spring adjustment” on page 72.

Replace the drum/transﬁx assembly.

Image is offset or cut off

Check the application for the correct image sizing and orientation.

Ensure that Letter or A4 is the selected paper-size.

Oil streaks on top of print

Clean the stripper ﬁngers.

Run chase pages through the printer to clean the drum. Use the front panel menu item Remove Ink Smears.

Clean the maintenance drawer blade or replace the maintenance kit.

Macintosh printing problems

Image never prints

The printer indicates it is receiving data, but no print comes out of printer or the printer goes back to Ready to Print mode without printing an image.

Make sure that the correct Phaser 840 printer icon was selected in the Chooser. Try printing the job again. Try printing a different ﬁle or from a different application.

In the Chooser, switch background printing off. Try printing the job again. With newer LaserWriter printer drivers, select Foreground Printing in the Print dialog box.

Download the Echo showpage snippet which produces a blank sheet of paper, to determine if the printer is receiving and processing ﬁles.

Make sure you are printing with the correct PPD ﬁle.

Activate Error Handler using the front panel Advanced Printer Settings menu. Alternately, download the Error Handler utility and

try printing the job again. If an error page is printed after printing the job again, call the Customer Support Hotline at 1-800-835-6100 for further assistance. Please have the error page in hand.

If available, try printing to a black-and-white PostScript Level 2 printer (such as an Apple LaserWriter). If the ﬁle does not print on the blackand-white PostScript printer, this may mean that the problem is application- or network-related.

Service Guide

Image prints in black-and-white

In the Chooser, ensure a color printer icon is displayed next to the Phaser 840 in the list of available printers. This indicates the printer’s PPD has been selected and conﬁgured.

In the Print dialog box, make sure that the Color/Grayscale option has been selected.

Make sure that the Phaser 840 printer icon was selected in the Chooser. Try printing the job again.

Check the version of your LaserWriter driver to ensure that it is version

6.0.x or higher. Earlier versions of the driver do not support color PostScript.

The application may require special instructions to print, such as those contained in a .PPD ﬁle; check in the Phaser 840 Printer CD-ROM.

Image is rotated 90 degrees

In the application's Page Setup, make sure that the image is selected to print in Portrait or Landscape orientation, as you expect.

Printer isn’t in the Chooser

Ensure that the printer is turned on and the rear panel health light is ﬂashing at a regular rate.

Check the Network or AppleTalk control panel to ensure the proper network or zone is selected.

Check to see if the printer has not been renamed or placed in another zone. You can print a Conﬁguration Page, which lists this EtherTalk information as well as other information about the printer.

Windows printing problems

Image never prints

The printer’s front panel Receiving data message is displayed as if receiving data, but nothing comes out of printer or the printer goes back to Ready to Print mode without printing an image.

From the printer driver, under the printer's set up options, set TRANSMISSION RETRY = 850.

Phaser 840 Color Printer

Adjustments

Bypass mode (manufacturing mode)

Bypass mode allows you to access the front panel menus (bypassing the engine and PostScript initializing processes) without having to wait for the printhead to warm up. This way, you can reset NVRAM or read fault codes immediately. Meanwhile, the printer continues to warm-up and initialize “in the background.”

At the rear of the printer, set DIP Switch 2 into the Ensure Switches 1, 3 and 4 are up. (Normal operation is all switches up.)

Turn on the printer.

The printer will not print a Cleaning page nor a Startup Page when placed in Bypass Mode.

Cool down mode

The printer features a menu item that accelerates the cooling down of the printhead. When the printer is turned off, it automatically gives the option of performing a quick cool down.

Turn off the printer.

down

position.

Scroll to the menu item

Select.

Open printer doors to help speed the cooling process.

The printer turns off all the engine heaters and runs the fans on high until the ink in the printhead has solidiﬁed. Then the printer shuts itself off. If you are shipping the printer, remove the maintenance drawer.

Shutdown For Moving Printer

Service Guide

and push

Hidden service menu

To access the hidden service menu:

Scroll to the

Press and hold the Left arrow button.

While holding the Left arrow button; press

Hidden Service Menu

Troubleshooting

Previous Menu Test Prints Fault History Reset NVRAM Cool Down for Power Off Reset Printer Head Adjust Adjust X-axis Scale Drift Compensation (On/Off) Head-to-Drum Adjust Execute Head Wipe Print Usage Proﬁle Engine Copy count: xxxxx Head SN: xxxxxxxx Head Cal Date: dd mmm yyyy Head Version: xx Engine FW Version x.xx Duplex Oil chase Exit

Troubleshooting

menu and press

Select

Bypassing a “short menu”

When the front panel is locked, the Printer Conﬁguration menu will not show the Default Printer Settings and Network Settings.

Scroll to the

While holding the Left arrow button; press display the complete menu list.

Exiting from the submenu returns the printer to the short version of the Printer Conﬁguration menu.

Printer Configuration

Phaser 840 Color Printer

menu.

Select

. The front panel will

Printing service test prints

Turn on the printer.

Allow the printer to complete its power-up self-tests. The front panel displays:

READY TO PRINT

Scroll to the

Press and hold the Left arrow button.

While holding the Left arrow button, press service menu.

Scroll to the menu item

Refer to “Test Prints” on page 133; it discusses each test print and what printing defect it reveals.

Troubleshooting

Test Prints

menu and press

Select

. Select a test print.

Select

to enter the hidden

Printing the Conﬁguration Page

Turn on the printer.

Allow the printer to complete its power-up self-tests. The front panel displays:

READY TO PRINT

Scroll to the

Scroll to the menu item

Select

button.

and press the

Printer Configuration

Select

button

and press the

Scroll to the menu item

Select

button.

The conﬁguration page shows a great deal of information regarding the data and set-up values stored in NVRAM. Refer to the topic, “Conﬁguration Page” on the

Color Printer Service & Support Resources CD-ROM

conﬁguration page.

Print Configuration Page

for an explanation of the

and press the

Selecting Duplex Oil Chase

This item is turned on to correct a print artifact called “blistering.” Blistering, when it occurs, affects the duplexed side of a solid ﬁll and appears as the texture of an orange peel. For blistering to occur, it must appear on the second side of the second of two or more solid-ﬁll duplex prints. Before enabling Duplex Oil Chase, try different, heavier paper. Duplex Oil Chase enabled causes a blank page to print on simplex to duplex printing transitions and after every 50 duplex prints.

Scroll to the hidden service menu.

Scroll and highlight the menu item

Press Select to turn the menu item on.

Exit the hidden service menu.

Duplex Oil Chase

Service Guide

Adjustments

Process belt tension adjustment

Turn off the printer and remove the left-side cabinet panel.

To adjust the belt tension, loosen the process belt tensioner. With a spring scale, press inward on the tension idler of the process belt with a pressure of 0.7 kgs (1.5 lbs) and then tighten the tensioner in place. Do not over-tension the belt.

Press here to set belt deflection

Setting process belt tension

Reinstall the left side panel.

Phaser 840 Color Printer

Process belt tensioner

0388-28

Exit roller drive belt tension adjustment

Turn off the printer and remove the left-side cabinet panel.

To adjust the belt tension, loosen the exit roller drive belt tensioner. With a spring scale, press downward on the idler tensioner of the exit roller drive belt with a pressure of 0.5 kg (1 lb) then tighten the tensioner in place. Do not over-tension the belt.

Press here to set belt deflection

Exit roller drive belt tensioner

Setting exit roller drive belt tension

Reinstall the left side panel.

Service Guide

0388-29

Y-axis belts tension adjustment

Perform this procedure after loosening or removing the Y-axis belt drive assembly.

Ensure that the three mounting screws that secure the Y-axis drive assembly to the chassis are 1 turn loose and that the Y-axis idler bracket slides freely with respect to the chassis.

Note

Attach the Y-axis belt tension tool (in its unloaded or folded out position) to the keyholes in the side frame of the printer just below and in front of the Y-axis drive assembly. The tool's ﬁshhook should engage the eyelet of the Y-axis drive assembly.

Pull forward and down on the lever arm of the tension tool to apply tension to the Y-axis belts.

While the belts are under tension, rotate the drum pulley 5 times to rotate the belts and seat them in place.

Beginning with the upper-right screw, tighten the three mounting screws to 30 in.-lbs. to secure the Y-axis drive assembly in place.

Using PC-based diagnostics, run the test: “Position for Belt Tightening” in the “Y-Axis Group” test suite. This positions the belts in the proper orientation for retensioning. Do not move the pulleys.

Place an index mark on the edge of each pulley: Mark the Y-axis drive pulley and the drum pulley where the edges are closest to one another, disregarding previous marks. Use a distinct color if the pulleys have been previously marked.

If there is a situation in which diagnostics are not available when installing a new Y-axis drive assembly or drum/transﬁx assembly, then locate any previously placed index marks on the pulleys and proceed as if re-using existing parts. Allow the system to cool as long as feasible before mounting the Y-axis drive assembly onto the chassis. Tensioning of the y-axis drive assembly without diagnostics increases the risk of failures associated with low belt tension (for example, a “growling” sound heard upon cold powerups).

Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re-tighten the screws to 30 in.-lb.

Release the tension tool's lever arm and remove the tool.

Phaser 840 Color Printer

10.

Reassemble the printer and make a test print.

Tighten screws after setting tension

Mark the pulleys

Attach tension tool to keyholes

Setting the Y-axis belt tension

Y-axis belt assembly

Pull lever arm to set tension

0388-30

Service Guide

Printhead-to-drum spacing adjustment

Tool required

■

Printhead-to-drum gap tools 9/64 in. hex tip

■

T-20 TORX tip

■

This procedure assures that the printhead is the proper distance from the drum. Make this adjustment after removing or replacing the printhead.

Remove the top cover. Remove the metal heat cover.

Tilt the printhead to its print position and, if removed, attach the head tilt spring.

For the “hot” adjustment, scroll to the printer’s hidden service support menu. Activate the diagnostic’s Printhead to Drum Gap Adjustment (Hot) routine. The routine automatically centers the printhead, and brings the printhead and drum to their operating temperatures.

Lift the ink loader up and back slightly so that the printhead can be accessed. Do not unplug the printhead.

If not already tightened, tighten the printhead mounting screws to 20 in- lbs.

If not already loose, loosen the printhead’s four locking screws (two at each end of the printhead until they are just snug in place.

Install the digital gap indicator and bracket to the left side of the printer frame and tilt arm. Ensure the digital indicator is set to inches, “in.”

Origin

Press

to zero the digital indicator.

■

Small (3/16 in.) ﬂat-blade screwdriver Magnetic screwdriver

■

Secure indicator in place with screw provided in frame

Attach digital gap indicator to side frame

Attaching the digital gap indicator

Phaser 840 Color Printer

0388-31

Place indicator bracket over hex-screw

Attach bracket in forward most position to tilt arm. Ensure a flush fit.

0388-36

RIGHT

At the right side of the printhead, insert the RIGHT printhead spacer between the printhead and the drum. Check the indicator; for a “hot adjustment” it should read 0.0070

/- 0.0010 inches, and 0.0030 +/-

0.0010 inches for a “cold” adjustment. Adjust the printhead’s spacing adjustment screws until the indicator reads the correct value.

Note

Do not insert both spacers at the same time as this will only measure the larger of the two gaps.

Insert flatblade screwdriver in adjusting slot. Use a twisting motion to move the printhead.

Gap tool

Tighten locking screws when both left and right adjustments are complete

Spacing the printhead to the drum

Position gap tool between the printhead and drum, hook in side frame and over shaft

Printhead in print position

Repeat adjustment at this end of printhead with LEFT gap tool

0388-31

10.

11.

12.

13.

14.

15.

16.

Remove the right printhead spacer and install the LEFT spacer between the printhead and drum. Repeat the adjustment.

Remove the spacer. Snug the four locking screws using an X-pattern. Then tighten the four screws, using the same X-pattern, to 20 in./lbs.

If not connected, plug the printhead’s data ribbon cable and power wiring harness into the power control board. Inspect both ends of the data ribbon cable to ensure they are properly seated.

Recheck the gap at both ends of the printhead.

Remove the head-to-drum gap indicator and bracket from the frame.

Reinstall the ink loader and metal heat cover.

Select complete from the front panel. Reinstall the top cover.

Print service test print Head to Drum Gap to check alignment.

Service Guide

Cap/wipe/purge assembly belt adjustments

The tension of the cap/wipe/purge assembly belts is factory-set. Do not adjust them unless you remove or replace one or both belts. The belts are Kevlarreinforced; they will not stretch over their lifetime. The belts are also factoryadjusted for parallel tracking (alignment). As long as the belts, cap/wipe/purge assembly motor, or the belt clips (which hold the cap/wipe/purge assembly) are not disturbed, no adjustment is needed.

However, if you replace one or both of the belts or the cap/wipe/purge drive motor, you must ensure that the belts are in alignment (timing) with each other; this ensures that the cap/wipe/purge assembly is perfectly aligned to the faceplate of the printhead. If the belts are not aligned, the printhead purging is ineffective, due to poor sealing between the printhead faceplate and the cap/ wipe/purge assembly.

Ensure that the cap/wipe/purge assembly is properly installed.

Rotate the large drive gear to pull the cap/wipe/purge assembly to about the middle of its travel in the chassis frame slot.

Ensure each timing belt lock is tightened to its fourth tooth, as illustrated.

Position the left-side timing belt lock so its pointer points between the index mark on the printer frame.

Holding the left belt so it does not move, inspect the right-side timing belt lock’s pointer. It should point at the index mark on the right-side printer frame.

If the right-side pointer does not point to the index mark while the leftside belt lock is between its marks, loosen the right timing belt by removing the lower idler pulley and adjusting the belt so that it aligns with the timing mark.

Repeat until the right-side timing lock’s pointer points at the index mark on the right-side frame as the left-side timing belt lock’s pointer points between its index marks on the left-side frame.

Phaser 840 Color Printer

Belt lock

Index mark on right frame

Fan

Idler pulley

Right cap/wipe/purge assembly belt

Unlock

Latch

For new belt, break off actuator on left-side belt lock

Left belt lock: align pointer between two index marks

Lock

Leave gap between latch and belt tensioner

0388-32

Aligning (timing) the cap/wipe/purge assembly drive belts

Service Guide

Drum position encoder gap

This procedure ensures that the drum-position sensor assembly’s encoder wheel rotates freely inside the gap of the drum-position sensor without the encoder wheel’s disk touching the sensor. If the disk touches the sensor, it can abrade the disk and result in erroneous drum position readings.

Ensure that the retaining spring is not in the drum-position sensor assembly’s encoder wheel groove. This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft.

If not already mounted in place, secure the drum-position sensor assembly onto the drum shaft and secure it to the printer frame.

Through the access hole in the drum-position sensor assembly, position the encoder gap tool on the drum shaft.

Reposition the drum-position sensor assembly’s encoder wheel on the drum shaft until it butts ﬁrmly against the encoder gap tool.

Holding the gap tool in place, with a small, ﬂatblade screwdriver, slide the encoder wheel’s retaining spring into the encoder wheel’s groove.

Remove the gap tool. Reassemble the printer and make a test print.

Phaser 840 Color Printer

Gap tool

Groove

Retaining spring

Drum position sensor assembly

Setting the drum position encoder gap

0388-33

Service Guide

Transﬁx roller pressure spring adjustment

Print the service test print YMCKRGB in duplex mode. Duplex mode can be set using the front panel menu Printer Default Settings.

If any of the prints are wrinkled on both the left and right sides of the print, the drum/transﬁx assembly must be replaced. No adjustment will solve the problem.

If wrinkling is only present on the left or right side of any print, note which side.

Remove the front cover to access the drum/transﬁx assembly.

Draw a reference mark on the both the left and right spring set screws.

On the side of the printer corresponding to the wrinkling, tighten the set screw clockwise 1/8 of a revolution, using a 4 mm hex driver. On the side that does not wrinkle, loosen its set screw 1/8 of a revolution.

Note

Reassemble the printer and again print the service test print YMCKRGB in duplex mode.

If wrinkling still occurs on the same side, repeat Step 6 and 7.

Do not adjust the set screws more than 3/8 of a revolution from their original position. Any adjustment beyond this point results in ink adhesion problems.

If wrinkling continues to occur, replace the drum/transﬁx assembly.

Whatever adjustment is added to one side must be taken away from the other side to maintain roller balance.)

Phaser 840 Color Printer

Original registration mark

3/8 turn maximum

Adjusting the transﬁx roller pressure springs

Tension spring set screws

0388-38

Service Guide

X-axis scale adjustment

This adjustment sets the gain or rate-of travel of the printhead’s x-axis movement. Perform this adjustment:

■ To correct thin, parallel pin stripes running the length of the page,

appearing evenly-spaced across the width of the page (not due to a weak or missing jet).

■ Anytime the NVRAM chip is replaced

■ Anytime an X-axis component is replaced.

Allow the printer to warm up to its idle, “Ready to Print,” state.

Enter the “hidden” service menu by scrolling to the Troubleshooting menu and pressing Select. Then press and hold the Left arrow button and, while holding the Left arrow button, press Select.

Scroll to the service menu item Test Prints and press Select. Choose the test print 1: X-axis Motion and press Select to print it.

Interpret the second of the two X-axis motion prints. The print features four purple columns, each containing a jagged black band. The black bands should all align horizontally with each other.

If an adjustment is needed, scroll to the menu item Set X-axis Scale. Change the displayed value to a new value, if necessary.

Increasing the scale value raises the two center black bars. Decreasing the scale value lowers the two center black bars.

Select the menu item Print X-axis calibration pattern to verify the adjustment. Repeat the adjustment, if necessary.

Increase scale

Correct Decrease scale adjust to raise center bars

Adjusting the x-axis scale adjustment

Phaser 840 Color Printer

adjust to lower center bars

0388-67

Vacuum check

Tools required

■ Magnetic screwdriver ■ Vacuum gauge

■ T-20 TORX tip ■ T-15 TORX tip

■ PC diagnostics

Use this check to verify the actions of the vacuum pump and the solenoid valve. In addition, you can determine if the cap/wipe/purge assembly is sealing properly against the printhead faceplate.

Turn off the printer.

Remove the top and right-side covers.

With a T-connector, connect the vacuum gauge to the between the vacuum/pump module and the cap/wipe/purge unit.

-76

Connecting the vacuum gauge to the printer

Vacuum guage

T-connector

Vacuum assembly

Cap/wipe/purge vacuum hose

0388-35

Service Guide

Turn on the printer and enable the PC diagnostics as explained in the topic, “PC-based diagnostics” on the Phaser 840 Printer Service CD- ROM.

Run the Purge Printhead Test from the Head Maintenance

test suite. When the solenoid valve is energized, you should see the vacuum gauge jump to about the value 51 cm Hg (20 in. Hg, 10 psi) and within 4 to 6 seconds bleed off to 0.

If the vacuum does not reach the expected value:

■ There is a leak in the vacuum system from the pump

■ The accumulator and their plumbing or the vacuum pump is defective

If the vacuum drops to zero immediately, the cap/wipe/purge unit is not sealed to the printhead.

This test allows you to check the action of the vacuum as it is applied to the printhead; the cap/wipe/purge assembly should be sharply sucked against the printhead faceplate. If it is not, there may be an ink clog in the vacuum tube leading to the cap/wipe/purge assembly.

If the vacuum does not bleed off, then the air valve is not opening properly, the 7mil oriﬁce (a part of the vacuum/pump assembly) is blocked or the vacuum tubing may be clogged. If the printhead is hot, such a condition can allow ink to be sucked into the vacuum system tubing. If the vacuum takes longer than 4 to 6 seconds to bleed off the cap/wipe/purge assembly is defective

If the vacuum bleeds off too quickly, then the cap/wipe/purge assembly is defective; check to see if the cap/wipe/purge assembly is not sealing properly to the faceplate. Check that the cap/wipe/purge assembly is properly positioned by performing the “Cap/wipe/purge assembly belt adjustments” on page 68.

Phaser 840 Color Printer

Cleaning and Maintenance

The printer requires periodic cleaning to keep it in peak operating condition. Some cleaning procedures, such as purging the ink-jets are done automatically when necessary. Other procedures, such as scrubbing the paper-feed rollers with an alcoholsoaked cloth, must be done by customers.

The printer should be cleaned when any of the following symptoms occur:

■

Light stripes or missing colors appear in prints.

■

Ink smears or random streaks appear on the front or back of prints.

■

Oily spots appear along the top of prints.

■

Mispicks or multiple picks occur at the media tray.

■

Persistent paper jams inside the printer or at the media tray.

■

Wiggly vertical stripes caused by too much oil created by a dirty maintenance drawer blade.

Most print-quality and media-transport problems can be cured by initiating cleaning procedures available through the printer’s front panel menu.

Service Guide

Cleaning

Supplies required

■

90% pure isopropyl alcohol Foam swabs

■

Alcohol-moistened wipes

Caution

Do not use

rubbing alcohol

because it can contain water and oils

that leave undesirable residue on the printer parts. Never use

water

to clean the printer’s internal components.

Appropriate cleaning procedures, as listed in the following tables, should be performed when speciﬁc print-quality or paper transport problems occur. All cleaning procedures are detailed in the

Troubleshooting Manual

Phaser 840 Printer Advanced Features and

Light stripes or missing colors

Problem type Solution

Missing or light-colored stripes on prints.

Select the automated procedure from the front panel

Troubleshooting

Eliminate Light Stripes

menu.

Ink smears, oil spots or random ink streaks

Problem type Solution

Ink smears on the front, back or edges of a page.

Oil (drum ﬂuid) on top edge of print.

Select the automated procedure the front panel

Check the drum maintenance tray for ink and paper-dust build-up on the wiper blade.

Select the automated procedure front panel

Troubleshooting

Remove Ink Smears

menu.

Remove Ink smears

menu.

from

from the

Media jams

Problem type Solution

Paper-pick or jamming problems at the tray.

Paper jamming problems at the front door.

Paper- jamming problems at the exit.

Paper-pick or jamming problems at the tray of the High-capacity Paper Tray Assembly.

Duplex path jam Clean the preheat, duplex and exit rollers. Use the blue

Double picks Clean pick pad with 90% alcohol

Phaser 840 Color Printer

Clean the pick roller.

Clean the transport rollers. Use the blue thumbwheel on the duplex roller to manually rotate the rollers.

Clean the exit rollers and the stripper ﬁngers. Use the blue thumbwheel on the duplex roller to manually rotate the rollers.

Clean the High-capacity Paper Tray Assembly feed roller.

thumbwheel on the duplex roller to manually rotate the rollers.

Cleaning Page

Under certain conditions, the printer purges its ink-jet nozzles to clear any jets plugged with ink. When the purge is completed, the printer outputs a cleaning page to clear the purge pattern from the print drum. Ink jets are purged under the following conditions:

■

During warm-up from a power-off condition.

■

When the printer exits the Energy Star mode.

■

When customers initiate the cleaning procedure from the front panel.

Eliminate Light Stripes

automatic

Vacuum

Vacuum dust from the top cover, the metal heat duct over the printhead and plastic dust cover under the stripper ﬁngers.

Drum temperature sensor

With a dry swab, clean any buildup around the drum temperature sensor. You can access the sensor through the opened stripper ﬁnger cover. Also make sure the sensor rides evenly on the drum surface. You can remove the sensor, if necessary, to clean under it.

Service Guide

Maintenance

Maintenance roller

The printer uses the maintenance roller as part of its self-maintenance routine to coat the print drum with oil before each print. The maintenance roller (and its counter) must be replaced after about 30,000 prints (the starter maintenance roller must be replaced after 10,000 prints). A front panel message indicates when the maintenance roller is low. Printing is still possible when the maintenance roller ﬂuid is low. When a front panel message indicates the maintenance roller is “empty,” the maintenance roller and its counter must be replaced before continued printing is possible. Refer to the instructions included with the kit to replace the maintenance roller kit.

Note

The drum ﬂuid, an oil, poses no known adverse health effects. Refer to the Material Safety Data Sheet for amino oil in

840 Printer Advanced Features and Troubleshooting Manual

for more information.

Phaser

Waste tray

The maintenance drawer contains a waste tray that collects ink that has been purged from the printer’s ink jets. The waste tray should be emptied each time the maintenance drawer is removed from the printer. Refer to “Caring for Your Printer,” in the emptying the waste tray. Be sure to insert the waste tray into the maintenance drawer before reinstalling the maintenance drawer in the printer. Never reuse waste ink in the printer.

Phaser 840 Quick Reference Guide

for instructions on removing and

Phaser 840 Color Printer

Lubrication

Tools and supplies required

■

Light oil Grease 006-7997-00

■

In general, all of the printer's bearings and motors are lifetime factory-lubricated. However, over time and under certain extreme operating conditions, oil and grease may dry out, causing squeaks and rumbling noises in the printer. Look for ﬁne metal particles — a clear sign of an old or worn bearing. Replace the bearing or the assembly it is a part of.

A drop of grease on a noisy bushing will quiet a noisy printer. Too much lubrication can get into the paper path and attract dust, so apply lubrication sparingly.

Lubricate the following only when needed:

■

Bushings:

dry.

■

Plastic gear train:

paper-feed module requires only a small amount of white grease for noise reduction purposes. Apply grease sparingly so that it does not ﬂing off of the gears when they turn. You need only to apply a dab of grease to a single gear and the grease will migrate throughout the entire gear train. Do not apply oil to gears; only use approved grease.

Apply a drop of light oil to a bushing if it is noisy or running

This gear train from the process motor to the

Note

Do not apply lubricant to the head tilt gear or the head tilt gear guide.

■

X-axis drive.

cone. Apply a

■

White (nylon) plastic bearings and cams:

Apply a

small

amount of grease on the tip of the nose

amount, 3 dabs, on the threads of the X-axis shaft.

No lubrication required.

Service Guide

Inspection

Rollers:

■

Gears:

Replace the rollers when you see any of the following defects:

Flat spots.

Out of roundness.

Cracked rubber.

Loss of traction (tackiness) causing pick or feed failures.

Replace gears that show any signs of wear or breakage. Look for these

problems:

■

Thinned gear teeth.

■

Bent or missing gear teeth; check especially where a metal gear drives a plastic gear.

■

Fractured or cracked gears. (Oil or incorrect grease on a plastic gear can cause the gear to crack.)

Belts:

Inspect the belts for wear. There are eight rubber belts in the printer:

■

A belt from the process motor to the compound gear

■

Two belts from the y-axis motor drive

■

A belt from the lower paper feed roller to the upper paper feed roller

■

Two belts on the cap/wipe/purge drive

■

An exit roller drive belt

■

A small belt for driving the cap/wipe purge assembly from the cap/ wipe/purge clutch

Look for these problems:

■

Loose rubber particles below the belts indicate a worn belt.

■

Missing teeth in the belts.

■

Cracking or moderate fraying; a small amount of fraying is inevitable, so look for other signs of wear before replacing the belt.

Clutches:

There are four clutches: the paper-pick roller clutch, the upper feed roller clutch, the maintenance drawer cam clutch and the cap/wipe/purge clutch. Symptoms of a malfunctioning clutch are the printer not picking paper from the tray or other paper jams. Also the cap/wipe/purge system could fail. In such cases, replace the clutch.

Phaser 840 Color Printer

Resetting NVRAM

Resetting NVRAM returns parameters, including those of the network card, to their factory defaults, except the print count (for images processed through the image processor), the Adobe ﬁrmware serial number, the usage proﬁle and the authorization codes. Print engine NVRAM values are not changed by the following procedure.

To reset the printer to its factory-default values, follow this procedure:

If possible, print the Conﬁguration Page for a record of all the printer’s port settings and other customer-unique settings.

Enter the

Press and hold the Left arrow button.

While holding the Left arrow button, press service menu.

Scroll to the menu item

Press OK to reset NVRAM.

Troubleshooting

all

the printers's PostScript NVRAM-stored

menu.

Select

to enter the hidden

Reset NVRAM

Service Guide

Alternately, you can also use the PC diagnostics to selectively return either the print engine NVRAM contents or the PostScript NVRAM contents to their factory default values as shown in the following illustrations.

Running the printer that performs the indicated reset function; there is no conﬁrmation or cancel function.

Reset PE NVRAM to Default

Clear PS NVRAM

downloads a ﬁle to

Resetting print engine NVRAM menu item

Phaser 840 Color Printer

Clearing PostScript NVRAM menu item

Service Guide

Phaser 840 Color Printer

Key FRU Removal and Replacement

This topic illustrates how to remove and replace key printer Field Replaceable Units (FRUs). For more detailed removal/replacement procedures, refer to the

Color Printer Service & Support Resources CD-ROM

Main board

■

Power control board

■

Power supply

■

Upper feed roller assembly

■

Preheat/drum heater assembly.

■

Drum/transﬁx assembly.

■

Drum position sensor assembly

■

Printhead

■

X-axis motor and drive assembly

■

Y-axis belt drive assembly

■

Cap/wipe/purge assembly

■

. Procedures included here are:

This topic concludes with a discussion about printhead locking.

Service Guide

Main board

Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove the interface cables.

Loosen the two rear panel securing screws.

Slide out the main board.

If you are replacing the main board, transfer the socketed realtime clock/ NVRAM chip and the printer ID chip to the new board so the printer’s settings and Ethernet address are retained. Also swap the SCSI riser board, code ROM DIMM and the SDRAM DIMMs.

RAM DIMMS

SCSI riser board

Printer ID

Main board

Real time clock/NVRAM

Code ROM DIMM

Removing the main board

Phaser 840 Color Printer

840-4-36

Power supply

Warning

Turn off the printer and remove the power cord.

Remove the right cover. Remove the left cover.

Remove the rear cover.

Remove the top cover.

At the right side of the printer, disconnect the two wiring harnesses leading to the power supply.

Remove the four screws securing the power supply in place. Remove the power supply.

Even when the printer is off, AC line voltages may be present at the printer heaters while the printer is plugged into AC power.

Wiring harnesses

Power supply

Removing the power supply

Service Guide

840-4-32

Power control board

Turn off the printer and remove the power cord.

Remove the right cover. Remove the left cover.

Remove the top cover.

Remove the ink loader.

Remove the main board.

Remove the power supply.

Remove the network card or its cover plate, whichever is in place.

Remove the internal hard drive or cover plate which ever is in place.

Disconnect the wiring harnesses leading to the power control board.

10.

Remove the four screws securing the power control board cover plate. Remove the plate.

11.

Remove the four screws securing the power control board in place. Lift and remove the board.

Cover plate

Removing the power control board

Phaser 840 Color Printer

Power control board

Tektronix Phaser 840 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual