Xerox 8200, 860, 850, 840 Service Manual

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Phaser

Color Printer

Service

Manual

With Phaser® 8200 Color Printer Addendum

840/850/860

Page 2

Page 3

PHASER® 840/850/860 NETWORK COLOR PRINTER

Service Manual

with the Phaser 8200 Color Printer Addendum

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so.

This printing: April 2002 071-0723-00

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Copyright © 2002, Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.

Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc.

XEROX Each Other

, The Document Company®, the stylized X®, CentreWare®, ColorStix®, DocuPrint®, Made For

, Phaser®, PhaserShare®, and the TekColor® icon are registered trademarks of Xerox Corporation. infoSMART™, PhaserLink™, PhaserPort™, PhaserPrint™, PhaserSMART™, PhaserSym™, PhaserTools™, and the TekColor™ name are trademarks of Xerox Corporation. Total Satisfaction Services

(formerly TekColor CareSM and RealSuppportSM) is a service mark of Xerox

Corporation.

, Acrobat® Reader®, and PostScript® are registered trademarks of Adobe Systems Incorporated.

Adobe

Apple

, LaserWriter®, LocalTalk®, Macintosh®, Mac® OS, and AppleTalk®are registered trademarks of

Apple Computer Incorporated.

and HP-GL® are registered trademarks of Hewlett-Packard Corporation.

PCL

MS-DOS

Novell

Sun

and Windows® are registered trademarks of Microsoft Corporation.

and NetWare® are registered trademarks of Novell, Incorporated.

and Sun Microsystems® are registered trademarks of Sun Microsystems, Incorporated. SPARC® is a registered trademark of SPARC International, Incorporated. SPARCstation™ is a trademark of SPARC International, Incorporated, licensed exclusively to Sun Microsystems, Incorporated.

UNIX

is a registered trademark in the US and other countries, licensed exclusively through X/Open

Company Limited.

This product includes an implementation of LZW licensed under U.S. Patent 4,558,302.

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

PANTONE

Colors generated by the Phaser 840 / 850 / 860 / 8200 Color Printers are four- and/or three-color process simulations and may not match PANTONE-identified solid color standards. Use current PANTONE Color Reference Manuals for accurate colors. PANTONE Color simulations are only obtainable on this product when driven by qualified Pantone-licensed software packages. Contact Pantone, Inc. for a current list of qualified licensees.

TE/MP

ck/mp

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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: For 110 VAC printers, do not apply more than 130 volts RMS 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: Avoid electric shock by contacting a qualified service

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-energize

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

Safety instructions: Read all installation instructions carefully before you plug the

product into a power source.

Terms on product

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

example, a panel may 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 by pulling the plug, not the cord.

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

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

Symbols as marked on product:

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DANGER high voltage:

Protective ground (earth) terminal:

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

WAR NIN G : If the product loses the ground connection, usage of knobs and controls

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

Service safety summary

For qualified service personnel only: Refer also to the preceding Users Safety

Summary.

Do not service alone: Do not perform internal service or adjustment of this product

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

Use care when servicing with power on: Dangerous voltages may exist at

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

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

Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and

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

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

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User safety summary ......................................................................................... iii

Service safety summary..................................................................................... iv

List of Tables.................................................................................................... vii

List of Figures.................................................................................................... ix

General Information 1 - 1

Phaser 840 Printer Overview..........................................................................1 - 2

Phaser 850 Printer Overview..........................................................................1 - 4

Phaser 860 Printer Overview..........................................................................1 - 5

Solid inks ................................................................................................................1 - 6

Phaser 840/850 RAM and Printer Capabilities.......................................................1 - 7

Memory Considerations Phaser 840/850........................................................1 - 8

Phaser 860 RAM and Printer Capabilities....................................................1 - 10

Memory Considerations Phaser 860.............................................................1 - 11

Print Engine Assemblies 840/850/860..................................................................1 - 12

Circuit Boards...............................................................................................1 - 13

The printer’s I

Printhead Maintenance System.....................................................................1 - 16

Sensor Maps..................................................................................................1 - 17

Combination sensors and their meanings.....................................................1 - 20

Media tray type sensing ................................................................................1 - 20

The Main Board....................................................................................................1 - 21

Front Panel - Phaser 840/850 Printers ..................................................................1 - 23

Front Panel - Phaser 860.......................................................................................1 - 24

Rear Panel Connections........................................................................................1 - 25

Rear Panel Status LEDs................................................................................1 - 28

DIP Switches ................................................................................................1 - 28

Phaser 840, 850 and 860 Printer Differences .......................................................1 - 29

Specifications........................................................................................................1 - 31

Regulatory Specifications.............................................................................1 - 35

C bus ....................................................................................1 - 15

Error Codes and Messages 2 - 37

Phaser 840/850 Rear Panel PS and PE LED Codes .............................................2 - 37

Phaser 860 Power-Up Error Messages and LED Codes.......................................2 - 40

The BIST (Built-In Self Test).......................................................................2 - 40

POST (Power On Self Test) .........................................................................2 - 41

Fault Codes...........................................................................................................2 - 44

Contents i

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Troubleshooting 3 - 73

Network Event Logs............................................................................................ 3 - 75

Electronics Troubleshooting ................................................................................ 3 - 76

System power-up sequence.......................................................................... 3 - 76

Inoperative printer problems........................................................................ 3 - 80

Main Board CPU operation ......................................................................... 3 - 80

Verifying print engine operation by printing a built in page....................... 3 - 81

Verifying power supply operation ............................................................... 3 - 81

Measuring power supply voltages ............................................................... 3 - 81

Inspecting the power supply fuses............................................................... 3 - 82

Testing for shorted drivers........................................................................... 3 - 83

Testing for a shorted motor.......................................................................... 3 - 84

Testing motor and solenoid resistances ....................................................... 3 - 84

Paper Path and Media-based Problems................................................................ 3 - 85

Media-based problems................................................................................. 3 - 85

Paper-pick errors.......................................................................................... 3 - 85

Print transfer jams........................................................................................ 3 - 86

Checking the process motor and drive train ................................................ 3 - 86

Media skews passing through the paper path .............................................. 3 - 87

Print Image Quality Problems.............................................................................. 3 - 88

Not printing.................................................................................................. 3 - 88

Missing ink or light colored ink band running length of print..................... 3 - 89

Color is uneven............................................................................................ 3 - 90

Streaks or lines down the print .................................................................... 3 - 91

Scratches parallel to the long axis of printing, particularly with film ......... 3 - 92

Printing too light or too dark........................................................................ 3 - 93

White portion of print is colored.................................................................. 3 - 94

Fuzzy Text ................................................................................................... 3 - 95

Poor primary color fills................................................................................ 3 - 96

Ghosting....................................................................................................... 3 - 97

Poor small text resolution ............................................................................ 3 - 98

Vertical line appear wavy ............................................................................ 3 - 99

Oil streaks on print..................................................................................... 3 - 100

Incomplete image transfer to paper ........................................................... 3 - 101

Ink smears on first side of duplex print ..................................................... 3 - 102

Repeating print defects on print................................................................. 3 - 103

Wrinkling................................................................................................... 3 - 104

Image is offset or cut off............................................................................ 3 - 105

Oil streaks on top of print .......................................................................... 3 - 105

Poor ink adhesion, poor image durability.................................................. 3 - 105

Evaluating the printhead and cap/wipe/purge system........................................ 3 - 106

Troubleshooting following cap/wipe/purge installation............................ 3 - 112

Macintosh printing problems............................................................................. 3 - 115

Image never prints ..................................................................................... 3 - 115

Image is rotated 90 degrees ....................................................................... 3 - 115

Image prints in black-and-white ................................................................ 3 - 115

Printer isn’t in the Chooser........................................................................ 3 - 116

Windows printing problems............................................................................... 3 - 117

ii Phaser 840/850/860/8200 Color Printer - Service Manual

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Diagnostics, Adjustments and NVRAM 4 - 119

Front Panel Shortcuts..........................................................................................4 - 119

Hidden Service Menu.................................................................................4 - 121

Built-in Diagnostics (Phaser 860 Only)..............................................................4 - 122

Check Menu Value Keys and Descriptions (Phaser 860 only)...........................4 - 126

Check Value Menu Parameters ..................................................................4 - 135

Adjustments........................................................................................................4 - 136

Printing service test prints ..........................................................................4 - 136

Printing the Configuration Page .................................................................4 - 136

Selecting Duplex (2-sided) Oil Chase ........................................................4 - 137

Selecting Envelope Oil Chase ....................................................................4 - 137

Center Image...............................................................................................4 - 137

Locking the printhead .................................................................................4 - 138

Process belt tension adjustment..................................................................4 - 139

Exit roller drive belt tension adjustment.....................................................4 - 140

Y-axis belt tension adjustment (Phaser 840 printer)...................................4 - 142

Y-axis belts tension adjustment (Phaser 850/860 printer)..........................4 - 144

Printhead-to-drum spacing adjustment (Phaser 840 Printer Only).............4 - 146

X-axis scale adjustment ..............................................................................4 - 149

Cap/wipe/purge assembly belt adjustments................................................4 - 150

Drum position encoder gap.........................................................................4 - 152

Transfix roller pressure spring adjustment .................................................4 - 154

Vacuum check (Phaser 840/850 Only)...............................................................4 - 155

Resetting NVRAM .............................................................................................4 - 156

Test Prints 5 - 159

1: X-axis motion .........................................................................................5 - 160

2: Weak/missing jet ....................................................................................5 - 161

3: Color Bands, RGBK Dither....................................................................5 - 161

4: Reverse Text...........................................................................................5 - 162

5: Big Bands Hand-fed OHP ......................................................................5 - 162

6: 66% Gray, dot size uniformity ...............................................................5 - 163

7: Manuf. Dot position (scanner)................................................................5 - 164

8: YMCKRGB Solid Fills ..........................................................................5 - 164

9: Drum Seal..............................................................................................5 - 165

10: Manuf. paper path.................................................................................5 - 165

11: Head-to-Drum Gap...............................................................................5 - 166

12.: Manuf x-axis (scanner)........................................................................5 - 166

13: Black Solid Fill.....................................................................................5 - 167

14: Red Solid Fill........................................................................................5 - 167

15: Green Solid Fill ....................................................................................5 - 168

16: Blue Solid Fill.......................................................................................5 - 168

17: Cyan Solid Fill......................................................................................5 - 169

18: Magenta Solid Fill ................................................................................5 - 169

19: Yellow Solid Fill ..................................................................................5 - 170

20: OHP Color Bands.................................................................................5 - 170

21: Primary Solid Fills 10x.........................................................................5 - 171

Contents iii

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22: Manuf. Skew Margins ......................................................................... 5 - 171

23: Manuf. Banding................................................................................... 5 - 171

Cleaning and Maintenance 6 - 173

Cleaning............................................................................................................. 6 - 174

Pick Roller Cleaning Method .................................................................... 6 - 175

Cleaning Page (Phaser 840 printer only)................................................... 6 - 175

Vacuum...................................................................................................... 6 - 175

Drum temperature sensor........................................................................... 6 - 175

Maintenance....................................................................................................... 6 - 176

Maintenance roller..................................................................................... 6 - 176

Waste tray .................................................................................................. 6 - 176

Lubrication......................................................................................................... 6 - 177

Inspection........................................................................................................... 6 - 178

Key FRU Removal and Replacement 7 - 179

Main board and its components................................................................. 7 - 180

Power supply.............................................................................................. 7 - 183

Power control board.................................................................................. 7 - 184

Upper feed roller assembly ........................................................................ 7 - 185

Paper/drum heater...................................................................................... 7 - 187

Drum/transfix assembly............................................................................. 7 - 188

Drum position sensor assembly (Phaser 840 printer) ................................ 7 - 192

Drum position sensor assembly (Phaser 850/860)..................................... 7 - 194

Printhead .................................................................................................... 7 - 196

X-axis motor and drive assembly .............................................................. 7 - 199

Y-axis belt drive assembly (Phaser 840 printer)........................................ 7 - 200

Y-axis belt drive assembly (Phaser 850/860 printer)................................. 7 - 201

Cap/wipe/purge assembly (Phaser 840 printer) ......................................... 7 - 202

Cap/wipe/purge assembly (Phaser 850/860 printer).................................. 7 - 204

FRU Parts List 8 - 207

Cabinet FRU’s ........................................................................................... 8 - 208

Imaging FRU’s .......................................................................................... 8 - 210

Paper Path FRU’s....................................................................................... 8 - 212

Motor and Fan FRUs ................................................................................. 8 - 214

Circuit Board FRUs ................................................................................... 8 - 216

Solenoid and Clutch FRUs ........................................................................ 8 - 218

Gear and Belt FRUs................................................................................... 8 - 220

Sensor and Flag FRUs ............................................................................... 8 - 222

High-capacity Paper Tray Assembly ......................................................... 8 - 224

Service tools....................................................................................................... 8 - 226

Supplies and accessories.................................................................................... 8 - 227

iv Phaser 840/850/860/8200 Color Printer - Service Manual

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Wiring Diagrams 9 - 235

Phaser 8200 Color Printer Addendum PA - 241

Phaser 8200 Printer Configurations........................................................ PA - 241

Hardware Updates .................................................................................. PA - 241

Internal Pages and Menu Items............................................................... PA - 241

Inks ......................................................................................................... PA - 242

Memory................................................................................................... PA - 242

Appendix A - 243

On-site Printhead Troubleshooting Checklist

Phaser 340/350/360/380/840/850..............................................................A - 244

On-site Electronics Troubleshooting Checklist Phaser 840/850 ...............A - 250

Z840/z850 Electronics Troubleshooting Guide.........................................A - 253

On-site Printhead Troubleshooting Checklist

Phaser 860/8200.........................................................................................A - 261

On-site Electronics Troubleshooting Checklist Phaser 860 ......................A - 266

Contents v

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vi Phaser 840/850/860/8200 Color Printer - Service Manual

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List of Tables

Installed RAM and printer capabilities - - - - - - - - - - - - - - - - - - - - - - - - - 1-8 Acceptible SDRAM DIMMs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9 Acceptible SODIMMs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10 Installed RAM and printer capabilities - - - - - - - - - - - - - - - - - - - - - - - - 1-11 Tray switch sensor combinations - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-20 Rear panel DIP switch settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-28 Summary of differences between Phaser 840/850/860 - - - - - - - - - - - - - - - - - 1-29 Physical dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31 Printer installation clearances - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31 Functional specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-32 Electrical specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-33 Environmental specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34 Main board power-up self-test error codes - - - - - - - - - - - - - - - - - - - - - - 2-37 BIST Rear Panel LED Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-40 POST (Power On Self Test) Error Messages - - - - - - - - - - - - - - - - - - - - - 2-41 Front Panel & Fault History Log Error Codes and Messages - - - - - - - - - - - - - - 2-45 22,LSS.TC Error Codes: Media Jams - - - - - - - - - - - - - - - - - - - - - - - - - 2-59 22,000 Fault Codes and Actions - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-60 Front Panel & Fault History Log Error Codes and Messages - - - - - - - - - - - - - - 2-71 Electrical Interface RAP Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-73 Media and Paper Path RAP Table - - - - - - - - - - - - - - - - - - - - - - - - - - 3-73 Print and Image Quality Problems RAP Table - - - - - - - - - - - - - - - - - - - - 3-74 Macintosh Printing Problems RAP Table - - - - - - - - - - - - - - - - - - - - - - - 3-74 Motor and solenoid resistances - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-84 Not Printing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-88 Missing or light colored ink band - - - - - - - - - - - - - - - - - - - - - - - - - - 3-89 Color is uneven - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-90 Streaks or lines down the print - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-91 Scratches parallel to the long axis of printing - - - - - - - - - - - - - - - - - - - - - 3-92 Printing too light or too dark - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-93 White portion of print is colored - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-94 Fuzzy Text - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-95 Poor primary color fills - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-96 Ghosting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-97 Poor small text resolution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-98 Vertical line appears wavy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-99 Oil streaks on print - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-100 Incomplete image transfer to paper - - - - - - - - - - - - - - - - - - - - - - - - - -3-101 Ink smears on first side of duplex printt - - - - - - - - - - - - - - - - - - - - - - - -3-102 Repeating print defects on the print - - - - - - - - - - - - - - - - - - - - - - - - - -3-103 Wrinkling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-104 Front Panel Shortcuts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-119

List of Tables vii

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Hidden Service Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-121 Diagnostic Menu Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-123 Check Menu Value Key - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-127 Test Print Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-159 Maintenance Kit Life - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-176 Cabinet FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-209 Imaging FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-210 Paper path FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-213 Motor and fan FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-215 Circuit board FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-216 Solenoid and clutch FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-219 Gear and belt FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-221 Sensor and flag FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-223 High-capacity Paper Tray FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - 8-225 Service tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-226 Supplies and accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-227

viii Phaser 840/850/860/8200 Color Printer - Service Manual

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List of Figures

The Phaser 840/850 printer shown with optional High-Capacity Paper Tray Assembly. - - 1-1 The Phaser 860 printer shown with the optional High-Capacity Paper Tray Assembly.- - - 1-1 Internal features of the print engine - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12 Circuit boards of the print engine (right front view of the Phaser 850)- - - - - - - - - - 1-13 Circuit boards of the print engine (left rear view Phaser 850) - - - - - - - - - - - - - - 1-14 Circuit Boards of the print engine (right rear view Phaser 860) - - - - - - - - - - - - - 1-14 The printer’s I Printhead maintenance system of the print engine - - - - - - - - - - - - - - - - - - - 1-16 Sensors and switches on the right side of the print engine - - - - - - - - - - - - - - - 1-17 Switches and Sensors on the left side of the print engine - - - - - - - - - - - - - - - - 1-18 Solenoids and clutches on the print engine - - - - - - - - - - - - - - - - - - - - - - 1-19 Features of the Phaser 840 printer main board - - - - - - - - - - - - - - - - - - - - - 1-21 Features of the Phaser 860 Main Board - - - - - - - - - - - - - - - - - - - - - - - - 1-22 Features of the Phaser 850 printer main board - - - - - - - - - - - - - - - - - - - - - 1-22 Printer front panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-23 Front Panel - Phaser 860 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-24 Phaser 840 printer rear panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25 Phaser 850 printer rear panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-26 Phaser 860 printer rear panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27 Attaching the service load connector to J250 - - - - - - - - - - - - - - - - - - - - - 3-83 Faceplate showing blade wipe with no drops, smudges or streaks - - - - - - - - - - - -3-107 Faceplate showing streaks and smudges from a poor wipe - - - - - - - - - - - - - - - 3-107 Connecting the vacuum gauge to the printer - - - - - - - - - - - - - - - - - - - - - -3-108 Maintenance tray showing good purge - - - - - - - - - - - - - - - - - - - - - - - -3-111 Damaged printhead data cable - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-113 Inadvertently disconnected thermistor cable connector - - - - - - - - - - - - - - - - -3-114 Setting process belt tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-139 Setting exit roller drive belt tension - - - - - - - - - - - - - - - - - - - - - - - - - -4-141 Pull the lever arm and press the tool firmly against the printer frame to set tension. - - - 4-143 Setting the Y-axis belt tension Phaser 850/860- - - - - - - - - - - - - - - - - - - - -4-145 Attaching clips. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-146 Adjusting the tension spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-147 Drum adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-148 Adjusting the x-axis scale adjustment - - - - - - - - - - - - - - - - - - - - - - - - -4-149 Aligning (timing) the cap/wipe/purge assembly drive belts - - - - - - - - - - - - - - - 4-151 Setting the drum position encoder gap- - - - - - - - - - - - - - - - - - - - - - - - - 4-153 Adjusting the transfix roller pressure springs - - - - - - - - - - - - - - - - - - - - -4-154 Connecting the vacuum gauge to the printer - - - - - - - - - - - - - - - - - - - - - -4-155 Resetting print engine NVRAM menu item - - - - - - - - - - - - - - - - - - - - - -4-157 Clearing PostScript NVRAM menu item - - - - - - - - - - - - - - - - - - - - - - -4-157 Lubricating the transfix cam - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6-177 Removing the Phaser 840 printer main board - - - - - - - - - - - - - - - - - - - - -7-180

C bus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15

List of Figures ix

Page 16

Removing the Phaser 850 printer main board - - - - - - - - - - - - - - - - - - - - 7-181 Removing the Main Board (Phaser 860) - - - - - - - - - - - - - - - - - - - - - - - 7-182 Removing the power supply- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-183 Removing the power control board - - - - - - - - - - - - - - - - - - - - - - - - - 7-184 Remove the upper feed roller assembly (left side) - - - - - - - - - - - - - - - - - - 7-185 Removing the upper feed roller assembly (front) - - - - - - - - - - - - - - - - - - - 7-186 Removing the paper/drum heater - - - - - - - - - - - - - - - - - - - - - - - - - - 7-187 Removing the drum transfix assembly (left side) - - - - - - - - - - - - - - - - - - - 7-189 Removing the drum/transfix assembly (right side) - - - - - - - - - - - - - - - - - - 7-190 Marking the drum home flag sensor alignment - - - - - - - - - - - - - - - - - - - - 7-192 Removing the drum position sensor assembly (Phaser 840 printer) - - - - - - - - - - 7-193 Marking the shaft for drum home alignment - - - - - - - - - - - - - - - - - - - - - 7-194 Removing the drum position sensor assembly (Phaser 850 printer) - - - - - - - - - - 7-195 Plugging the reservoir holes- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-196 Removing the printhead - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-197 Removing the x-axis motor and drive assembly - - - - - - - - - - - - - - - - - - - 7-199 Removing the Y-axis belt drive assembly (Phaser 840 printer) - - - - - - - - - - - - 7-200 Removing the Y-axis belt drive assembly (Phaser 850/860 printer) - - - - - - - - - - 7-201 Removing the cap/wipe/purge assembly (Phaser 840 printer) - - - - - - - - - - - - - 7-203 Removing the lower cap/wipe/purge retainer clip- - - - - - - - - - - - - - - - - - - 7-204 Removing the lower cap/wipe/purge retainer clip- - - - - - - - - - - - - - - - - - - 7-205 Removing the cap/wipe/purge assembly (Phaser 850/860 printer) - - - - - - - - - - - 7-206 Cabinet FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-208 Imaging FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-210 Paper path FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-212 Motor and fan FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-214 Circuit Board FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-216 Solenoid and Clutch FRUs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-218 Gear and belt FRUs- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-220 Sensor and flag FRUs- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-222 High-capacity Paper Tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-224 New ink sticks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - PA-242

x Phaser 840/850/860/8200 Color Printer - Service Manual

Page 17

General Information

This service guide contains information used to verify operation, troubleshoot, repair, adjust, and maintain the Xerox Phaser® 840, Phaser® 850 and Phaser® 860 Color Printers. This guide includes a Field Replacement Unit Parts list. Topics such as printer theory of operation, detailed removal/replacement procedures, configuration page details, and verifying printer operation are located on the companion Color Printer Service & Support Resources CD-ROM.

To ensure complete understanding of the product, we recommend participation in Phaser 840/850/860 printer service training.

0388-01

Fig 1-1 The Phaser 840/850 printer shown with optional

High-Capacity Paper Tray Assembly.

P860-001

Fig 1-2 The Phaser 860 printer shown with the optional

High-Capacity Paper Tray Assembly.

General Inormation 1 - 1

Page 18

Phaser 840 Printer Overview

The Phaser 840 Color Printer is an Adobe PostScript® Level 3 (Version 3010) color, solid-ink 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 page-per-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 automatic two-sided printing.

Standard Phaser 840N. The Standard Phaser 840 printer features 136 built-in fonts,

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 32-, and 64-Mbyte RAM DIMMs.

The Phaser 840DP. The Phaser 840 DP printer option upgrades the base printer to

64 Mbytes of RAM. It includes 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 First page Preview mode. With job pipelining, the printer can print one image and process the data for the next image at the same time. First Page Preview mode prints the first page of a multiple page print job while holding the remainder of the job pending front panel approval.

The Phaser 840DX. The extended features option has all the features of the Phaser

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

The Phaser 840GP. This Designer Edition printer includes all the features of the

Phaser 840DP but includes 128 Mbytes of RAM, a 10/100BaseT network card, and translucent blue cabinet panels.

The Phaser 840DPF. This freecolorprinters.com program printer is a Phaser 840DP

printer but it also includes a High-Capacity paper Tray and 3 years of onsite service.

All printers support four available paper trays: Two A and A4 trays are intended 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 High-capacity Paper Tray Assembly 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.

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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 10/100BaseT/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.

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

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, PhaserShare or CentreWare IS software.

General Information 1 - 3

Page 20

Phaser 850 Printer Overview

The Phaser 850 Color Printer is an Adobe PostScript Level 3 (Version 3010) color, solid-ink printer. It also supports color PCL 5c at 600 x 600 dots-per-inch resolution. The Phaser 850 printer prints at a number of resolutions: A 13.9 page-per-minute (ppm) Fast Color Mode, a standard 7.9 ppm mode, an Enhanced mode of 450 x 818 dpi (with dot-size switching) at 4 ppm and a High-Resolution/Photo mode of 600 x 1200 dpi at 2.2 ppm. The printer also includes a 6.3 ppm Fast Transparency Mode and a 3.4 ppm Standard Transparency Mode.

Standard Phaser 850N. The Standard Phaser 850 printer features 136 built-in fonts,

and is equipped with 32 Mbytes of RAM. It can be upgraded to configurations of 64, 128, 192, and 256 Mbytes of RAM using combinations of two 32-, and 64-, and 128-Mbyte RAM DIMMs.

The Phaser 850DP. The Phaser 850DP printer option upgrades the printer to

64 Mbytes of RAM and includes additional features like 2-sided printing, job pipelining and First Page Preview mode.

The Phaser 850DPF. This is a freecolorprinters.com program printer which includes a

High-Capacity paper tray and 3 years of on-site service.

The Phaser 850DX. The extended features DX option has all the features of the

Phaser 850DP printer, but includes additional RAM to bring the printer to 128 Mbytes of RAM. It also includes a High-Capacity Paper Tray and an internal IDE hard drive.

Like the Phaser 840 printer, all printers support four available paper trays. They also support the optional 500-sheet High-Capacity Paper Tray Assembly. The printer can also print seven sizes of hand-fed envelopes.

A 200-MHz PowerPC processor oversees print engine operations and PostScript image processing. The printer features a 10/100BaseT 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 a Token Ring card supporting TokenTalk, Novell NetWare/NDS and TCP/IP. When inserted, this card also disables the standard 10/100BaseT port. LocalTalk and 10Base2 are not supported by the Phaser 850 printer. A second rear panel slot accommodates an internal IDE hard drive for print job collation, job accounting, font storage and PDF direct printing.

An integral bi-directional parallel port (IEEE 1284C with ECP mode) supports printing and also allows connecting a parallel interface scanner for optical copying support.

Like the Phaser 840 printer, the Phaser 850 printer supports Job Accounting.

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Phaser 860 Printer Overview

The Phaser 860 Color Printer is an Adobe PostScript Level 3 (Version 3010) color, solid-ink printer. It also supports color PCL 5c at 600 x 600 dots-per-inch resolution. The printer can print at the following resolutions:

■ Fast Color mode, 16 page-per-minute (ppm)

■ Standard mode, 10 ppm mode at 355 x 464 dpi

■ Enhanced mode, 6 ppm at 464 x 928 dpi

■ High-Resolution/Photo mode, 3.5 ppm at of 600 x 1200 dpi.

The printer also includes a 7 ppm Fast Transparency mode and a 4 ppm Standard Transparency Mode (double-pass). Both modes are at 355 x 464 dpi.

The Phaser 860B. The Phaser 860B printer features 136 built-in fonts, and is equipped

with 64 Mbytes of RAM. The Phaser 860B can be upgraded to configurations of 64, 128, 192 and 256 Mbytes of RAM using combinations of 64- and 128 Mbytes RAM SODIMMs. The Phaser 860B does not support networking or High-resolution/Photo mode.

The Phaser 860N. The Phaser 860N printer adds a 10/100 BaseT Ethernet port and

has all the same features as the Phaser 860B model.

The Phaser 860DP. The Phaser 860DP printer option upgrades the printer to

128 Mbytes of RAM and includes additional features like 2-sided printing, job pipelining and High Resolution Photo mode.

The Phaser 860DPF. This is a freecolorprinters.com program printer. The Phaser

860DPF has all the features of the Phaser 860DP printer, but adds a High-capacity paper tray and 3 years of on-site service.

The Phaser 860DX. The extended features DX option has all the features of the

Phaser 860DP printer, but includes a High-capacity Paper Tray and an internal IDE hard drive.

All printers support five 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; and a legal size paper tray which comes with an output bail. There is an optional 500-sheet High-capacity Paper Tray Assembly 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 hand-fed envelopes.

A 250-MHz PowerPC processor oversees print engine operations and PostScript image processing. All configurations, except the Phaser 860B feature a 10/100BaseT 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. LocalTalk, Tolken Ring and 10Base2 are not supported by the Phaser 860 printer. An internal IDE hard drive can be installed on the main board for font storage and job accounting, if the printer has DP features the hard drive will support collation, proof print, saved print and secure print.

An integral bi-directional parallel port (IEEE 1284C with ECP mode) supports printing and also allows connecting a parallel interface scanner for optical copying support.

General Information 1 - 5

Page 22

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

Proof Print Jobs. A proof job is a specific case of a multiple-copy job. With a proof

job, the customer assigns a password and copy account at the client workstation before printing. The first set of prints are printed immediately. The original number of requested sets are printed after the customer enters the matching password on the printer’s control panel. The customer has the option of printing the original number of requested sets or deleting the job. Using the same password will cause any previous job(s) to be deleted. A proof job that has not been printed is retained on hard disk through power cycles. Proof jobs sent to a printer without the hard disk option are not printed and are discarded.

Secure Print Jobs. Secure printing allows the customer to defer printing of a job until

a matching password is entered from the control panel. The customer assigns the password at the client workstation before printing. The job is stored, and printing is delayed until the password is entered on the printer’s control panel. Using the same password will cause any previous jobs(s) to be deleted. A secure job that has not been printed or released is retained on disk through power cycles. This function requires the internal hard drive.

Saved Print Jobs.

Saved print allows the user to save print jobs to the internal hard drive of the printer. The print job is not deleted after printing, it is stored on the hard drive for print on demand. This function requires the internal hard drive.

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 Xerox proprietary solid inks bleed much less than ordinary liquid inks, they allow the printer to print brilliant colors on plain paper.

Each Xerox solid-ink printer’s inks are especially formulated for that printer; the inks are NOT interchangeable. Using the wrong ink in a printer may damage the

printhead or other subsystems. The Phaser 860 uses the ColorSticks® II ink formulation which enables solid ink documents to be fed through auto-document feeders on copiers.

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.

1 - 6 Phaser 840/850/860/8200 Color Printer - Service Manual

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Phaser 840/850 RAM and Printer Capabilities

The Phaser 840 printer features two DIMM connectors which accept both 32- or 64-Mbytes RAM DIMMs (16-Mbyte RAM DIMMs work but are not offered). The Phaser 850 printer features two DIMM connectors which will accept both 64- or 128-Mbytes RAM DIMMs. The printers 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 (Phaser 850 printer allows 32-Mbytes DIMM to be in 8

columns)

■ Maximum of 2.8 cm (1.1 in.) in height (Phaser 840 printer only). 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 EEPROM, 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.

General Information 1 - 7

Page 24

Memory Considerations Phaser 840/850

With more memory, the printer dual-frame buffers for printing one image while processing a second image (which gives greater printing throughput). The printer’s capabilities can be increase as detailed in the following table.

For the Phaser 840 printer, adding RAM memory, and installing the SCSI daughter card enables the Plus and Extended configurations features.

For the Phaser 850 printer, installing the DP Option code ROM module and adding RAM enables these features.

Table 1-1 Installed RAM and printer capabilities

Feature (32 Mbytes)

Fast Color (draft) printing

Standard Printing yes yes yes

Enhanced Printing yes yes yes

High-Resolution/ Photo Printing

2-sided printing no yes. The printer

Color PCL 5C yes yes yes

Pipelining no yes yes

Check Print no yes yes

Collation (requires hard drive)

Job accounting 50 records 500 records. 5000

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

840N 850N

yes yes yes

no yes yes

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

(64 Mbytes) 840DP 850DP

supports fast, standard and enhanced 2-sided prints

records with optional hard drive

(128 Mbytes) 840DX 850DX

yes. The printer supports 2-sided, high-resolution, 1200 x 600 dpi print

5000 records with included hard drive

1 - 8 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 25

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 Xerox in this printer at the time this guide was published:

Table 1-2 Acceptible SDRAM DIMMs

Size Maker Part Number Printer

32 Mbytes Samsung KMM366S403CTL-G0 840/850

32 Mbytes Micron MT16LSDT464AG-662XX 840/850

64 Mbytes Samsung KMM366S823BTL-G0 840/850

64 Mbytes Micron/Crucial CT8M64S4D10-MBTBGLP 840/850

32 Mbyte Samsung KMM366S424DTS-GL 850 (see note)

64 Mbyte Samsung KMM366S823DTS-GL 850

64 Mbyte Samsung KMM366S924BTS-GL 850

128 Mbytes Samsung KMM366S1623DT-GL 850

128 Mbytes Samsung KMM366S1724BT-GL 850

32 Mbytes Micron MT4LSDT464AG-662xx 850 (see note)

32 Mbytes Micron MT4LSDT464AG-10Exx 850 (see note)

64 Mbytes Micron MT8LSDT864AG-662xx 850

64 Mbytes Micron MT8LSDT864AG-10Exx 850

64 Mbytes Micron MT4LSDT864AG-662xx 850

64 Mbytes Micron MT4LSDT864AG-10Exx 850

128 Mbytes Micron MT16LSDT1664AG-662xx 850

128 Mbytes Micron MT16LSDT1664AG-10Exx 850

Note The 32-Mbyte DIMM marked for 850-only are not compatible

with the other RAM DIMMs because the 32-Mbyte RAM DIMM is an 8-column type; the other DIMMs are 9-column types.

If one of each type is installed in the Phaser 850 printer, only the 9-column DIMM will be enabled.

General Information 1 - 9

Page 26

Phaser 860 RAM and Printer Capabilities

The Phaser 860 printer features two SODIMM connectors which accept off the shelf 64MB or 128 MB SODIMM SDRAM memory modules meeting these specifications:

■ 144-pin SODIMM

■ Synchronous DRAM

■ 3.3 volts

■ PC100 compliant

■ Valid on-board Serial Presence Detect ROM

■ Built using 64 or 128Mbit SDRAM parts

■ 100MHz operation at CAS Latency = 2

Upon power-up, the image processor interrogates the Serial Presence Detect EEPROM, which describes the SODIMM in great detail, such as data width, clock delay, number of address columns and row, refresh rate and more. If the SODIMM does not meet the required specifications, it will be not be used. If there are no good SODIMMs you will receive a RAM error. If one SODIMM is good you will receive a temporary error message and the printer will continue with power up.

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

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

Table 1-3 Acceptible SODIMMs

Size Maker Part Number

64 Mbytes Samsung 156-4831-00

64 Mbytes Micron MT8LSDT864HG-10E

128 Mbytes Samsung 156-4832-00

128 Mbytes Micron MT8LSDT1664HG-10E

1 - 10 Phaser 840/850/860/8200 Color Printer - Service Manual

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Memory Considerations Phaser 860

For the Phaser 860 printer, installing the DP Option code ROM module and adding RAM enables these features.

Table 1-4 Installed RAM and printer capabilities

Feature (64 Mbytes)

Fast Color (draft) printing

Standard Printing yes yes

Enhanced Printing yes yes

High-Resolution/ Photo Printing

2-sided printing no yes. The printer

Color PCL 5c yes yes

Pipelining no yes

Collation (requires hard drive)

Job accounting 500 records. 500 records. 5000

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

Proof Print Secure Print Saved Print

(Requires Hard Drive)

860B 860N

yes yes

no yes

1 Letter-size image 2 Letter-size images

no yes

(128 Mbytes) 860DP 860DPF 860DX

supports 2-sided, high-resolution, 1200 x 600 dpi print

records with included hard drive

General Information 1 - 11

Page 28

Print Engine Assemblies 840/850/860

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-

Fig 1-3 Internal features of the print engine

1 - 12 Phaser 840/850/860/8200 Color Printer - Service Manual

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Circuit Boards

Seven circuit boards support the printer’s electronics. Two boards, called I/O boards (left and right), 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 and many of the printer motors. The power supply converts the AC line voltage into internal AC and DC voltages. The front panel provides a user interface to the printer. The printhead drive board, a part of the printhead, manages the signals and voltages of the printhead’s printing elements and sensors. The optional network card (Phaser 840 and 850 only) and internal hard drive could be considered eight and ninth circuit boards.

Front panel

I/O board right

0388-03

Fig 1-4 Circuit boards of the print engine (right front view of the Phaser 850)

General Information 1 - 13

Page 30

Printhead drive board

Internal hard drive

Drum Maintenance counter

Network

EEPROM

card

Power supply

I/O board

Main board

left

Fig 1-5 Circuit boards of the print engine (left rear view Phaser 850)

Printhead Drive Board

Power Control Board

I/O Board left

Power control board

0388-04

Drum Maintenance Counter EEPROM

Internal Hard Drive

Main Board

Power Supply

P860-004

Fig 1-6 Circuit Boards of the print engine (right rear view Phaser 860)

1 - 14 Phaser 840/850/860/8200 Color Printer - Service Manual

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The printer’s I2C bus

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 Tray connection

Fig 1-7 The printer’s I2C bus

I2C bus

0388-05

General Information 1 - 15

Page 32

Printhead Maintenance System

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

Fig 1-8 Printhead maintenance system of the print engine

1 - 16 Phaser 840/850/860/8200 Color Printer - Service Manual

Vacuum pump assembly

0388-06

Page 33

Sensor Maps

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.

Note Unlike the Phaser 840 printer, the Phaser 850 /860 printer does

not have a separate drum-home position sensor.

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

Fig 1-9 Sensors and switches on the right side of the print engine

General Information 1 - 17

0388-07

Page 34

Transfix exit sensor

Drum temperature sensor

Duplex paper sensor

Drum-homeposition sensor (Phaser 840 only)

Drum encoder sensor

Preheater exit sensor

Process gear position sensor

Transfix roller

Preheater exit sensor located on inside

Preheater

wall of drum/transfix frame

Drum

Fig 1-10 Switches and Sensors on the left side of the print engine

1 - 18 Phaser 840/850/860/8200 Color Printer - Service Manual

0388-34

Page 35

Caution 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.

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.

Upper feedroller clutch

Pick clutch

Drum maintenance cam clutch

Cap/wipe/purge clutch

Air valve solenoid

Transfix solenoid

Fig 1-11 Solenoids and clutches on the print engine

General Information 1 - 19

0388-0

Page 36

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 five tray types:

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

low-volumes of A-size transparency film.

■ Metric Letter (A4-size). This tray is used for 210 x 297 mm (Metric) paper as

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

■ High-volume Transparency/Label (A). This tray supports high volumes of

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

■ High-volume Transparency/Label (A4). This tray supports high volumes of

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

■ Legal Tray (Phaser 860 only) This tray supports Legal-size, US 8.5 x 14 inch

paper.

Table 1-5 Tray switch sensor combinations

Tray type A Paper A4 Paper A

Top switch Closed Open Closed Open Closed

Middle switch Open Closed Open Closed Closed

Bottom switch

Open Open Closed Closed Open

The slide switch actuators on the media trays will open a switch in the forward position and close a switch in the rear position.

Transparency

A4 Transparency

Legal Size

1 - 20 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 37

The Main Board

The main board features the printer’s PowerPC 603e 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. For the Phaser 840, alternate ROM code DIMMs contain language fonts such as Kanji or Hangul. The Phaser 850 printer support two base Heisei Kanji fonts; other Asian fonts are available on the internal IDE drive. For the Phaser 860, all Asian fonts are available on the internal IDE drive.

Network connection is provided through a built-in 10BaseT port in the Phaser 840 printer and a 10/100BaseT port for the Phaser 850/860 printer (not enabled in the Phaser 860B). For the Phaser 840 printer, a plug-in SCSI interface adapter board provides a SCSI port for an external hard drive or scanner.

The Phaser 840 printer stores unique printer status and PostScript values in its socketed NVRAM and EEPROM modules. The printer’s Ethernet address, unique to each printer, is stored in the EEPROM (printer ID chip), an 8-pin socketed IC.

For the Phaser 850/860 printer, all printer NVRAM parameters, such as the printer ID, unique printer status and PostScript values, and Ethernet address, are all stored in the socketed EEPROM.

All socketed components should be transferred to a replacement main board to maintain customer-unique settings.

SCSI riser board

EEPROM Printer ID

RAM DIMMs

NV RAM/ Real Time Clock

Code ROM DIMM

Fig 1-12 Features of the Phaser 840 printer main board

General Information 1 - 21

0388-09

Page 38

EEPROM Printer ID

RAM DIMMs

Code ROM module

Fig 1-13 Features of the Phaser 850 printer main board

0388-76

Factory Code ROM

EEPROM Printer ID

RAM SODIMMs

Hard Drive

Fig 1-14 Features of the Phaser 860 Main Board

ROM Upgrade Code DIMM

P860-002

1 - 22 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 39

Front Panel - Phaser 840/850 Printers

These front panel features are found on the printer:

■ 128 x 64 pixel backlighted graphic display

■ Two push buttons and four arrow buttons

■ Two L ED s

LCD. The backlighted 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 Ready to print, Receiving

data and Printing. Print engine status includes messages such as Outofpaper, Paper Jam, Add ink as well as error messages.

Customers can review and modify certain NVRAM, I/O ports and peripheral parameters.

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

two buttons are used as Select and Help.

Refer to "Check Value Menu Parameters", on page 4-135 for details on using the front panel controls to enter special printer modes.

The topic "Resetting NVRAM", on page 4-156 explains how to use the front panel buttons to reset the NVRAM to its factory-default values.

Navigation buttons

Power

Error

Fig 1-15 Printer front panel

READY TO PRINT

Help button

Select button

0388-10

General Information 1 - 23

Page 40

Front Panel - Phaser 860

These front panel features are found on the printer:

■ 128 x 64 pixel backlighted graphic display

■ Four push buttons and two arrow buttons

■ One LED status indicator

LCD. The backlighted LCD serves two purposes: displaying the current image processor

and print engine status information and displaying an interactive menu. Status information includes an image processor status such as Ready to print,

Receiving data and Printing. Print engine status includes messages such as Outofpaper; Paper Jam; Add ink and error messages.

Customers can review and modify certain NVRAM, I/O ports and peripheral parameters.

Buttons.

1. Status Indicator light

2. LCD Display Screen

3. Cancel

4. Back or Exit

5. Scroll Up and Scroll Down

6. OK

7. ‘i’ will display additional or help infromation regarding the message or menu item

currently displayed on the screen.

Refer to "Front Panel Shortcuts", on page 4-119 for details on using the front panel controls to enter special printer modes.

The topic "Resetting NVRAM", on page 4-156 explains how to use the front panel buttons to reset the NVRAM to its factory-default values.

Phaser 860

123467

0726-42

Fig 1-16 Front Panel - Phaser 860

1 - 24 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 41

Rear Panel Connections

Phaser 840 printer connectors

The rear panel of the Phaser 840 printer features the host interface connectors to the printer:

■ 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 Token Ring PhaserShare card is installed,

the printer’s built-in 10BaseT Ethernet port is disabled.

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

PhaserShare

Series B

Ethernet Card

SCSI

100 Mbs

TP LINK

10/100Base-TX

Ethernet

10Base2

10BaseT Service RS-232

Fig 1-17 Phaser 840 printer rear panel

IDE hard drive

Network card

PostScript health light

Parallel

USB

DIP

switches

General Information 1 - 25

Engine health light

0388-

Page 42

Phaser 850 printer connectors

The rear panel of the Phaser 850 printer features the host interface connectors to the printer:

■ Standard parallel (high-density connector), IEEE 1284C. For the Phaser 850

printer, it can also be used to connect a parallel-interface scanner

■ Twisted Pair (10/100BaseT) Ethernet connector.

■ A Universal Serial Bus port.

■ 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. One slot accommodates a Token Ring Card. When the Token Ring card is installed, the printer’s built-in 10/100BaseT Ethernet port is disabled.

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

IDE hard drive

Optional Token Ring card

PostScript health light

Ethernet 10/100BaseT

Service RS-232

Parallel

USB

DIP switches

Fig 1-18 Phaser 850 printer rear panel

1 - 26 Phaser 840/850/860/8200 Color Printer - Service Manual

Engine health light

0388-77

Page 43

Phaser 860 printer connectors

The rear panel of the Phaser 860 printer features the host interface connectors to the printer:

■ Standard parallel (high-density connector), IEEE 1284C. For the Phaser 860

printer, it can also be used to connect a parallel-interface scanner

■ Twisted Pair (10/100BaseT) Ethernet connector.

■ A Universal Serial Bus (USB) port.

■ An optional hard drive can be installed on the main board.

■ Optional Network cards are not supported for the Phaser 860.

Ethernet

RCV

XMT

Service

Only

USB

RESET

1 2 3

PS PE

Fig 1-19 Phaser 860 printer rear panel

Parallel

P860-005

General Information 1 - 27

Page 44

Rear Panel Status LEDs

Two LEDs on the rear panel indicate the status of the printer’s CPU functions: PostScript processing and print engine control or diagnostics.

1. PostScript health light (LED) normally blinks once per second.

2. Engine health light (PE LED) normally blinks twice every 2.5 seconds.

3. During the first minute of power-up the LEDs are used to indicate diagnostic progress

refer to "System power-up sequence", on page 3-76.

4. If the LEDs stop blinking for more than a minute refer to the topic "Error Codes and

Messages", on page 2-37.

5. If the LEDs are blinking in a repeating pattern, other than normal operating health

status as described, refer to the topic "Error Codes and Messages", on page 2-37.

DIP Switches

Four DIP switches allow you to reset the printer or place the printer in different operating modes. You must set the switches before power is turned on to enter the selected mode.

Table 1-6 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 mode)

Development mode (engineering use only)

Recovery mode (engineering use only)

* Recommended DIP switch postion. ** If DIP switch 4 is left in the down position the printer will not turn off.

UP DOWN UP* UP

DOWN DOWN DOWN* UP

DOWN UP DOWN UP

then UP**

1 - 28 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 45

Phaser 840, 850 and 860 Printer Differences

Note There are additional part differences not detailed in this table.

Please refer to "FRU Parts List", on page 8-207 for a complete listing of parts and part numbers.

Table 1-7 Summary of differences between Phaser 840/850/860

Phaser 840 Part Description

Main board The main board is based on a 603E

RAM DIMMs Phaser 850 printer is not as

Power control board

Printhead The Phaser 850 printhead mount

Y-axis pulley assembly

Cap/wipe/purge assembly

Preheater entry flags

840 to 850 Difference 850 to 860 Difference

processor at 200 MHz. It features a new rear panel with built-in 10/100BaseT and no SCSI port or riser card. The large Dallas NVRAM chip is no longer used. Also the RAM connectors are angled. A battery on the main board will support the real-time clock (10 year life). The printer supports up to 256 Mbytes of RAM. Only a Token Ring Card and an IDE Internal Hard Drive are available.

restricted on the height of the RAM DIMMs the main board will accept since it uses angled RAM DIMM connectors. PC66 compliant.

Improved fusing. Resettable fuses (by disconnecting AC power) on +5v and +40v High-Capacity Paper Tray leads. No x-axis fuse.

has been factory calibrated so no head-to-drum adjustment is required when installing the printhead (as

long as the printhead’s four mounting screws have not been loosened nor the printhead tilt setting altered on the left side of the frame).

The Y-axis pulley assembly now features a built-in spring tension. A Y-axis belt tension tool is not required.

This is a new assembly. It also uses a new mounting system that does not require the disassembling of the timing belts in order to remove the cap/wipe/purge assembly

New sensor flags, less prone to snagging paper when jammed paper is pulled from the printer, are mounted on the upper feed roller assembly.

The 8240 processor at 250 MHz. Internal Hard drive now mounted

on the main board. No network cards are supported. Code ROM is usually soldered

down. Easier insertion. New integrated ASICs.

Uses the smaller 144-pin SODIMMs.

PC100 compliant.

40V service load connector no longer needed.

Internal changes to support new ColorStix

New Y-Axis pulley assembly made of aluminum to imporve print quality and reduce noise.

® II ink.

General Information 1 - 29

Page 46

Table 1-7 Summary of differences between Phaser 840/850/860

Phaser 840 Part Description

Left I/O board A new left I/O board.

Right I/O board New board to support the new

Y-axis drum encoder assembly

Lower stripper blade holder and stripper blade

Rollers and clutches

Preheater A new paper preheater designed to

Inks Ink is NOT interchangeable between models.

Legal Tray w/Bail New feature for the Phaser 860

High-Capacity Paper Tray Assembly

Front Panel Display Improved design for ease of

840 to 850 Difference 850 to 860 Difference

front panel.

A new Y-axis drum encoder is used, which does not use a separate drum home sensor.

The lower stripper fingers of the have been replaced with a replaceable stripper blade, called a rapid release guide, and a guide holder which is backward compatible to the Phaser 840.

Phaser 850 roller shafts are re-tooled for clutches with C-clips instead of the Phaser 840 printer’s snap-fit feature. The parts are reversed compatible only if the shaft, clutch and e-ring combination replace the Phaser 840 parts. The bushings for the Phaser 850’s duplex roller are installed with C-clips from the inside of the chassis.

A new Drum Maintenance clutch is used in the Phaser 850 printer to dramatically improve reliability.

accommodate the travel of the paper preheater entry flags is used in the Phaser 850 printer. The preheater

is reverse compatible into the Phaser 840 printer.

The Phaser 850 printer uses new inks using a different formulation.

Color change.

Round pick roller to improve reliablility.

The pick roller now uses the same clutch as the upper feed roller and the cap/wip/purge drive.

New Drum Maintenace Cam to support new Drum Maintenance alogrithms.

New ColorStix specific to the Phaser 860.

only.

Reliability improvements. These improvements are also being made on the Phaser 840 and

850.

navigation. Service diagnostics are accessible through the Front Panel, for more information refer to "Front Panel Shortcuts", on page 4-119.

Reduced ESD susceptibility.

® II formulation

1 - 30 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 47

Specifications

Table 1-8 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;

Table 1-9 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:

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.

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

General Information 1 - 31

Page 48

Table 1-10 Functional specifications

Characteristic Specification

Printing process Solid-ink onto plain paper.

Color medium Cyan, magenta, yellow and black ink sticks, each shape-coded. The

Addressability Phaser 840 printer: Selectable 273 x 300, 409 x 409, 491 x 982 or

Engine printing speed (single-sided)

Minimum printing margins

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

Usable paper sizes Tray fed: A-size and A4-size, legal-size (860 only), auto-duplex

Usable paper weights Tray-fed:

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

600 x 1200 dots-per-inch (horizontal and vertical). Phaser 850 printer: Selectable 177 x 409, 355 x 464, 450 x 818 or

600 x 1200 dots-per-inch (horizontal and vertical). Phaser 860 printer: Selectable 205 x 409, 355 x 464, 464 x 927 or

600 x 1200 dots-per-inch (horizontal and vertical).

Phaser 840 Phaser 850 Phaser 860 Fast Color 10.0 14.0 15.9 ppm Standard 5.7 7.8 10.0 ppm Enhanced 3.3 4.4 6.4 ppm Photo 2.2 2.2 3.6 ppm Fast Tranperancy 5.0 6.3 7.0 ppm Standard Transperancy 2.7 3.5 3.5 ppm Print times do not include image processing time, which varies due

to image complexity. 25 mm (1 in.) margins assumed with 35% ink coverage.

All sides: 5 mm (0.2 in.)

Legal size: 1 inch (Top and Bottom) 5mm (right and left sides) Envelope margins vary, see user guide for specifications.

A4-size: 200 x 283 mm

Legal size: 8.1 x 12 in. (Phaser 860 only)

Manual fed: A-size and A4-size, legal-size (860 only), auto-duplex

Phaser 850/860 only, single-sided printing only

Executive (7.25 x 10.5 in.) A5 (148 x 210 mm)

16 - 32 lb. Bond (60 - 120 g/m 16 - 40 lb. Bond (60 - 150 g/m up to 65 lb. (176 g/m

) Cover stock (main tray only)

) (Phaser 840)

) (Phaser 850/860)

single-sided* 20 - 28 lb. Bond Legal size (Phaser 860 only)

Manual-fed:

16 - 40 lb. Bond (60 - 150 g/m up to 80 lb. Cover (135 - 220 g/m up to 110 lb (216 g/m

20 - 28 lb. Bond Legal size (860 only)

*Note: media up to 150 g/m

)

) -single-sided*

) Index stock

can be auto-duplexed. Tektronix/Xerox brand cover paper and glossy paper exceed this specification but are supported.

1 - 32 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 49

Table 1-10 Functional specifications

Characteristic Specification

Usable envelopes #10 (U.S.) DL (Metric)

Specialty Media Labels : A/A4 laser quality sheet stock only, Recommended Avery®

#6 3/4 (U.S.) Choukei 3 Gou C5 (Metric) Choukei 4 Gou US Monarch (Phaser 850/860 printer only)

Note: Do not use envelopes with endflaps (except Choukei 3 & 4 Gou), plastic windows or metal clasps; they can damage the printer.

white laser labels: Phaser 840/850/860 use: Tek-branded labels.

The Phaser 840 also supports: U.S.: 5160, 5960 and Metric: L7162. The Phaser 840/850/860 also support:

Glossy, Photo, Cover stock and Transparencies

Table 1-11 Electrical specifications

Characteristic Specification

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

Primary voltage frequency range

Power consumption 200 watts standby; 300 watts at idle; 600 watts during printing.

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

Fusing F1: DC switcher – 6.3 amp slo-blo

Secondary voltages +5V ± 2.5%

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

47 to 63 Hz

Maximum power consumption 1000 watts during warm-up.

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

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.

+12 V ± 5%

-12 V ± 5% +40 V -5%, +12%

-52 V ± 10% +54 V ± 10%

General Information 1 - 33

Page 50

Table 1-11 Electrical specifications

Characteristic Specification

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 (Electostatic 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

Table 1-12 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)

10 to 32

-30 to 60

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.

C (50 to 90° F)

C (-22 to 140° F)

Operating (shock)

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.

1 - 34 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 51

Regulatory Specifications

The printers are 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.

General Information 1 - 35

Page 52

1 - 36 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 53

Error Codes and Messages

Phaser 840/850 Rear Panel PS and PE LED Codes

The rear panel LEDs are located on each side of the rear panel DIP switches. The left LED represents the operation of the PostScript firmware. The right LED represents operation of the main board’s print engine firmware. During the POST tests, the two LEDs toggle

back and forth for each successful pass through each 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. For the Phaser 850 printer, when a fatal error occurs, the front panel Error LED flashes the same pattern as the PS LED. The possible LED-encoded error codes are listed in the following table. Other failures are indicated by the failure being printed on the Startup Page.

After successful power-up, the left LED flashes at a regular “heartbeat” rate. The front panel Power light turns on, the Error light flashes, and the LCD is cleared.

When troubleshooting Rear Panel LED Codes try reseating the affected components first. If the problem continues then replace the affected components.

Table 2-1 Main board power-up self-test error codes

PS LED flashes

Long flash =5 Short flash=1 2L+1S=11

1 not used

2 SDRAM SIMM

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

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

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

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

7 not used

Meaning Details

Presence

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

located in Position 1 (closest to the rear panel).

located in Position 2 (farthest from the rear panel).

Error Codes and Messages 2 - 37

Page 54

Table 2-1 Main board power-up self-test error codes (cont'd.)

PS LED

Meaning Details

flashes

Long flash =5 Short flash=1 2L+1S=11

8 not used

9NVRAM

(Phaser 840

This test does a walking 1s and a walking 0s test for that last 4 bytes in the VxWorks section of the NVRAM.

only)

10 EEPROM This test reads in the first 24 bytes from the EEPROM 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 on the main board.

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

Medusa ASIC on the main board.

13 Super Glue

ASIC

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

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

parallel port controller CL1284 chip on the main board.

17 Ethernet chip This test verifies the existence of the Ethernet chip on the

main board.

18 TEA error

(Phaser 850 only)

The error occurs during power-up self tests when one of the main devices previously enabled fails to respond, unexpectedly causing a TEA. (Normal TEAs cause the corresponding specific error.) This could be caused by either the Code ROM or Main Board.

none SCSI

(Phaser 840 only)

This test verifies the functionality of the SCSI I/O processor. Any test failures with this component are treated as non-fatal errors with the error information written to the Startup Page. If a failure is detected, the message “SCSI Option Card:” with one of the following messages will be sent to the Startup 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 IDE hard drive This test verifies that the main board is able to

communicate with the IDE drive.

2 - 38 Phaser 840/850/860/8200 Color Printer - Service Manual

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Table 2-1 Main board power-up self-test error codes (cont'd.)

PS LED

Meaning Details

flashes

Long flash =5 Short flash=1 2L+1S=11

none 10baseT

(Phaser 840 only)

none Ethernet

10/100BaseT Option Card (Phaser 840 only)

none Token Ring

Option Card (Phaser 840/850 Only)

Token Ring is not supported in the Phaser 860 printer.

none LocalTalk

Option Card (Phaser 840 printer only.)

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 Startup Page.

■ General Failure.

■ MAC internal loopback failure.

■ MII internal loopback failure (currently disabled).

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 Startup Page. If a failure is detected, the message “Ethernet Option Card: with one of the following messages will be sent to the Startup Page.

■ General Failure.

■ MAC internal loopback failure.

■ MII internal loopback failure.

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

■ 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

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 Startup Page. If a failure is detected, the message LocalTalk Option Card: General Error will be sent to the Startup Page.

Error Codes and Messages 2 - 39

Page 56

Phaser 860 Power-Up Error Messages and LED Codes

The Phaser 860 has two sets of tests that are run when the printer is first powered on: Built-In Self Tests (BIST) and Power-On Self Tests (POST). BIST verifies basic main board CPU operation and reports failures with rear panel LED blink codes (refer back to the 840/850 Rear Panel LED Codes for greater detail on blink codes). POST checks communication paths from the main board CPU to other parts of the main board and other systems of the printer.

POST testing initializes the front panel and if an error occurs a POST error message will be displayed on the front panel LCD. POST errors are also displayed using rear panel LED patterns in case the communication path to the front panel has failed.

Some POST errors are "soft" errors which do not prevent the printer from powering up completely. These errors are displayed on the front panel for 5 seconds and then the printer continues through the remainder of POST. Because soft errors do not stop the printer from powering up, there are no rear panel LED codes associated with them in normal mode. Most soft errors will also cause the printer to print a Startup Page with the error message on it. BIST and POST errors are not stored in the fault history logs.

The BIST (Built-In Self Test)

These tests occur immediately at power-up, before the front panel is initialized.

Table 2-2 BIST Rear Panel LED Codes

PS LED PE LED Description

1 Blink

and then

off

On Solid On Solid The printer is held in reset mode. Make sure the DIP switches are

1 Rapid

2 Rapid

3 Rapid

1 Blink

and then

blinking

The power supply could not remain regulated when the DC power was applied so it was shut down. Follow the troubleshooting procedures for electrical shorts and check the power supply fuses.

off

all in the up position. This can be caused by a faulty or missing MIG chip. (In early printers this chip is socketed rather than soldered down. Make sure it wasn’t accidentally removed instead of the Printer ID chip.) Try reseating the main board and all it’s components and remove any unnecessary components (extra RAM, Hard drive, ROM upgrade). Replace the main board if required.

CPU Bridge and/or PCI bus is not communicating. reseat and then replace the main board.

ROM not responding. Tr y reseating the main board and all of its components, replace the Code ROM, if it is socketed and not soldered down, and then replacing the main board.

System hangs during code initialization. Reseat the main board and all of its components. Replace the main board.

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POST (Power On Self Test)

When these tests begin the front panel has been initialized. In most cases, if an error occurs, a text message is displayed on the front panel along with an LED blink code flashing on all three LEDs (front panel LED, PS LED and PE LED). The LED blink codes are setup similarily to the 840 and 850: Short Blink = 1, Long Blink = 5. Both rear panel LED’s and the front panel LED all blink together for the 860 POST messages.

Table 2-3 POST (Power On Self Test) Error Messages

PS, PE and Front Panel LEDs

Rear panel

LEDs cycle

back and

for th

2 2.01 Failure to read the chip ID’s. Reseat and then replace the main

2 2.02 Failure testing timer values. Reseat and then replace the main

4 4.01 Neither I/O Right or the front panel are detected. Verify the IIC

5 5.01 The front panel is not detected. Verify the IIC cable connections

6 6.01 The duplex sensor is detected but the front panel is not

7 7.01 Front panel is detected but the I/O Right is not responding. Replace

10 10.01 EEPROM read failure. Reseat then replace the Printer ID chip.

10 10.02 EEPROM write failure. Reseat then replace the Printe ID chip.

10 10.03 EEPROM re-read failure. Reseat then replace the Printer ID chip.

10 10.04 EEPROM write/read mismatch. Reseat then replace the main

11 11.01 Ethernet port chip failure. Reseat then replace the main board.

11 11.02 Ethernet port ID error. Reseat then replace the main board.

12 12.xx CPU Interrupt test failure or unexpected interrupt request. Reseat

13 13.01 USB test failure. Reseat then replace main board.

Front Panel Error Code

RAM

ERROR

Description

Neither RAM socket has a supported RAM SODIMM installed. Ensure that supported RAM is being used. Reseat and then replace the RAM SODIMM.

board.

cable connections then replace the I/O Right. NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR.

and the state of the front panel sensor. Replace the front panel. NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR.

responding. Verify the IIC cable connections. Replace the front panel. NO FRONT PANEL MESSAGE WILL BE DISPLAYED FOR THIS ERROR.

I/O Right.

board.

then replace the main board.

Error Codes and Messages 2 - 41

Page 58

Table 2-3 POST (Power On Self Test) Error Messages (cont'd.)

PS, PE and Front Panel LEDs

Soft Error 14.xx Real Time Clock test failures. These are soft errors and will allow

Soft Error 15.01 RAM SODIMM in slot 1 failed. Ensure supported RAM is being

Soft Error 15.02 RAM SODIMM in slot 2 failed. Ensure supported RAM is being

Soft Error 15.03 RAM SODIMM in slot 1 incompatible. Ensure supported RAM is

Soft Error 15.04 RAM SODIMM in slot 2 incompatible. Ensure supported RAM is

Soft Error 16.01 Less than 64 MB of RAM is detected. This is the minimum RAM

17 17.xx An unrecognized option card is responding. This failure should

Soft Error 18.xx Optional Token Ring card failures. This failure should never occur,

20 20.01 I/O Left not detected. Verify the IIC cable connetion. Replace the

20 20.02 I/O Left partially responding. Verify the IIC cable connection.

21 21.01 Printhead not responding. Verify printhead cable is properly

21 21.02 Printhead NVRAM is not responding. Verify printhead cable is

Soft Error 21.03 Printhead ink level sensed below range. Ensure the ink level

Soft Error 21.04 One color is sensed out of range for the printhead ink level. Ensure

21 21.05 Printhead reservoir thermistor is above range. Ensure the

Front Panel Error Code

Description

the printer to continue printing, though all time stamping activities will be incorrect. Reseat then replace the main board.

used. Reseat then replace the RAM SODIMM.

being used. Reseat then replace the RAM SODIMM.

required. Add more RAM, reseat the RAM SODIMM(s), then replace the RAM SODIMM(s).

never occur, the Phaser 860 does not support optional cards. If this error occurs check the main board to power control board connector for damage. Replace the main board and then the power control board.

the Phaser 860 does not support optional cards. If this error occurs check the main board to power control board connector for damage. Replace the main board and then the power control board.

I/O Left.

Replace the I/O Left.

attaced. Reseat main board, then replace printhead.

properly attached. Reseat main board, then replace printhead..

connector on the printhead is plugged in. Reseat main board, then replace the printhead.

the ink level connector on the printhead is plugged in. Reseat main board, then replace the printhead.

thermistor cable is plugged in. Reseat main board, then replace the printhead.

2 - 42 Phaser 840/850/860/8200 Color Printer - Service Manual

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Table 2-3 POST (Power On Self Test) Error Messages (cont'd.)

PS, PE and Front Panel LEDs

21 21.06 Left printhead jetstack thermistor is out of range. Replace the

21 21.07 Right printhead jetstack thermistor is out of range. Replace the

21 21.08 Printhead reservoir thermistor is out of range. Replace the

Soft Error 22.01 Maintenance Kit counter is not responding. Check for bent pins on

Soft Error 22.02 Intermittent response from the maintenance kit counter. Reseat the

Front Panel Error Code

Description

printhead.

the counter. Reseat then replace the maintenance kit.

maintenance kit, cycle power then replace the maintenance kit.

Error Codes and Messages 2 - 43

Page 60

Fault Codes

Error codes indicate the following:

■ The failing system (XX,yyy.zz)

■ The failing subsystem (xx,YYY.zz)

■ The type of problem (xx,yyy.ZZ).

■ The print engine copy count (xx,yyy.zz:123) when the error occurred.

Program faults indicated by a 6 in the tenths place of the fault code (xx,yyy.6z).

and most program faults will not mean anything unless you are intimately familiar with the code base. Some of the more common program faults are documented in this section.

In customer mode, program faults cause the printer to automatically reboot and no message is displayed on the Front Panel. The fault codes are saved into non-volatile memory and can be retrieved from the fault history.

CPU exceptions are indicated by a 7 in the tenths place of the fault code (xx,yyy.7x).

the region of firmware that was executing when the exception occurred; Engine, PostScript, Network, or Operating System.

The PowerPC 603e processor, used in the Phaser 850 and 860, can detect a number of exceptions that occur as a result of external signals on the Print Engine Controller Board, other errors or unusual conditions during the execution of instructions. A CPU exception can either be caused by hardware or firmware error. Refer to infoSMART for descriptions of the most common faults.

Unfortunately, there are too many program faults to enumerate them all

The error code indicates both the PowerPC exception number and

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

2,000: SYSTEM FAULT I/O BOARD...

2,001.40: SY_DEV_FAULT_IO_ RIGHT

2,002.40: SY_DEV_FAULT_IO_ LEFT

2,002.61: SY_PROG_FAULT(2)

2,003.62: SY_PROG_FAULT(3)

4,000: PC (PROCESS CONTROL SUPERVISOR)....

04,001.40: PC_DEV_FAULT_HEAD_ READ

04,002.41): PC_DEV_FAULT_HEAD_Z EROS

4,003.42: PC_DEV_FAULT_HEAD_ ONES

4,004.43: PC_DEV_FAULT_HEAD_ CHECKSUM

4,006.67: PC_PROG_FAULT(0x06)

The engine cannot detect the presence of the right I/O board. Ensure the connections are sound.

The engine cannot detect the presence of the left I/O board. Ensure the connections are sound.

Queue Initialization failure during execution of sy_app_init() (early initialization code), the engine firmware was unable to initialize the queues used for inter-task communication. This indicates a failure in the call to function sy_creat_queues().

Can’t start service diagnostic tasks, (while booting into diagnostic mode) during execution of sy_app_init() (early initialization code), the engine firmware was unable to start the service diagnostics task.

Failure reading printhead NVRAM data: check the wiring to the printhead, I

May also be related to ESD.

Printhead NVRAM data was all 0s: has this printhead been through normalization? If so, check wiring to printhead.

May also be related to ESD.

Printhead NVRAM data was all 1s: 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).

This indicates that an undefined message was found by the processor. This may be caused by ESD. Check grounding and media issues.

C bus and other hardware.

Error Codes and Messages 2 - 45

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

4,013.43 PC_DEV_FAULT_GEAR_ GRIND

***see SB399***

4,013.43

Printhead

unable to tilt

The printhead is unable to move on its tilt axis. The head is unable to move on its tilt axis, because it is colliding with something (head restraint pin, cap, poorly installed ink loader, screwdriver.) 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.

Tilt

arm motion

obstructed?

Ye s

Tilt

arm parked on its

locking pin?

Ye s

Measure the resistance

of the x-axis motor

Resistance

approximately

12.5 Ohms?

Ye s

Replace the power

control board

Visually inspect the

process motor drive

train (left side

Remove obstruction:

printhead heater cable,

C/W/P assembly, poorly

installed ink loader

Replace the x-axis

of printer)

motor

Replace damaged gears or reset belt

tension

0388-82

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

4,014.44 PC_DEV_FAULT_6x6DPI_ CAL

4,015.45 PC_DEV_FAULT_HEAD_A DJUST_TIMEOUT

4,016.46 PC_DEV_FAULT_HEAD_ NV_FORMAT

4,016.68 PC_PROG_FAULT(0x10)

4,017.47 PC_DEV_FAULT_ AMBIENT_TOO_COLD

4,018.48 PC_DEV_FAULT_LATE_ CLEAN_REQUEST

4,019.40 PC_DEV_FAULT_ 193DPI_CAL

4,020.41 PC_DEV_FAULT_FTTR_H EADCAP

4,021.42 PC_DEV_FAULT_FTTR_D IRTYDRUM

4,023.66 PC_PROG_FAULT(0x17):

4,029.63 PC_PROG_FAULT(0x1d)

Calibration Failure: Defined but not used.

The engine spent over 20 minutes in the printhead adjust-state. The engine declares a device fault and shuts down, rather than leave a hot heater against a cold drum for an indefinite period. Remove the adjustment tools and cycle power.

The printhead format number, stored in printhead NVRAM, is not understood by this version of engine firmware. Verify the correct printhead is installed. Replace the printhead.

Bad Message in main pc_ready() loop. The main message loop in pc_ready() received an unexpected message while the printer was in ready state waiting for a command from PostScript. Typically this message is an unexpected or out of order RESULT_OK message that is the result of a previous command to one of the server tasks to accomplish some action (like tilt the head back). The odd behavior is that PC not waiting for the operation to finish.

Ambient temperature has fallen to less than 10 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 printhead cabling. Replace the printhead.

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.

Dangerous Process Motor Motion Detected. The PC task is about to send a command to the process motor to print, chase, move the eccentric cam or move the dm cam, while the PC task detects that the printer is in a dangerous position from such a move (damage could result).

Head Cal Task Spawn Failed. An attempt to spawn the head calibrate task failed. This may be due to a low memory condition.

C. Something

Error Codes and Messages 2 - 47

Page 64

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

4,032.66 PC_PROG_FAULT(0x20)

4,035.60 PC_PROG_FAULT(0x23)

4,040.65 PC_PROG_FAULT(0x28)

4,046.62 PC_PROG_FAULT(0x2e)

4,051.67 PC_PROG_FAULT(0x33)

4,059.66 PC_PROG_FAULT(0x3b)

4,064.62 PC_PROG_FAULT(0x40)

4,128.63 PC_PROG_FAULT(0x80)

4,243.61 Some Phaser 850 printers were built with printheads that had

Undefined result in pc_process_result(). The PC task function pc_process_result() received an undefined inter-task communication (ITC) result message from one of the tasks it communicates with. This is typically caused by out-of-order messages due to fault condtions different than what the software expects.

Bad Status Message in pc_process_status() The PC task received a inter-task communication (ITC) status message that it did not expect.

Re-entrant call to halt detected. This error is generated in pc_syshalt_seq(), (the soft shutdown state sequencer) when a request during the enter state is made, while the printer is already in the halt state.

I/O Right has been known to cause this fault code.

Dangerous Process Motor Detected. The PC task is about to send a command to the process motor task to move the print head into standby, home the print head or turn the process motor while the PC task detects that the printer is in a dangerous position (damage could result) from such a move. typically this happens when a soft shutdown request is issued when the x-axis is in a position where the print head would bind against the left side ot the frame, if the process motor were moved.

Bad Command Result during Drum warm-up processing of a PostScript command message in pc_process_message() returned SERVICE_NEEDED during the drum warm-up period. This should never happen and is flagged by pc_warmup_seq() as an error.

Bad Command Result during Big Drop Flush Processing of a PostScript command message in pc_process_message() returned SERVICE_NEEDED during the big drop flush. This should never happen and is flagged by do_big_drop_flush() as an error.

Bogus Thermal State. The thermal state value stored in non-volatile memory was not valid. This error is detected in show_thermal_state() and probably indicates a corrupt NVRAM device.

Bad Command Result waiting for Fault to clear processing of a PostScript command message returned SERVICE_NEEDED while waiting go the fault state to clear. This should never happen and is flagged by pend_waiting _for_fault_to_clear() as an error.

different set points for different print modes. If the printer sees what it believes to be an invalid set point this fault occurs. Review the print options that the user is selecting and try a different print quality mode or avoid selecting different page sources within a job. Changing the printer defaults may also help, turn off 2-sided printing, turn on the Startup Page, etc.

If these work-arounds are unsuccessful, replace the printhead.

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

5,000: Y-AXIS PROGRAM FAULT CODES, see also SB457, SB461, SF167

5,001.41: YA_HOME_FAIL Drum-home sensor failure. The drum has turned a full revolution

5,002.42: YA_POS_FAIL

5,005.67 YA_BAD_MESSAGE_IN_

HOME

5,026.61 YA_NO_RENDEZVOUS_

IN_IMAGE

6,000: X AXIS TASK PROGRAM FAULT CODES

6,000.41: XA_FAULT_MCURRENT

6,001.42 Indication that the motor coil(s) is open or shorted, or the X-axis

6,002.43 Indication that the motor coil(s) is open or shorted, or the X-axis

without seeing the drum-home sensor activate. Check the Y-axis encoder and I/O Left board. Note: The Phaser 840 has a separate drum-home sensor. The Phaser 850 printer’s home sensor is part of the drum-position sensor.

Run the Y-axis Encoder Diagnostic Test. (Phaser 860 only)

Y-axis position failure. The drum is not where it should be. Something is blocking the motion of the drum, the y-axis belts or motor have failed, or there is a problem with the Y-axis encoder signal.

Run the Y-axis Encoder and Y-axis Geometry Tests.

Bad ITC command in home state. The YA task received a YA_CMD_INIT command or a unrecognized command while in the home state.

Missed ITC message during rendezvous. The YA task failed to receive the rendezvous message to sync the drum motion to paper path motion during transfix at the end of a print. This is probably caused by the printer unexpectedly entering a fault condition and not sending a rendezvous message.

Indication that the motor coil(s) is open or shorted, or the X-axis motor fuse has opened. Follow the procedure "Testing motor and solenoid resistances", on page 84 of this manual. Try diagnostics to verify X-axis movement. If there is not any movement, it is propable that the fuse is defective. The fuse is located in the power control board; the whole baord should be replaced.

Some Phaser 840 printers in the serial number range of B9B1372 to B9B3218 may have a problem with the Power Controller Board that will result in a fault code 6,000.41 ***see SF146 for more details.

motor fuse has opened. Follow the procedure "Testing motor and solenoid resistances", on page 84 of this manual. Try diagnostics to verify X-axis movement. If there is not any movement, it is propable that the fuse is defective. The fuse is located in the power control board; the whole baord should be replaced.

***See SF146 for more details

Error Codes and Messages 2 - 49

Page 66

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

6,003.44 Indication that the motor coil(s) is open or shorted, or the X-axis

06,005.68 This error occurs when a printer is in Energy Star mode and a

6,033.66 XA_PROGFAULT_X6

7,000: PROCESS MOTOR TASK PROGRAM FAULT CODES

07,001.43 There is a problem with the lower tray assembly or it’s installation.

07,001.65 There have been instances where a bad I/O Right circuit board

07,002.44: PM_FAULT_PROCESS_ MOTOR_STALL

07,003.45: PM_FAULT_ COMPOUND_ GEAR_SENSOR_BAD

See SF146 for more details.

door is opened. Instead of just waking the printer up, the firmware reports a fault. Sending a file to the printer or pressing one of the front panel buttons will wake the printer up normally.

There is no sevice action to correct this programming bug. Cycle the power to restart the printer.

XA Unexpected Message. The XA task received an unexpected ITC message while in the idle state.

INSURE THE INK HAS SOLIDIFIED PRIOR TO THE REMOVAL OF THE PRINTER FROM THE LTA. Remove the printer and inspect the LTA connection. If there is any damage to the connector, replace the lower tray assembly or connector. If there is not any damage, remove and inspect the connnection to the printer. This connection is on the left side of the printer next to the left rear foot. it is mounted with two e-rings and plugs into the power control board.

can cause this fault code.

Verify process motor operation with the Process Motor diagnostic test. Also exercise processes run with the process motor; transfix, drum maintenance and head tilt. This can be caused by the power control board. The process motor may have more than one task initiated. Reset all solenoids and the pressure roller prior to cycling power.

No transistions are observed for the compound gear sensor, when the compound gear should be turning. Verify that compound gear sensor is not physically broken and is plugged in to the left I/O board. Run diagnostics to verify operation or change the sensor.

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

07,004.46: PM_FAULT_DM_CAM_ State_Error ***see SF165 & SF167***

7,004.46

Maintenance blade position

sensor (right I/O board) failed

to detect transitions of the

drum-maintenance

home flag

Observe drum-

maintenance home

flag motion while

turning on the printer

The Drum Maintenance home sensor did not actuate or change state as expected. Run diagnostics to verify clutch and sensor operation. Also verify that the shaft is properly assembled.

Does flag

rotate during power

on sequence?

Ye s Ye s

Replace I/O

right board

07,005.47 PM_FAULT_DM_CAM_ POSITION_ERROR

07,006.48 PM_FAULT_DM_CAM UNEXPECTED_MOTION

Check operation of the

compound gear, belt,

and drive train

Does process

gear train rotate

smoothly?

Remove maintenance

drawer and inspect

drum-maintenance cam,

bushings, and

cam lifters

All parts installed

correctly?

Replace (in this order):

• drum-maintenance clutch

• I/O board

• Power control board

Ye s

Replace or reseat gears; replace or

reseat the parts

The Drum Maintenance home sensor actuated, but not at the expected time. Inspect the maintenance drawer lift pins for wear.

Run diagnostics to verify clutch and sensor operation. Also verify that the drum maintenance shaft is properly assembled.

The Drum Maintenance home sensor actuated, when no motion should have occurred. Run diagnostics to verify clutch and sensor operation. Also verify that the shaft is properly assembled.

retension belt

Reinstall or

0388-83

Error Codes and Messages 2 - 51

Page 68

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

7,035.63: PM_PROG_FAULT_

FUNCS(3)

7,036.64: PM_PROG_FAULT_ FUNCS(4)

7,052.62: PM_PROG_FAULT_ FUNCS(20)

Negative delay in pm_sleep_for(). A negative delay argument was passed to pm_sleep_for().

Unexpected message in pm_sleep_for(). An unexpected ITC message was received by pm_get_message() during processing of pm_sleep_for().

Bad message ID in pm_update_dmc_status(). The ITC message received and passed to pm_update_dmc status() did not match any DMC status message that the Process Motor task was expecting.

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

8,000: CAP TASK PROGRAM FAULT CODES

08,001.44: CAP_FAULT_HOME_ SENSOR *** see SB464***

8,001.44

C/W/P can't

find home

Check alignment

of C/W/P assembly

belts

The cap-home sensor did not see the sensor’s flag when expected. The home sensor may be faulty, or the paper- feed motor may not be operating. The cap/wipe/purge clutch may be failing, or the assembly may be jammed and unable to move. Inspect check the paper-exit drive belt and the gear on the right end of the duplex roller shaft next to the paper path motor.

Ensure that the paper path is free of media. For the Phaser 860 only, run the Cap Axis Geometry and Cap

Axis Drive diagnostic tests.

C/W/P

belts aligned

OK?

Ye s

With C/W/P out of home

position, observe

exit roller while

turning on the printer

Does the

exit roller turn?

Ye s

With C/W/P out of home position, observe C/W/P

assembly motion while

turning on the printer

Does C/W/P

assembly move

at all?

Ye s

Is C/W/P

home sensor flag

functional?

Ye s

Replace I/O right

board

motor drive train and exit-roller drive belt,

gears and bushings

Replace C/W/P clutch

Align the C/W/P

assembly belts

Inspect paper-path

or reseat belt

Replace or

reseat flag

Does

error clear?

Ye s

Done

Drive train OK?

Ye s

Measure resistance of paper-path motor

Resistance

approximately

2 Ohms?

Ye s

Replace power

control board

Replace or reseat

defective parts

Replace paper

path motor

0388-84

Error Codes and Messages 2 - 53

Page 70

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

8,002.67 CAP_PROG_FAULT(22)

08,003.46 The cap-home sensor was activated too soon. This can occur if

08,009.65 An unexpected message was received while homing the

8,022.60 CAP_PROG_FAULT(22)

9,000: INK LOADER: INK MELTERS AND PRINTHEAD INK-LEVEL SENSORS.

9,001.45: IL_FAULT_C_ TWANGER

9,002.46: IL_FAULT_M_ TWANGER

9,003.47: IL_FAULT_Y_ TWANGER

9,004.48: IL_FAULT_K_ TWANGER

9,005.40: IL_FAULT_C_JAM

9,006.41 and 9,069.41: IL_FAULT_M_JAM

9,007.42 and 9,037.42: IL_FAULT_Y_JAM

Generic Cap Task Program Fault. This error indicates that the main CAP state sequencer, cap_main(), has entered the program fault state. There are multiple reasons that this can happen. Genereally they involve unexpected conditions while performing CAP movements; home, goto, etc.

the cap/wipe/purge assembly was obstructed while moving up and therefore retruned to the home position too soon. Ensure that the head tilt mechanism is working properly. Run diagnostics to verify cap drive motion and alignment.

Cap/Wipe/Purge assembly, usually during system initialization. This fault is due to a failure of the Y-Axis Encoder

Unexpected CAP Command in Idle State. An invalid CAP command or unknown ITC message was received by the CAP task, while it was in the idle state.

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

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

Malfunction of the ink-level sensor in the yellow 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. Replace the ink loader. If the problem persists, replace the power supply. ***see SF157***

The magenta 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. Replace the ink loader. If the problem persists, replace the power supply. ***see SF157***

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. Replace the ink loader. If the problem persists, replace the power supply. ***see SF157***

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Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

9,008.43 and 9,101:43 IL_FAULT_K_JAM

09,009.44 IL_FAULT_INK_UNPLUG

11,000: Digita Motion Control (DMC) ASIC LIBRARY PROGRAM FAULT CODES

11,001.60 DMC_PROG_FAULT(1)

11,007.66 DMC_PROG_FAULT(7)

11,008.67 DMC_PROG_FAULT(8)

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

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

11,022.63 DMC_PROG_FAULT(22)

11,025.66 DMC_PROG_FAULT(25)

11,029.61 DMC_PROG_FAULT(29)

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. Replace the ink loader. If the problem persists, replace the power supply. ***see SF157***

Ink well sense cable on the printhead appears to be unplugged.

Timer Event Missed. A health check routine is called every 400 milliseconds, the A/D update period, and checks that all the currently pending timer events are for some time in the future. It generates this error if it detects a timer event for some time in the past. A missed DMC interrupt, due to interrupts disabled too long by any region, is the probable cause.

Event parameter Block not Prepped. The parameter block associated with a DMC event notification was not prepped with a call to dmc_prep_event_parm_block() before the call to dmc_request_event_notification().

Bad Message ID in Event Request. The parameter block for a DMC event notification request contains an inconsistent state field in the ITC status message.

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

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

Invalid Get Device State Argument. The ITC message base passed into dmc_get_device_stat() was not a valid DMC type, DMC_STATUS_MSG_BASE or DMCB_STATUS_MSG_BASE.

Motion Segment Too Late. The DMC ASIC interrupt to program the event control hardware for the next segment in a motion control profile occurred too late. A motion profile consists of a list of absolute times and motor register values. After the hardware writes a DSP value, the software must program the event control store hardware for the next segment in the profile. This error occurs when any region, PostScript, Network or engine disables interrrupts for a long period of time, preventing the DMC interrupt service routine from running. This may be due to an unintentional coding error or because a task took a CPU exception which is processed with interrupts disabled, taking a long time to execute.

Motion Segment Too Short. Software attempted to program a motion profile with a motion segment shorter than 750 microseconds. If this specifcation is violated the DMC interrupt service routine may not have time to reload the control store hardware event, when the system is busy.

Error Codes and Messages 2 - 55

Page 72

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

11,033.65 DMC_PROG_FAULT(33)

11,034.66 DMC_PROG_FAULT(34)

11,038.61 DMC_PROG_FAULT(38)

11,039.62 DMC_PROG_FAULT(39)

12,000. INTER-TASK COMMUNICATION PROGRAM FAULT CODES

12,002.62 ITC_PROG_FAULT(2)

13,000: PRINTHEAD THERMAL CONTROL TASK PROGRAM FAULT CODE. Printhead thermal faults are determined by a thermistor in the printhead. Ensure that there is adequate clearance for airflow (at least 4 inches (10 cms.) on all sides) and that the room temperature is below 90 are changing.

13,001.40: TCH_JS_LEFT_OPEN

13,002.41 TCH_JS_LEFT_SHORT

13,003.42: TCH_JS_LEFT_HOT

13,004.43: TCH_JS_LEFT_SLOW

Motion Control Event Missed. A missed control store event was detected. A health check routine is called every 400 milliseconds, the A/D update period, and checks that all the currently pending hardware motion profile events are for some time in the future. If one is pending for a time in the past, then it generates this error. A missed DMC interrupt due to interrupts disabled too long, by any region, is a probable cause.

Motion Control Done Timer Too Late. A motion control profile done event could not be programmed. It was too late for the software to program the done event for a motion profile handled by control store event hardware. This error indicates that DMC interrupts were disabled for a long period of time. Almost always, this happens when a non-engine region generates a CPU exception during printing. The operating system processes CPU exceptions with interrupts off and the processing takes a long length of time. The user should check the task name saved with this fault to identify the culprit.

A/D Input Out of Range. This error is generated during MEDUSA ASIC analog to digital calibration and indicates that one or more of the A/D mixed inputs, 5 volt, 40 volt or 3.3 volts, are out of tolerance.

Printhead NVRAM Read Failure. An attempt to read the non-volatile memory on the printhead, via the I2C interface, failed. This can happen if the wires are loose to the printhead or if the NVRAM part does not ACK the read request.

This is a secondary failure. Something failed resulting in the message stack overflowing. Unable to Send Message. The ITC send message function, itc_send_msg(), was unable to place the specified message in the destination message queue (msgQSend() returned fail code). A full message queue is most likely the cause.

F (35oC). Use diagnostics to verify that the thermals

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

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

The left jet stack heater is running away. Unplug the printer NOW! Check the printhead cabling. Replace the printhead.

The left jet stack heater is not heating at all, or is heating too slowly. Ensure the printer is not located next to an air-conditioning duct. Check that the printhead-to-drum gap is not too close (the drum can act as a heatsink). Inspect the printer wiring. Replace the printhead.

2 - 56 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 73

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

13,011.66 tc_bomb(this, 11)

13,017.47: TCH_JS_RIGHT_OPEN

13,018.48: TCH_JS_RIGHT_SHORT

13,019.40): TCH_JS_RIGHT_HOT

13,020.41: TCH_JS_RIGHT_SLOW

13,033.45: TCH_RESERVOIR_OPEN

13,034.46:

TCH_RESERVOIR_SHORT

13,035.47: TCH_RESERVOIR_HOT

13,036.48: TCH_RESERVOIR_SLOW

13,037.61 TCH_RESERVOIR_ADC_ IS_BAD

15,000: DRUM THERMALS. Drum thermal faults are determined by a thermistor in contact with the drum surface. Ensure that there is adequate clearance for airflow (at least 4 inches (10 cms.) on all sides) and that the room temperature is between 90 diagnostics to verify the thermals are changing.

15,000.40: TCD_THERMISTOR_ FAULT

15,001.42: TCD_THERMISTOR_ OPEN

15,002.43: TCD_THERMISTOR_ SHORT

15,003.44: TCD_THERMISTOR_ HOT

Bad TCH message in fault state. While in the divice fault state, the reervoir thermal manager received an unexpected message, not a turn off or a regulate command. The device fault state is entered whenever the engine firmware detects a device fault (x,xxx.4x).

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

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

The right jet stack heater is running away. Unplug the printer NOW! Check the printhead cabling. Replace the printhead.

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. Check the printhead cabling. Replace the printhead.

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

The reservoir heater is running away. Unplug the printer NOW! Check the printhead cabling. Then replace the power supply. If the problem continues replace the printhead.

The reservoir heater is not heating at all, or is not heating as quickly as it should. Check the printhead cabling. Replace the printhead.

The analog to digital converter appears to be bad. Try reseating the printhead data cable. Then reseat the main board. If the problem continues try replacing the main board and then the printhead.

F (35oC) and 50oF (10oC). User

The drum temperature is incorrect as sensed by the drum thermistor. Ensure that there is adequate clearance for airflow (at least 4 inches (10 cms.) on all sides) and that the room temperature is within specification.

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

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. Ensure that the drum fan rotates and is installed correctly.

Error Codes and Messages 2 - 57

Page 74

Table 2-4 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

15,004.45: TCD_THERMISTOR_ SLOW

16,000: PREHEATER THERMALS. Preheater thermal faults are determined by a thermistor in contact with the preheater. Ensure that there is adequate clearance for airflow (at least 4 inches (10 cms.) on all sides) and that the room temperature is below

F (35oC).

16,000.40: TCD_THERMISTOR_ FAU LT

16,001.43: TCP_THERMISTOR_ OPEN

16,002.44: TCP_THERMISTOR_ SHORT

16,003.45: TCP_THERMISTOR_ HOT

16,004.46: TCP_THERMISTOR_ SLOW

16,005.47 TCP_THERMISTOR_ADC _BAD

19,000: PRINTHEAD CALIBRATION PROGRAM FAULT CODES

19,001.4X HC_DEV_FAULT (0x01)

19,002.4X HC_DEV_FAULT (0x02)

19,008.63 HC_PROG_FAULT(8)

Most likely cause is a failed drum heater. The head to drum gap should only be checked or adjusted on the Phaser 840. The Phaser 850 and 860 have a pre-adjusted head.

The preheater temperature is incorrect as sensed by the a thermistor in the preheater. Ensure that there is adequate clearance for airflow (at least 4 inches (10 cms.) on all sides) and that the room temperature is correct.

The preheater thermistor appears to be open. Check the preheater cables on the right side of the printer. Replace the paper preheater. Replace the power supply.

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

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

The preheater is not heating at all, or is not heating as quickly as it should. Check for an open connection. Replace the paper preheater. Replace the power supply.

An inalid reading is being reported by the preheater thermistor. Verify the connections to the paper preheater, replace the paper preheater, replace the main board, and then replace the power control board.

Occurs during the scales and offset calibration. Any part in the chain could be responsible for the incorrect reading including the printhead electronics, the A/D electronics, the waveform generation electronics, power supply, wave amplifier (on the power control board), printhead interconnect cable.

Occurs when the printer is attempting to determine how many data taps the printhead uses. Any part in the chain may be responsible for the reading, including the printhead electronics, the A/D electronics, the waveform generation electronics, power supply, wave amplifier (on the power control board), and printhead interconnect cable.

Incorrect Printhead Installed. The printhead installed on the printer is not the correct type the software was compiled for.

22,024.01 The indicates that the printhead was not parked when powered off In the 840/850 this error code may be reported in conjuction with other faults that cause the

printer to reset. This code is not related to media jams.

2 - 58 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 75

Table 2-5 22,LSS.TC Error Codes: Media Jams

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)

8. Door opened jams

(see following error codes)

T indicates whether a timeout or an event occurred 0 = event. An unexpected event occurred 1 = timeout. Time expired without the expected event occurring

C indicates checksum

Refer to the fault history when troubleshooting media jams, this offers the quickest and easiest method of troubleshooting.

For the Phaser 840 printer:

1. Pull the paper tray out about 1 inch (2.5 cms.). This activates all three tray sensors.

2. Hold down the left arrow and press “?” (the help button). This displays the fault history menu with the most recent code at the top.

For the Phaser 850 printer:

1. Hold down the left arrow and press “?” (the help button). This displays the fault history menu with the most recent code at the top.

For the Phaser 860 printer:

1. Hold down the Scroll Up button and press OK.

SS 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 Stripper Sensor not activated 10 A and A4 width sensors 11 A and A4 width sensor 12 Preheat exit sensor 13 Stripper exit sensor 14 Duplex entry sensor 15 Media Exit Sensor 16 VE_DM CYCLE_DONE out of order 17 VE_TF_ROLLER_LIFTED out of order 18 Duplex length measured to be too long 19 Timing delay affected transfix staging 20 Media not visible in top cover (not used) 21 High-Capacity media length too long (not used) 22 Unknown reason

Error Codes and Messages 2 - 59

Page 76

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,101.06 Unexpected Lower -tray-present sensor event in Lower Feeder 2 with media in

Lower Feeder 2

Tray pulled out during printing a. Tray not present

b. Static (rear-tray sensor)

22,102.07 . Sticky pick flag in Lower Feeder 2 with media picked from Lower Feeder 2 Use diagnostics to verify sensor operation.

1. Media flat in tray a. Excess friction in pick-flag

22,102.18 Time-out on pick flag of Lower Feeder 2 with media picked from Lower Feeder 2 Verify that the lower tray is properly loaded. Use diagnostics to verify pick roller motion.

1. Leading-edge jam (right corner is folded)

2. The spring-loaded, media bias block in the lower tray is clamping the media in the tray (usually there will be black marks on the media)

Media is found above the pick arm

motion

a. Media is low in tray b. Media has natural curvature c. Media is short-grained d. Using light weight media

a. Media loaded poorly b. Problem with bias block c. Bad batch of media (too

wide)

a. A sheet of paper from the

bottom of the stack is lining the ramp at the front of the

tray b. Media has natural curvature c. Media is short-grained d. Using light weight media

a. Put tray back b. Use anti-static spray

made for office equipment, or replace lower feeder

a. Replace the Lower

Feeder

a. Add more media b. Flip over media or replace

media c. Use long-grain media d. Use heavier weight media

a. Remove bad sheets and

reload tray more carefully b. Flip media over or replace

media c. Use long grain media d. Use heavier weight media

a. Remove jammed sheets

and reload tray more

carefully b. Flip over media or replace

media c. Use long-grained media d. Use heavier weight media

22,103.08 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 2

*** Same as 22,101.06 ***

22,104.00 Sticky pick flag in Lower Feeder 1 with media picked from Lower Feeder 2 *** Same as 22,102.07 ***

22,104.11 Time-out on pick flag of Lower Feeder 1 with media picked from Lower Feeder 2 Verify that the lower tray is properly loaded. Use diagnostics to verify pick roller motion.

1. The spring loaded, media bias block in the lower tray is clamping the media in the tray (usually there will be black marks on the media)

a. Media loaded poorly b. Bad batch of media (too

wide)

a. Remove bad sheets and

reload tray b. Get a different batch of

media

2 - 60 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 77

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

2. Leading edge jam (right corner fold)

22,105.01 Unexpected standard tray sensor event with media in Lower Feeder 2

1. Pulled upper tray out during printing

2. None a. Upper tray sensor

22,106.13 Time-out on pick flag of printer with media picked from Lower Feeder 2 *** Same as 22,104.11 ***

22,200.06 Command stop event with media in lower feeder 1.

1. Media perfect in media path a. A paper tray or door was

22,201.08 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in Lower Feeder 1 *** Same as 22,101.06 ***

22,203.00 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in Lower Feeder 1 *** Same as 22,101.06 ***

22,204.00 Sticky pick flag in Lower Feeder 1 with media picked from Lower Feeder 1 *** Same as 22,102.07 ***

22,204.12 Time-out on pick flag of Lower Feeder 1 with media picked from Lower Feeder 1 *** Same as 22,102.18 *** Verify that the lower tray is properly loaded. Use diagnostics to verify pick roller motion.

22,205.02 Unexpected standard tray sensor event with media in Lower Feeder 1 *** Same as 22,105.01 ***

22,206.14 Time-out on pick flag of main printer with media picked from Lower Feeder 1 *** Same as 22,104.11 *** Verify that the lower tray is properly loaded. Use diagnostics to verify pick roller motion.

22,301.01 Unexpected Lower tray present sensor event in Lower Feeder 2 with media in the main tray *** Same as 22,101.06 ***

22,303.03 Unexpected Lower tray present sensor event in Lower Feeder 1 with media in the main tray *** Same as 22,101.06 ***

22,305.05 Unexpected standard tray sensor event with media in the main tray *** Same as 22,105.01 ***

a. Media is low in tray b. Media has natural curvature c. Media is short grained d. Using lightweight media e. Paper path is obstructed

a. Upper tray not present a. Put upper tray back

damaged, missing, or mis-installed

open

b. Worn maintenance drawer

lift pins c. PostScript Fault d. Front Panel error e. Power Supply problem f. Poss ible ESD event affecting

Lower Feeder Sensors

a. Add more media b. Flip over media or replace

media c. Use long-grain media d. Use heavier weight media e. Check paper path for

obstructions and ensure

all trays are fully seated

a. Verify that upper tray type

plug is present; replace

sensors

a. Avoid opening trays or

doors during printing b. Replace Maintenance

Drawer c. Try again, cycle power or

NVRAM reset d. Check front panel

sensors or replace front

panel e. Replace power supply f. Use anti-static spray for

office equipment

Error Codes and Messages 2 - 61

Page 78

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,306.15 Time-out of pick flag on main tray with media picked from the main tray

1. Pick roller is slipping a. Media is too heavy and/or

2. Last sheet in tray a. Stuck on media grip a. Fill tray (more likely with

3. Media skewed with no noticeable damage

4. Media skewed with noticeable damage

5. Media wedged in tray a. Too much friction or lift plate

6. Media is folded, damaged, or deformed

7. Media found flat in tray chronic problem

8. Media damage in center a. Pick pad a. Don't load media too

9. Media at lower roller, pick flag area

22,322.13 Unknown standard tray event *** Same as 22,105.01 ***

22,411.01 Handfeed width A or A4 sensor event

1. None a. Media is not pushed far

has high sheet-to-sheet friction

a. Media tray over filled a. Fill tray appropriately

a. Problem with pick-guide

assembly

cannot operate correctly (bottom sheet may be wedged between lift plate and pick pad)

a. Media cannot get out of the

tray

a. Problem with pick clutch b. Too much pick-shaft motion

a. Pick -lag problem b. Sensor Problem c. Lower roller problem

enough into the handfeed slot

b. Media is not the expected

size

a. Try different media. b. Clean the pick pad and

pick roller with packing tape. See “Pick Roller Cleaning Method” on page 6-175. Verify roller motion with diagnostics.

heavier media)

a. Reseat or replace if

damaged

a. Remove media, inspect

and reload

a. Use diagnostics to verify

pick roller motion and clutch activation

a. Reinstall or replace the

pick clutch

b. Check bushings and

e-clips

close to fill line. Replace pick pad if needed

a. Reseat flag b. Verify I/O right is installed

correctly, reinstall or replace if needed

c. Check bushings and e-clips

a. Feed paper in until the

printer grabs

b. Use a ruler to verify exact

media dimensions

2 - 62 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 79

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,500.00 Command stop event with media in front door area

*** See SF144 & SB460***

a. Inspect the maintenance

drawer for worn lift pins,

replace if needed

1. Media perfect in media path (front door area)

22,501.01 Unexpected Lower-tray-present sensor event in Lower Feeder 2 with media in the front door area *** Same as 22,101.06 ***

22,503.03 Unexpected Lower-tray-present sensor event in Lower Feeder 1 with media in the front door area *** Same as 22,101.06 ***

22,505.05 Unexpected standard-tray-sensor event with media in the front door area *** Same as 22,105.01 ***

22,506.06 Unexpected standard tray pick flag event.

1. Paper found in the front door and lower tray at the same time, multipicks, or 22,721.05 in the fault history.

22,508.08 Unexpected preheat entry sensor (left side) event. Can be caused by media off the sensor too soon.

1. Skew a. Last sheet in tray

2. Media deformed or damaged in media tray

22,508.10 Time-out on preheat entry sensor (left side)

1. Media came from the lower feeder with corner fold

a. Drum maintenance clutch b. Worn maintenance drawer

lift pins c. PostScript fault d. Front panel error e. Power supply problem

a. Standard tray pick roller

clutch slipping.

b. First sheet in tray c. Failure of deskew system

a. Left trailing edge bent b. Hole or tear in media

a. Low stack of media in tray b. Sticky lower feeder pick flag c. Missing support foil (clear

L-shaped plastic media

guide on front left side of

the lower tray)

a. Replace drum

maintenance clutch

b. Replace maintenance

drawer

c. Try again, cycle power, or

NVRAM reset

d. Check front panel

sensors or replace front panel assembly

e. Replace power supply

a. Replace the pick roller

clutch. ““see Service Bulletin 462**

a. Verify that the lower tray

is properly loaded

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and media is square in tray

c. Check deskew fingers. If

chronic check preheat entry assembly for deformation

a. Remove and inspect

media and reload

b. Remove and inspect

media and reload. May be caused by 3-hole punch media

a. Verify that the lower tray

is properly loaded

a. Refill tray (can be

common with low media

stack) b. Replace lower feeder c. Replace lower tray

Error Codes and Messages 2 - 63

Page 80

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

2. Media came from lower feeder and missed preheat entry flag

3. Media damaged in center a. Pick pad a. Don't load too close to fill

4. Media is folded, damaged, or deformed in tray

5. Media is excessively skewed

6. Media really skewed with side edge damage

22,511.02 Unexpected A/A4 sensor event

1. Media stops just inside preheat entry rollers

2. Media folded, damaged, or deformed in tray

a. Lower feeder bias problem a. Make sure media is on

a. Media makes it out of tray,

but cannot trip preheat entry flag

a. Tray overfilled b. Media was hand fed and

was loaded skewed

c. Last sheet in tray

a. Problem with pick-guide

assembly

a. A4-width media in A-size

tray

a. Media gets out of the tray

but hits the sensors at the wrong times

the left side of the tray

line. Replace pick pad if needed

a. Remove and inspect

media and reload tray

a. Make sure tray isn't

overfilled and media is square

b. Reload media more

carefully

c. Refill tray(s)

a. Make sure pick guide is

snapped into the printer's frame

a. Check media and replace

with good media; verify tray-type plug position

a. Remove media, inspect

and reload

22,512.14 Time-out on preheat exit sensor

1. Damage on the right corner of A Size media

2. Tight wrinkles across media a. Short-grained media

3. Media found flat inside preheater

4. Media found flat right at deskew roller

22,514.05 Unexpected Exit Sensor event

1. Media in both duplex path and simplex path

a. Probable preheater problem a. Replace preheater

b. Too much drag in preheater

a. Too much drag in drive train

stalling media path motor

a. Feed clutch problem a. Replace feed clutch

a. Media was pulled from exit

into duplex path while

printing b. Shor t-grained media c. Label stock curling d. Extreme environment

a. Use long-grained or

heavier weight media

b. Replace preheater

a. Use diagnostics to verify

drive current requirements, or feel for unevenness in motor rotation by manually turning. Replace paper path motor if needed.

a. Make sure exit tray is not

overfilled or messy;

empty tray b. Use long grain media c. Empty the exit tray often d. Do not leave media out of

wrapper for extended

periods of time in

extreme environments

2 - 64 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 81

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,522.04 Media not exiting completely

1. None a. Media slipping on exit

22,538.13 Time-out on preheat exit sensor (duplex) with media in the front door area

1. Skew a. Last sheet in tray

2. More than one sheet in duplex path

3. Media is from lower feeder and has small left margin

4. Stiff media a. Can't turn corner form paper

22,541.05 Unexpected A/A4 sensor event *** Same as 22,511.02 ***

22,542.17 Time-out on preheat exit sensor (duplex). Unexpected duplex sensor event ***

Same as 22,512.14 ***

22,548.03 Duplex long declaration determined from duplex sensor

1. More than one sheet in duplex path

22,600.01 Command stop event with media in exit cover area *** See SF144 ***

1. Media perfect in media path (exit door area)

rollers

b. First sheet in tray c. Failure of deskew system

a. Media was pulled from exit

into duplex while printing

b. Multiple pick

a. Lower feeder bias problem b. Make sure media is flush

tray to drum

a. Media was pulled from exit

into duplex while printing

b. Multiple pick

a. Drum maintenance clutch b. PostScript fault c. Front panel error d. Power supply problem

a. Try different media, clean

the exit rollers or replace

the exit cover b. Clean the exit rollers c. Replace the exit cover

a. Verify that the lower tray

is properly loaded

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and

media is square in tray c. Check deskew fingers. If

chronic check preheat

entry assembly for

deformation

a. Empty exit tray b. Retr y

with the left side of the

tray

b. Run lighter media

(< 32#)

a. Empty exit bin b. Retr y

a. Inspect maintenance

drawer for worn lift pins

and replace if needed b. Replace the DM Clutch,

this is a solution for the

Phaser 840 only

c. Try again, cycle power, or

NVRAM reset d. Replace front panel

assembly e. Replace power supply

22,601.02 Unexpected Lower-tray-present-sensor event in Lower Feeder 2 with media in the exit door area *** Same as 22,101.06 ***

22,603.04 Unexpected Lower-tray-present-sensor event in Lower Feeder 1 with media in the exit door area *** Same as 22,101.06 ***

Error Codes and Messages 2 - 65

Page 82

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,605.05 Unexpected standard-tray-sensor event with media in exit door area *** Same as

22,105.01 ***

22,613.05 Unexpected stripper exit sensor event

1. Paper started backing up before a jam

2. Paper was still exiting a. Stripper exit sensor

22,613.16 ***same as 22,613.05***

22,614.06 Unexpected duplex-sensor event *** Same as 22,514.05 ***

22,638.14 Time-out on preheat-entry sensor (duplex) with media in exit cover

1. More than one sheet of paper in path

2. Skew a. Last sheet in tray

3. Media perfectly straight a. Media path motor stall a. Use diagnostics to run

22,644.11 Time-out on duplex sensor

1. Printer is pulling the paper from the customer

2. Media damage left lead corner

3. More than one sheet in duplex path

a. Paper didn’t fully exit in time a. Ensure media is the

bounced

a. Media was pulled from exit

into duplex while printing

a. Multiple pick

b. First sheet in tray c. Failure of deskew system

a. Customer tried to remove

media after first side and didn't let it enter the duplex path

a. Hitting the left wall under

control panel

a. Media was pulled from exit

into duplex while printing

correct size, try a different media, clean the exit rollers or replace the exit cover.

a. Try increasing the str ipper

sensor spring tension slightly (too much tension may cause jams on light weight media).

a. Empty exit b. Run again

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and media is square in tray

c. Check deskew fingers. If

chronic, check preheat entry assembly for deformation.

“verify drive current requirements”, or feel for unevenness in motor rotation by manually turning. Replace paper path motor if needed. Check electronics if needed.

a. Train the customer

a. Move front panel to left; If

necessary, replace front panel assembly. Replace printer if chassis warped

a. Empty exit tray

2 - 66 Phaser 840/850/860/8200 Color Printer - Service Manual

Page 83

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

4. Excess skew a. Last sheet in tray

5. Media deformed or damaged in media tray

6. Media perfectly straight a. Media path motor stall

7. Media goes back down simplex path

22,700.02 Command-stop event while transfixing. Typically becuase of a positioning error at the start of drum maintenance or imaging.

1. More than one sheet of media in the path

2. Media perfect in media path (exit door area)

b. First sheet in tray c. Failure of deskew system d. Exit roller is out of position

a. Left corner folded in tray

(simplex trailing edge)

b. Bad gear in drive train c. Duplex sensor not snapped

into front panel assembly

d. Bad duplex sensor

a. Roller slip b. Media impeded from exiting

by top cover

c. Media impeded from exiting

by a tall stack of paper

a. Multiple pick a. Try again

a. Check for drum rotation b. Y-axis encoder defective, or

not seated properly c. Drum maintenance clutch d. PostScript fault e. Front panel error f. Power supply problem

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and media is square in tray

c. Check deskew fingers. If

chronic check preheat entry assembly for deformation

d. Reseat exit roller

b. Remove media, inspect

and reload

a. Use diags to run “verify

drive current requirements” from the paper path group to check for stall, or feel for unevenness in motor rotation by manually turning. Replace paperpath motor if needed. Check electronics if

needed b. Replace stripped gears c. Reassemble front panel d. Replace front cover

display assembly

a. Replace exit roller, insure

exit idler rollers are

providing adequate force b. Reassemble top cover c. Remove media from

output tray

a. Verify that the lower tray

is properly loaded. b. Try heavier media c.

a. Check for Y-axis motion

blockage b. Reseat or replace

encoder c. Replace the drum

maintenance clutch d. Try again, cycle power, or

NVRAM reset e. Replace front panel

assembly f. Replace power supply

Error Codes and Messages 2 - 67

Page 84

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,703.05 Y-axis stall. Typically during transfix. May result from belt slippage.

a. Verify that the lower tray

is properly loaded.

b. Try heavier media

2. More than one sheet of paper in duplex path

3. Media all wrinkled up a. Short-grained media a. Run stiffer long-grained

22,705.07 Y-axis time-out during transfix while moving media to the exit sensor.

1. Exit tray nearly full a. Media was pulled from exit

2. Media unable to get out of exit

3. Media 1 inch out of exit, flat and undamaged

4. Media not able to exit cleanly

5. Printing transparencies a. Printer running at fast color

22,706.08 Y-axis declared page short. Uses the A4 sensor or preheat exit sensor for smaller size media.

1. Skew a. Last sheet in tray

2. Media deformed or damaged in media tray

3. Media perfectly straight a. Unknown (static?) a. Try again

a. Multiple pick a. Try again

media

into duplex while printing, exit flag can't move properly

a. Top cover has exit flag

trapped

b. Exit flag bound up

a. Exit flag warped and not

functioning

b. Bad paper exit sensor

a. Problem with idler rollers on

exit cover b. Top cover installed too high c. Problem with exit roller

speed

b. First sheet in tray c. Media was hand fed and

was loaded skewed d. Failure of deskew system

a. Right trailing edge bent b. Hole or tear in media

a. Empty exit tray

a. Remove and replace top

cover without capturing exit flag

b. Replace exit cover

a. Exit flag warped and not

functioning

b. Bad paper exit sensor

a. Ensure all idler roller

springs are present and

not damaged b. Reassemble top cover c. Ensure that all bushings

and e-clips are properly

installed

a. Reboot printer and rerun

prints

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and

media is square in tray c. Reload media more

carefully d. Check deskew fingers on

inside of front door. If

chronic, check preheat

entry assembly for

deformation

a. Remove media, inspect

and reload b. Remove media, inspect

and reload

2 - 68 Phaser 840/850/860/8200 Color Printer - Service Manual

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Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

22,707.00 Y-axis declared media is too long. Typically caused by a multipick or stuck A4 sensor

1. None a. Verify that the lower tray

2. More than one sheet found in paper path

3. One sheet hangs out at exit a. A or A4 flag not seated

22,721.05 Y-axis print failure. Media did not arrive at the preheat exit sensor soon enough to complete the print. May also be due to an unexpected high-capacity tray sensor event

1. None a. Lower tray assembly sensor

22,722.06 Y-axis timeout during transfix moving media to the stripper sensor

1. Media jammed on stripper fingers or rapid release guide excessive skew

2. Media jammed on stripper fingers or rapid release guide folded corner

3. Media jammed on stripper fingers or rapid release guide bad media

4. Media jammed on stripper fingers or rapid release guide margin good, stripper down on eccentric cam location good

5. Media jammed on stripper fingers or rapid release guide margin good, stripper down on eccentric cam location; repeatedly fails

6. Media jammed on stripper fingers or rapid release guide margin good, stripper down on eccentric cam location

a. Multiple pick a. Run again

properly

b. A4 flag is sticking to the

steel roller

bouncing

a. Last sheet in tray b. First sheet in tray c. Failure of deskew system

a. Missing support foil (clear

L-shaped plastic media guide on the front left side of the lower tray)

b. Folded in tray

a. Damaged or deformed

media

a. Excess plastic on end of

stripper fingers - part defect b. Deformed stripper fingers c. Damaged from jam earlier

a. Transfix eccentric shaft

key-way problem

a. Process motor problem a. Replace process motor

is properly loaded.

b. Try heavier media

a. Inspect and reinsert flag b. Replace upper preheat

entry assembly

a. Try lighter or smoother

media (less friction)

b. Replace lower tray

a. Refill tray(s) b. Make sure tray(s) is

loaded properly and media is square in tray

c. Check deskew fingers on

inside of front door. If chronic, check preheat entry assembly for deformation

a. Replace Lower tray b. Remove media, inspect

and reload

a. Replace media

a. Replace stripper fingers

or rapid release guide

b. Replace stripper fingers

or rapid release guide

c. Replace stripper fingers

or rapid release guide

a. Replace drum transfix

assembly

Error Codes and Messages 2 - 69

Page 86

Table 2-6 22,000 Fault Codes and Actions

Error code

Additional clues Probable cause Action

7. Stripper fingers or rapid release guide do not move freely

8. Media jammed on or completely under stripper fingers or rapid release guide margin too large or too small

9. Media over stripper fingers or rapid release guide - not damaged and stopped at strip sensor

10. Media under transfix roller right at stripper fingers

11. Media doesn't make it to the transfix roller

22,900.04 Unexpected front door event

1. Media perfect in media path or tray

22,901.05 Unexpected exit cover event

1. Media perfect in media path or tray

a. Bushing out of place b. E-ring missing c. Parts bound up

a. Preheat sensor not seated

properly

b. Preheat sensor not properly

assembled to bracket

c. Preheat sensor is bad

a. Problem with strip flag b. Bad transfix exit sensor

a. Eccentric solenoid problem b. Transfix cam problem c. Cam spring problem

a. Too much drag in drive-train

or preheater

a. Short-grained media

a. Unknown (static?) b. Someone opened a door

a. Reassemble stripper

b. Reassemble stripper

c. Reassemble stripper

a. Confirm bracket is

b. Reseat sensor c. Replace preheat exit

a. Replace pivoting blue

b. Replace sensor assembly

a. Replace eccentric

b. Replace cam c. Replace drum transfix

a. Use PC-based

b. Use long-grained media

a. Run again b. Close door

fingers or rapid release guide

fingers or release guide

properly screwed down onto load frame

sensor

lower exit guide

solenoid

assembly

diagnostics to run “verify drive current requirements” from the paper path group, to check for stall, or feel for unevenness in motor rotation by manually turning. Replace paper path motor if needed. Check electronics if needed

2 - 70 Phaser 840/850/860/8200 Color Printer - Service Manual

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Table 2-7 Front Panel & Fault History Log Error Codes and Messages

Error code Definition

23,000: NVRAM SYSTEM FAULTS

23,003.65 SYS_NVRAM_PROG_ FAULT(3)

23,089.61 SYS_NVRAM_PROG_ FAULT(0x59)

23,133.60 SYS_NVRAM_PROG_ FAULT(0x85)

31,000 MOTOR FAULTS

31,001.4x MP_FAULT_AUX_MOTOR_ ERROR

31,002.4x MP_FAULT_PROCESS_ MOTOR_STALL

31,003.4x MP_FAULT_PREHEAT_ EXIT_SENSOR_BAD

31,003.42 Use diagnostics sensor tests to locate the blocked sensor.

31,044.60 Bad Message in mp_sleep_for() - While the media path task

31,049.65

31,058.65 Bad message during auxillary tray pick. This is a program fault

Head Tweak Read Failed. A read of the head tweak value from non-volatile memory failed. The tweak value is saved twice in NVRAM. If the two values are different then this error is generated. The most likely cause of this error is a corrupt NVRAM part.

***same as 23,003.65***

NVRAM Corruption Detected On powerup, the firmware checks each NVRAM variable for validity. Usually when this fault is reported the printer has already wiped out the NVRAM contents to clear up the corruption. Any user configurations will need to be reset.

Not used as a device fault condition.

Declared when the sensors around the preheater exit sensor indicate the presence or absence of media contrary to that indicated by the preheater exit sensor. This is usually caused by a piece of media stuck in the preheater exit sensor.

was in the process of delaying for acertain period of time it received an unexpected inter-task communication message. This error can occur due to a bad sensor, like the preheat exit flag.

from the media path task. It most likely indicates a problem with a sensor while feeding paper from an auxillary tray.

While the media path task was in the process of picking paper out of the auxillary tray, it received an unexpected inter-task communication message. This error can occur due to a bad sensor or sensor bouncing, for example the auxillary tray pick flag.

Error Codes and Messages 2 - 71

Page 88

Blank Page

2 - 72 Phaser 840/850/860/8200 Color Printer - Service Manual

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Troubleshooting

The troubleshooting section discusses Repair Analysis Procedures (RAPs) for the Phaser 840/850/860 printers. This section is broken into the following groups:

■ Network Event Logs

■ Electrical Interface Problems

■ Media and Paper Path Problems

■ Printing and Print Image Quality Problems

■ Windows Printing problems

■ Macintosh Printing problems

■ Cap/Wipe/Purge Troubleshooting: Evaluating and troubleshooting the

printhead cap/wipe/purge system can be found on page 106.

Electrical Interface Problems (RAP) Table

Table 3-1 Electrical Interface RAP Table

Problem on Page

System Power-Up Sequence page 76

Inoperative Printer: No Lights, No Sound on power-up page 80

Verifying Main Board CPU Operation page 80

Verifying Print Engine operation by its startup page page 81

Verifying Power Supply and Measuring Voltages page 81

Inspecting the power supply fuses page 82

Testing for shorted drivers page 83

Testing for a shorted motor page 84

Testing motor and solenoid resistances page 84

Media and Paper Path Problems (RAP) Table

Table 3-2 Media and Paper Path RAP Table

Problem on Page

Media-Based Problems page 85

Paper Pick Errors page 85

Print Transfer Jams page 86

Checking the Process Motor and Drive Train page 86

Media skews passing through the Paper Path page 87

Troubleshooting 3 - 73

Page 90

Print Image Quality Problems (RAP) Table

Table 3-3 Print and Image Quality Problems RAP Table

Problem on Page

Not Printing page 88

Missing ink or light colored ink band running length of print page 89

Color is uneven page 90

Streaks or lines in the prints page 91

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

Printing too light or too dark page 93

White portion of print is colored or marked page 94

Fuzzy text page 95

Poor primary color fills page 96

Ghosting page 97

Poor small text resolution page 98

Vertical line appears wavy page 99

Oil streaks on print (top or bottom) page 100

Incomplete image transfer to paper page 101

Ink smears on first side of duplex print page 102

Repeating print defects on print page 103

Wrinkling page 104

Image is offset or cut off page 105

Poor ink adhesion, poor image durability page 105

page 92

Macintosh Printing Problems

Table 3-4 Macintosh Printing Problems RAP Table

Problem on Page

Image Never Prints page 115

Image is rotated 90 degrees page 115

Image prints in black and white page 115

Printer isn’t the Chooser page 116

3 - 74 Phaser 840/850/860/8200 Color Printer - Service Manual

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Network Event Logs

Phaser 850

The Phaser 850 printer maintains three logs in memory detailing network functions. The logs contain TCP/IP and Netware initialization landmarks and limited print-time processes. The log also shows the state of the networking hardware.

The logs are useful for troubleshooting network setup problems and isolate network problems from printer problems. The log indicates that network hardware is properly functioning with messages like “NETWORK HARDWARE PROVEN GOOD USING IPX”.

The logs can be accessed through the front panel menu.

1. Navigate to Menu/ Printer Configuration/ Network Setting/ Network Logs.

2. Scroll to Hardware Startup Log or TCP/IP Startup Log or NetWare Startup Log

and press Select.

The log can also be accessed remotely via PhaserLink 2.0.

The logs lists events chronologically. The log is limited in length; logging stops when the log is full. The log is stored in RAM only so new data is stored each time the printer’s power is cycled.

Phaser 860

The Phaser 860 printer maintains four logs in memory detailing network functions. The logs contain; Netware, TCP/IP, AppleTalk and Hardware initialization landmarks and limited print-time processes.

The logs can be accessed throught the front panel menu.

1. Navigate to Menu/ Support/ Network Questions?.

2. Scroll to the appropriate Network Runtime Log for you network and press OK.

The log can also be accessed remotely via CentreWare IS.

The logs lists events chronologically. The log is limited in length; logging stops when the log is full. The log is stored in RAM only so new data is stored each time the printer’s power is cycled.

Troubleshooting 3 - 75

Page 92

Electronics 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 the DIP switch settings, the last power down condition and where the printer “believes” the printhead is positioned. The printer records in non-volatile RAM the last known position of the printhead and the cap/wipe/purge assembly. The Electronics Troubleshooting Checklist is the primary reference for troubleshooting power-up problems, see "On-site Electronics Troubleshooting Checklist Phaser 840/850" on page A-250 or "On-site Electronics Troubleshooting Checklist Phaser 860/8200" on page A-266.

Phaser 840/850 Customer Mode Power-Up Sequence

Power switch is turned on:

1. Power supply senses AC line voltage conditions (110 VAC or 220 VAC) and enables

DC voltages. If an overload occurs, the printer turns off the DC supplies, giving a “blink” effect to the front panel LEDs.

2. Low-level, power-on self-test (POST) diagnostics are performed. The two status LEDs

at the rear panel should toggle and the front panel LEDs are turned on. The front panel display is blank. This test takes from 4 to 15 seconds depending on installed RAM.

3. If POST diagnostics pass, the front panel Error LED is turned off and the front panel

displays the Tektronix logo while the mechanical initialization checks are performed.

If an error is detected, the Phaser 850 printer flashes the front panel Error LED with a repeating error code pattern as well as the rear panel PS LED. On the Phaser 840 printer, the pattern is displayed only on the rear panel PS LED (left side of the DIP switches).

4. The mechanical initialization is conditional on the initial position of the printhead and

cap/wipe/purge assembly. Two NVRAM parameters are checked for the last known position.

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

a. The cap/wipe/purge motor is run to ensure that the cap/wipe/purge

assembly activates its home-position sensor.

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

a. The heaters in the printhead and cap/wipe/purge assembly are activated, as

a precaution, to melt the ink which may have cooled and solidified, thus gluing the cap/wipe/purge and printhead together. 10 minutes pass while the cap/wipe/purge assembly heats up.

b. The printhead is tilted back.

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

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

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5. The process motor is activated to rotate the head tilt gear into its home position. (If the

printhead is in the locked position it will not tilt forward.) The process motor also rotates all the rollers to their ready positions, disengage the transfix roller, and lower the maintenance drawer blade and wiper.

6. The x-axis motor activates to move printhead off its locking post. The x-axis motor

activates for three short bursts to ensure the printhead is in its far-left travel (printhead home position). Then the x-axis motor is reversed to move the printhead to the center the of the x-axis travel.

7. The process motor is again activated to tilt the printhead forward into the print position.

The drum is rotated to sense it home position. (The Phaser 850 printer uses a slower rotation to find its home position.)

8. A short cap/wipe/purge assembly motion is performed and the assembly is returned to

its home position.

9. After the print engine is in a known, valid state, the AC heaters are enabled and the

front panel display shows the warm-up progress. The Ready LED flashes; when warm-up completes, the Ready LED lights solid.

10.The drum begins to rotate.

11.If the temperature of the printhead ink reservoirs or jetstack are below the purge

threshold, then the printer performs a head clean cycle.

a. When the ink in the printhead is molten and printhead temperatures are

correct, the cap/wipe/purge assembly is positioned to the purge position.

b. The printhead tilts forward against the cap/wipe/purge assembly and a

purge cycle begins.

c. The front panel indicates the printer is in a clean cycle.

d. If the printer senses ink or debris on the drum, a drum cleaning page is

printed (Phaser 840 printer only).

12.The temperature of the printhead, drum and paper preheater are allowed to stabilize at

their operating temperatures and ink is melted if needed.

13.If needed, a cleaning page is printed at this time.

14.A start page is printed (if enabled).

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

The print engine is initialized.

Troubleshooting 3 - 77

Page 94

Phaser 860 Customer Mode Power-Up Sequence

Power switch is turned on:

1. Power supply senses AC line voltage conditions (110 VAC or 220 VAC) and enables

DC voltages. If an overload occurs, the printer turns off the DC supplies, giving a “blink” effect to the front panel LEDs.

2. BIST test flashes the PE LED very breifly at a fast rate (for only 1/3 of a second at a

rate of 8 Hz; a total of 3 flashes) until the end of the next test.

3. The Boot loader performs CPU initialization and RAM test (RAM test is less than 0.1

seconds, even with 256 Mbytes). It then sends the boot loader version to the serial port.

4. Power-on self-test (POST) initializes the front panel; front panel LED turns red, then

green, then orange and then off, the front panel LCD goes black and then clear. The POST version is displayed on the LCD and waits two seconds. During this time the operator can press the Back button to bypass the remaining POST test.

5. Low level power-on self-test (POST) diagnostics are performed. The front panel

displays status messages as each sub-test is performed. This test takes about 8 seconds. All LEDs are off during the test.

If POST diagnostics pass, the front panel displays the Xerox logo.

If an error is detected, the error message is displayed on the LCD and the printer flashes the LEDs with a repeating error code pattern.

6. The VxWorks operating system is initialized and engine code is started. This takes

about 15 seconds. The Xerox logo is displayed.

7. The mechanical initialization is conditional on the initial position of the printhead and

cap/wipe/purge assembly. Two NVRAM parameters are checked for the last known position.

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

a. The cap/wipe/purge motor is run to ensure that the cap/wipe/purge

assembly activates its home-position sensor.

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

a. The heaters in the printhead and cap/wipe/purge assembly are activated, as

a precaution, to melt the ink which may have cooled and solidified, thus gluing the cap/wipe/purge and printhead together. 10 minutes pass while the cap/wipe/purge assembly heats up.

b. The printhead is tilted back.

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

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

8. The process motor is activated to rotate the head tilt gear into its home position. (If the

3 - 78 Phaser 840/850/860/8200 Color Printer - Service Manual

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9. The x-axis motor activates to move printhead off its locking post. The x-axis motor

10.The process motor is again activated to tilt the printhead forward into the print

position. The drum is rotated to sense it home position (The Phaser 850 printer uses a slower rotation to find its home position).

11.A short cap/wipe/purge assembly motion is performed and the assembly is returned to

its home position.

12.After the print engine is in a known, valid state, The AC heaters are enabled and the

front panel display shows the warm-up progress. The Ready LED flashes; when warm-up completes, the Ready LED lights solid.

13.The drum begins to rotate.

14.If the temperature of the printhead ink reservoirs or jetstack are below the purge

threshold, then the printer performs a head clean cycle.

a. When the ink in the printhead is molten and printhead temperatures are

correct, the cap/wipe/purge assembly is positioned to the purge position.

b. The printhead tilts forward against the cap/wipe/purge assembly and a

purge cycle begins.

c. The front panel indicates the printer is in a clean cycle.

15.The temperature of the printhead, drum and paper preheater are allowed to stabilize at

their operating temperatures and ink is melted if needed.

16.If needed, a cleaning page is printed at this time.

17.A start page is printed (if enabled).

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

The print engine is initialized.

Troubleshooting 3 - 79

Page 96

Inoperative printer problems.

Refer to Appendix Electronics Troubleshooting Checklist.

The printer shuts down with the power switch on.

The printer may have experienced a spurious over-current event. If the printer powers-up within 2 seconds, do nothing. If the printer powers-up after 6 seconds, the printer power supply has auto-ranged to the 220 VAC setting

Remove the power cord, wait 30 seconds, then reinstall the power cord. The printer should power-up at its 110 VAC setting within two seconds, refer to SF156, Phaser 840 only.

If the fans “twitch” and the LEDs flash,

There may be a short in the power supply system. Refer to the later procedure "Testing for shorted drivers" on page 3-83.

If the fans do not move and the LEDs do not flash,

There is either no AC power to the printer or the power supply has failed. Check the AC voltage. If replacing the power supply does not correct the problem, refer to the later procedure "Testing for shorted drivers" on page 3-83.

There are no lights and no sound upon power up (Phaser 850).

A manufacturing process error resulted in some power control board brackets getting bent. The serial number range for this potential problem is M0A7600 to M0D3800. These bent brackets prevent the 40v loopback connector from fully seating, and in some cases can result in it disconnecting due to shipping vibrations. When the power switch is turned on with a disconnected 40v loopback connector, the front and rear panel LED's will blink briefly and go out, and the printer will appear to have no power. See ***SF169***

Main Board CPU operation

The main board has sophisticated self-test capabilities. The main board is usually not the cause of the fault unless an error code specifically indicates a potential main board fault.

Refer to Appendix Electronics Troubleshooting Checklist. A few rare conditions were specifically not included in the checklist:

■ The power switch is turned off and the printer remains on. Check the DIP

switches, then pull the plug and reseat the main board.

■ If LEDs blink and then hang (either both off/on/unknown combination) the

issue is unknown. Reseat everything, then replace the main board.

Also, refer to "Error Codes and Messages" on page 2-37 and "System power-up sequence" on page 3-76.

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Verifying print engine operation by printing a built in page.

1. If not already on, turn on the printer. If the printer does not begin initializing, go to the

topic, “Measuring power supply voltages”.

2. Once the Power light is on (not blinking) and the front panel displays Ready to

Print it is now possible to print any built-in pages.

3. If the printer prints the Page, the print engine is working correctly. If the printer does

not print the 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.

■ See SF 156 ( Phaser 840 only).

Measuring power supply voltages

Warning AC line voltages are present on the power supply and possibly in

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

2. AC Input: With a DMM set to measure AC voltages, measure the power being

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

3. 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 Service Required error code is displayed on the front panel.

the printer, via the heaters, while the printer is plugged into an AC outlet, even if the power switch is off.

Troubleshooting 3 - 81

Page 98

Inspecting the power supply fuses

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

1. Turn off the printer and remove the power cord.

2. Remove side and rear covers.

3. Remove the screws securing the power supply.

4. Disconnect the wiring harnesses plugged into the right side of the power supply and

remove power supply.

5. With a DMM, determine that the fuses on the power supply are functional. Measure the

resistance of all fuses to LINE as indicated on the power supply’s shield.

If any fuse opens, the power supply does not function and should be replaced.

Caution Fuses 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, 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.

Fuse F1 is for the DC power supply, all DC outputs. Fuse F2 is for the following heaters:

Fuse F3 is for the following heaters:

■ H3 Jet Stack Left

■ H4 Paper PreHeat

■ H10 Jet Stack Right

■ H11 Reservoir #2

■ H12 Drum #2

■ H14 Reservoir #4

■ H1 Drum #1

■ H2 Reservoir #1

■ H5 Black Ink Melt

■ H6 Magenta Ink Melt

■ H7 Cyan Ink Melt

■ H8 Yellow Ink Melt

■ H9 Cap Wipe Heat

■ H13 Reservoir #3

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 3-83. Also refer to SF157.

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Testing for shorted drivers

1. Turn off the printer.

2. 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).

3. The 40 volt service load connector is not needed for the Phaser 860 printer, go to step

4. For the Phaser 840/850 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 powered-up 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

0388-66

Fig 3-1 Attaching the service load connector to J250

4. 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 lighted LEDs), replace the power supply.

5. Turn off the printer. Reconnect the +40 volt loopback connector to the power control

board; then disconnect all load connectors from the power control board. Turn on the printer. If the rear panel LEDs still do not illuminate, the power control board has a shorted driver and must be replaced. If the LEDs do illuminate, isolate which motor or fan is overloading the power control board and power supply. Turn off the printer. Sequentially plug each cable in one at a time, and turn on the printer until the power supply is disabled. Replace the defective component. Also refer to the next topic, "Testing motor and solenoid resistances" on page 3-84.

6. Turn off the printer. Disconnect the two I/O board ribbon 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/O board ribbon cable is defective.

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

Troubleshooting 3 - 83

Page 100

Testing for a shorted motor

1. Reinstall the power supply if removed in the previous procedure.

2. Disconnect the process motor, the Y-axis motor, X-axis motor and the cap/wipe/purge

assembly motor wiring harness.

3. 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 following procedure, “Testing motor and solenoid resistances”.

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

1. Turn off the printer and disconnect the power cord.

2. With a DMM set for measuring resistance, test each motor's windings for correct

resistance (disconnected from the printer). Rotate the motor's drive shaft slightly while taking the measurement.

Table 3-5 Motor and solenoid resistances

Motor or solenoid Phaser 840 printer

Process motor 2.9 ohms +/-15% (Difficult to

Y-axis motor 1.4ohms +/- 15% (Difficult to

X-axis motor 12.5 ohms/phase (red-to-yellow

Paper-feed motor 1.5 +/- 20% ohms/phase 1.5 +/- 20% ohms/phase

Maintenance drawer camshaft electric clutch

Paper-pick electric clutch

Cap/wipe/purge clutch, feed clutch and Phaser 860 pick clutch.

Transfix cam solenoid 108 ohms +/- 10% 108 ohms +/- 10%

Resistance (approximately)

measure due to variability at the brush/commutator interface.)

and blue-to-orange

186 ohms +/- 15% 132 ohms +/- 15%

186 ohms +/- 15% 186 ohms +/- 15%

125 ohms +/- 12% 124 ohms +/- 5%

Phaser 850/860 Printer Resistance (approximately)

4.3 ohms +/-15% (Difficult to measure due to variability at the brush/commutator interface.)

1.4ohms +/- 15% (Difficult to measure due to variability at the brush/commutator interface.)

12.5 ohms/phase (red-to-yellow and blue-to-orange

Phaser 850 only

3 - 84 Phaser 840/850/860/8200 Color Printer - Service Manual

Xerox 8200, 860, 850, 840 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

List of Tables

List of Figures

General Information

Phaser 840 Printer Overview

Phaser 850 Printer Overview

Phaser 860 Printer Overview

Solid inks

Phaser 840/850 RAM and Printer Capabilities

Memory Considerations Phaser 840/850

Phaser 860 RAM and Printer Capabilities

Memory Considerations Phaser 860

Print Engine Assemblies 840/850/860

Circuit Boards

The printer’s I2C bus

Printhead Maintenance System

Sensor Maps

Combination sensors and their meanings

Media tray type sensing

The Main Board

Front Panel - Phaser 840/850 Printers

Front Panel - Phaser 860

Rear Panel Connections

Phaser 840 printer connectors

Phaser 850 printer connectors

Phaser 860 printer connectors

Rear Panel Status LEDs

DIP Switches

Phaser 840, 850 and 860 Printer Differences

Specifications

Regulatory Specifications

Error Codes and Messages

Phaser 840/850 Rear Panel PS and PE LED Codes

Phaser 860 Power-Up Error Messages and LED Codes

The BIST (Built-In Self Test)

POST (Power On Self Test)

Fault Codes

Troubleshooting

Electrical Interface Problems (RAP) Table

Media and Paper Path Problems (RAP) Table

Print Image Quality Problems (RAP) Table

Macintosh Printing Problems

Network Event Logs

Phaser 850

Phaser 860

Electronics Troubleshooting

System power-up sequence

Phaser 840/850 Customer Mode Power-Up Sequence

Phaser 860 Customer Mode Power-Up Sequence

Inoperative printer problems.

Main Board CPU operation

Verifying print engine operation by printing a built in page.

Verifying power supply operation

Measuring power supply voltages

Inspecting the power supply fuses

Testing motor and solenoid resistances