Xerox 8400 Service Manual

Phaser Color Printer

Service

Manual

8400

Phaser

Service Manual

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.

8400 Color Printer

This Printing: 2004

071-0865-01

Copyright

Copyright © 2004, 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 Unpublished rights reserved under the copyright laws of the United States.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 Other Corporation. PhaserCal

trademarks of Xerox Corporation.

Adobe Birch Brilliant Screens

subsidiaries which may be registered in certain jurisdictions.

Apple Chicago

trademark of Apple Computer Incorporated.

PCL

Windows

Novell and Novell Distributed Print Services

Sun registered trademark of SPARC International, Incorporated. SPARCstation

International, Incorporated, licensed exclusively to Sun Microsystems, Incorporated.

SWOP

UNIX Company Limited.

As an E meets the E U.S. marks.

, The Document Company®, the stylized X®, CentreWare®, infoSMART®, Made For Each

, Phaser®, PhaserSMART®, and the TekColor® icon are registered trademarks of Xerox

Reader®, Illustrator®, PageMaker®, Photoshop®, PostScript®, ATM®, Adobe Garamond®,

, Carta®, Mythos®, Quake®, and Tekton® are registered trademarks and Adobe Jenson™, Adobe

, LaserWriter®, LocalTalk®, Macintosh®, Mac® OS, AppleTalk®, TrueType2®, Apple Chancery®,

, Geneva®, Monaco®, and New York® are registered trademarks, and QuickDraw™ is a

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

and Windows NT® are registered trademarks of Microsoft Corporation.

, NetWare®, NDPS®, NDS®, and Novell Directory Services® are registered trademarks, and IPX™

and Sun Microsystems® are registered trademarks of Sun Microsystems, Incorporated. SPARC® is a

is a registered trademark of SWOP, Inc.

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

NERGY STAR

NERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered

™

, PhaserMatch™, PhaserPort™, PhaserTools™, and the TekColor™ name are

™

technology, and IntelliSelect™ are trademarks of Adobe Systems Incorporated or its

™

are trademarks of Novell, Incorporated.

™

is a trademark of SPARC

partner, Xerox Corporation has determined that this product with an ES Option

This product uses code for SHA-1 written by John Halleck, which is being used with his permission. 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.

User Safety Summary

Terms in manual

Caution

Conditions that can result in damage to the product.

Warning

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

Power source:

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

Operation of product: 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

Warning

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.

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

product

Warning

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.

Service Manual i

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: DANGER high voltage:

Protective ground (earth) terminal:

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

WARNING: 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:

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.

ii Phaser 8400 Color Printer

Do not perform internal service or adjustment of this

Regulatory Specifications

United States

The equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with Xerox' instructions, it may cause interference with radio and television reception or may not function properly due to interference from another device. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

■ Reorient or relocate the receiver (device being interfered with).

■ Increase the separation between the printer and the receiver.

■ Connect the printer into an outlet on a circuit different from that which the

receiver is connected.

■ Route the interface cables on the printer away from the receiver.

■ Consult the dealer, Xerox service, or an experienced radio/television technician

for help.

Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interface cables. A shielded parallel cable can be purchased directly from Xerox at www.xerox.com/office/supplies

Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is also suitable for use in a residential environment based on the levels tested.

In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference; (2) this device must accept any interference received, including interference that may cause undesired operation.

Canada

This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications, ICES-003.

Service Manual iii

Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les limits applicables aux appareils numériques de la classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté par le ministere des Communications du Canada, NMB-003.

European Union

Xerox Corporation declares, under our sole responsibility, that the printer to which this declaration relates is in conformity with the following standards and other normative documents:

Following the provisions of the Low Voltage Directive 73/23/EEC and its amendments:

EN 60950 (IEC 60950) "Safety of Information Technology Equipment including Electrical

Following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:

EN 55022:1998 (CISPR 22)

EN 61000-3-2:2000 (IEC61000-3-2)

EN 61000-3-3:1995 +A1:2001 (IEC61000-3-3)

EN 55024:1997 (CISPR 24)

Business Equipment"

"Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment." Class B.

"Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase)."

"Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A."

"Information technology equipment - Immunity characteristics Limits and methods of measurement. "

CISPR 24 Immunity Phenomena

Electrostatic Discharge IEC 61000-4-2:1995 6 kV Contact, 10 kV Air

Radio-Frequency Electromagnetic Field (radiated)

Fast Burst Transients IEC 61000-4-4:1995 5/50 Tr/Th ns, 5 kHz Rep. Freq

Line Surge IEC 61000-4-5:1995 Combination wave

Radio-Frequency Electromagnetic Field (Conducted)

Line voltage dips IEC 61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz

Basic Standard Test Specification

IEC 61000-4-3:1995 80-1000 MHz, 3 V/m, 80% AM

@1KHz

0.5 kV Signal Lines 1 kV AC Mains

2.0 kV Common mode

2.0 kV Differential mode

IEC 61000-4-6:1996 0.15 - 80 MHz, 3 V, 80% AM

@1kHz

30% dip for 25 cycles @ 50 Hz

iv Phaser 8400 Color Printer

CISPR 24 Immunity Phenomena

Line voltage drop-out IEC 61000-4-11:1994 >95% dropout for 250 cycles

Basic Standard Test Specification

@50Hz

This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment.

A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

Service Manual v

Electrostatic Discharge (ESD) Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs). Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.

■ Immediately before handling any semiconductor components assemblies, drain

the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.

■ After removing a static sensitivity assembly from its anti-static bag, place it on a

grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

■ Do not use freon-propelled chemicals. These can generate electrical charges

sufficient to damage some devices.

■ Do not remove a replacement component or electrical sub-assembly from its

protective package until you are ready to install it.

■ Immediately before removing the protective material from the leads of a

replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

■ Minimize body motions when handling unpacked replacement devices. Motion

such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device.

■ Handle IC’s and EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on

Printed Circuit Boards (PCB’s).

vi Phaser 8400 Color Printer

User Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Regulatory Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Electrostatic Discharge (ESD) Precautions. . . . . . . . . . . . . . . . . . . . . . . . . vi

1 General Information

Printer Introduction and Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Front Panel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

LED indicators: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Front Panel Feature Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Front Panel Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Parts of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Side View with Printer Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Routine Maintenance Items and Consumables . . . . . . . . . . . . . . . . . . . . 1-9

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Physical Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . 1-10

Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2 Theory of Operation

Main Printer Subsystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Process Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Media Path Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transfix System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Drum Maintenance System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Ink Loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Drum Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Paper Pick for Trays 2 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Paper Pick for Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Transfixing and Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Service Manual vii

Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Transfix and Print Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Printer Self-Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Printhead Maintenance Cycle (Eliminate Light Stripes) . . . . . . . 2-34

Paper Preheater Cleaning (Remove Print Smears). . . . . . . . . . . 2-35

Transfix Roller Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Drum Cleaning - Chase Page . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Configuration Card Personality Parameters. . . . . . . . . . . . . . . . . . . . . . 2-36

3 Error Messages and Codes

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Power-Up Error Messages and LED Codes . . . . . . . . . . . . . . . . . . . . . . . 3-2

Jam Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

The BIST (Built-In Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

POST (Power On Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PEST (Print Engine Self Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Code Definition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Code Definitions and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 3-8

3-Digit Jam Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Jam Code Definition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

4 General Troubleshooting

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Hidden Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

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

Check Menu Definition Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Check / Activators Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Check Shafts Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Check Fans Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Check Heaters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Check Paper Path Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Check Drive Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Check Drum Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Check Motors Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Check Misc Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

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

System Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Mechanical Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Miscellaneous Electrical Troubleshooting . . . . . . . . . . . . . . . . . 4-55

Verifying Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . 4-65

Measuring AC Power Supply Voltages. . . . . . . . . . . . . . . . . . . . 4-65

Measuring DC Power Supply Voltages. . . . . . . . . . . . . . . . . . . . 4-66

Ensuring Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

viii Phaser 8400 Color Printer

Testing Motor and Solenoid Resistances . . . . . . . . . . . . . . . . . . 4-69

Paper Path and Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Media-Based Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Paper-Pick Errors - Trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . 4-70

Paper-Pick Errors - Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Preheater and Transfix Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Checking the Process and Media Path Drive. . . . . . . . . . . . . . . . 4-72

Media Skews Passing Through the Paper Path. . . . . . . . . . . . . . 4-72

Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . 4-73

Testing Communications Ports. . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Obtaining Serial Back Channel Trace . . . . . . . . . . . . . . . . . . . . . 4-76

5 Print-Quality Troubleshooting

Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Random Light Stripes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Predominate Light Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Smudges or Smears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Printing Too Light or Too Dark. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Not Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Color is Uneven or Color is Wrong . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Streaks or Lines Down the Print . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Scratches or Marks Parallel to the Long Axis of Printing,

Particularly with Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

White Portion of Print is Colored . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Fuzzy Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Ghosting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Poor Small Text Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Vertical Lines Appear Wavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Oil Streaks on Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Incomplete Image Transfer to Paper. . . . . . . . . . . . . . . . . . . . . . 5-18

Ink Smears on First Printed Side of Duplex Print . . . . . . . . . . . . 5-19

Repeating Print Defects on Print. . . . . . . . . . . . . . . . . . . . . . . . . 5-20

White Stripes (Pinstripes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Wrinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Image is Offset or Cut-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Poor Ink Adhesion, Poor Image Durability . . . . . . . . . . . . . . . . . 5-23

Analyzing Service Test Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Test Print Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

6 Adjustments and Calibrations

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Wiper Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Printer Component Homing Positions and Indicators. . . . . . . . . . 6-4

Wiper Assembly Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Homing the Head Tilt Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Service Manual ix

Homing the Process Gear Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Printer Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Wiper Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Jet Substitution Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Enabling Jet Substitution Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Disabling Jet Substitution Mode . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

7 Cleaning and Maintenance

Service Cleaning Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Pick Roller Cleaning Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

8 Service Parts Disassembly

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Standard Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . 8-2

General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Front Door (Tray 1/MPT) Assembly. . . . . . . . . . . . . . . . . . . . . . . 8-4

Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Front (Control) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Exit Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Ink Loader Assembly and Door . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Imaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly8-10

Printhead Assembly, Right and Left Printhead Restraints . . . . . 8-13

X-Axis Bias Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Printhead Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Media Release Blade Carriage Assembly and Transfix Roller. . . 8-22

Paper Preheater and Deskew Assembly. . . . . . . . . . . . . . . . . . . 8-24

Duplex Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Transfix Load Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Transfix Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

Drum Maintenance Camshaft Assembly . . . . . . . . . . . . . . . . . . 8-31

Drum Maintenance Pivot Plate Assembly . . . . . . . . . . . . . . . . . 8-32

Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Purge Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Paper Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Exit Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

x Phaser 8400 Color Printer

Take Away Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

Pick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Media Tray Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Motors, Gears, Solenoids, Clutches, and Fans . . . . . . . . . . . . . . . . . . . . 8-48

Media Drive Gearbox with Two Clutches and Solenoid. . . . . . . . 8-48

Tray 1 (MPT) Pick Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Process Drive Motor and Gearbox . . . . . . . . . . . . . . . . . . . . . . . 8-50

X-Axis Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Head Tilt Compound Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Wave Amp Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

Drum Heater Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

NVRAM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

9 Parts Lists

Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Motors, Gears, Solenoids, Clutches, and Fans . . . . . . . . . . . . . . 9-10

Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Sensors and Flags (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Xerox Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

10 Wiring Diagrams

Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Right-Side Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Left-Side Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Inside Front Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Inside Top Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Inside Top - printhead Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Appendix

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Media Margin Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Paper Weight Equivalence Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

On-site Printhead Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . A-6

Service Manual xi

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Front Panel Configuration

■ Parts of the Printer

■ Routine Maintenance Items and Consumables

■ Printer Specifications

Section

Printer Introduction and Overview

The Xerox Phaser 8400 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.

To ensure understanding of this product, complete the Xerox Phaser 8400 Color Printer Service Training and self study guide.

Back

Left

Right

Front

s8400-001

1-2 Phaser 8400 Color Printer

Printer Configurations

The Configuration Card holds configuration information that enables or disables built-in features as described below.

Note

Some features are not included as options to a configuration but they are included when you upgrade the configuration.

Printer Configuration

Features 8400B 8400BD 8400N 8400DP 8400DX

Maximum Print Speed 24 24 24 24 24

Memory (Std/Max) 128/

512MB

Hard Drive No No Optional** Optional** Standard

PostScript Fonts 137 137 137 137 137

PCL Fonts 81 81 81 81 81

Japanese Fonts* No No Optional Optional Optional

Job Pipelining No Yes No Yes Yes

Automatic 2-Sided Printing No Standard No Standard Standard

100-Sheet Tray 1(MPT) Standard Standard Standard Standard Standard

525-Sheet Tray 2 Standard Standard Standard Standard Standard

525-Sheet Feeder Tray 3 Optional Optional Optional Optional Standard

525-Sheet Feeder Tray 4 Optional Optional Optional Optional Optional

USB, Parallel Connection Standard Standard Standard Standard Standard

10/100 Ethernet

Connection

*Japanese fonts are provided for applicable countries per special licensing requirements. ** The following features are not included in this configuration: proof print, saved print,

secure print, and collation.

No No Standard Standard Standard

256/

512MB

128/

512MB

256/

512MB

256/

512MB

Service Manual 1-3

Front Panel Configuration

The Front Panel consists of one tricolor LED, a display window and six functional buttons. These buttons navigate the menu system, perform functions, and select modes of operation for the printer.

LED indicators:

■ Green = Ready to Print ■ Flashing Green = Receiving, Processing Data,

■ Flashing Amber = Warning ■ Flashing Red = Error

Printing or Power Saver Mode

Front Panel Feature Descriptions

Phaser 8400

PHASER 8400 READY TO PRINT

Menus

Information Printer Identification Troubleshooting

LED (Power/Status)

Graphic front panel display

Cancel button

Back button

Up Arrow button - scrolls up the menu

system

Down Arrow button - scrolls down the menu

system

OK (select) button

Information button - for additional

explanation or help

s8400-002

1-4 Phaser 8400 Color Printer

Front Panel Shortcuts

■ To access the Service Tools menu:

From anywhere within the menu (not diagnostics): press and hold the Up Arrow button, then press the OK button. You can also press and hold the Cancel button, then press the OK button.

■ To set the front panel language:

Press and hold the Cancel button, then press the Information button.

■ To bypass protected menus:

Press and hold the Cancel button, then press the Back button.

■ To add Jet Substitution Mode to the Print Quality Problems menu:

From the Print Quality Problems menu: press and hold the Up Arrow button, then press the Back button.

Service Manual 1-5

Parts of the Printer

Front View

1. Optional 525-Sheet Tray 4

s8400-003

2. Optional 525-Sheet Tray 3

3. Standard 525-Sheet Tray 2

4. 100-Sheet Multi-Purpose Tray 1

5. Front Panel

6. Exit Cover Release

7. Front Cover Release

8. Exit Cover

9. Ink Loader/Top Cover

10.Legal/A4 Output Tray Extension

Side View with Printer Interfaces

1. Maintenance Kit

1-6 Phaser 8400 Color Printer

2. Waste Tray

3. Power Cord

4. On/Off Switch

5. Parallel Cable Connection

6. USB Connection

7. Configuration Card

8. Ethernet Connection

Electronics Module

The printer’s main electronics and power supply are enclosed in a metal case called the Electronics Module. The rear panel allows access to the Electronics module, RAM, and NVRAM chips. The printer’s hard drive is mounted on the rear panel.

When installing a new electronic module in the printer, the following components need to be transferred from the old board.

1. Hard Drive (optional) 3. Configuration Card (Installed from the

2. Memory (RAM) DIMM 1 and DIMM 2 4. NVRAM

s8400-135

side under the interface cover.)

Service Manual 1-7

Sensors

The following graphic identifies the location of the printer’s sensors.

Exit door sensor

Preheater sensor

Front door sensor

Deskew sensor

Pick sensor (525-sheet feeder)

Strip sensor

Paper exit sensor

Drum temperature sensor

Drum position encoder

Tray paper size sensor board

s8400-198

1-8 Phaser 8400 Color Printer

Routine Maintenance Items and Consumables

Routine Maintenance Items Consumable

1. Maintenance Kit 3. Ink

2. Waste Tray

Routine Maintenance: Consumable:

Extended Maintenance Kit

Startup Maintenance Kit

Waste Tray Empty every 7 Purges

*Consumable capacity is based on 5% coverage per color on plain A4 paper.

30,000 cycles (0-20% coverage) 20,000 (20-100% coverage)

10,000 cycles

Ink 1140 prints per stick*

Service Manual 1-9

Printer Specifications

Physical Dimensions and Clearances

Print Engine Only Value

Width: 422 mm (16.6 in.) find in EIS

Depth: 514 mm (20.24 in.)

Height: 368 mm (14.48 in.)

Weight: 26.8 kg (59 lbs.)

Optional 525-Sheet Feeder Value

Width: 422 mm (16.6 in.)

Depth: 514 mm (20.24 in.)

Height: 132 mm (5.2 in.)

Weight: 5.4 kg (12 lbs.)

Minimum Clearances Supplemental Information

Left side & rear - 102 mm (4 in.) Required for airflow.

Right side - 394 mm (15.5 in.) Required for maintenance kit and waste tray access,

and airflow.

Front - Unrestricted Required for media tray and jam access.

Top - 559 mm (22 in.) printer only Required for inkload and jam access.

Bottom - No obstruction between mounting surface and printer

Min. install width - 711 mm (28 in.) Requires placing printer at an angle to remove waste

Required for airflow.

tray.

A. Absolute Mi nimum

6.0 6.0

4.0

Note: All dimensions in inches

28.0

24.0

Front

B. Recommended Minimum

4.0 15.5

4.0

35.5

1-10 Phaser 8400 Color Printer

Functional Specifications

Characteristic Specification

Printing process Solid-ink

Color medium

Operating Modes and Resolutions

Maximum Operating Printing Speed

First-Print-Out (in seconds, Letter/A4)

Warm-up time: from Off (cold start) from power saver

Yellow, cyan, magenta, and black ink sticks, each shape-coded. The printer uses the subtractive color system to produce the colors red, green, and blue.

Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced (563x400 dpi), High Resolution/Photo (525x2400)

24 ppm

As low as 6 seconds

12 minutes 4 minutes

Electrical Specifications

Characteristic Specification

115 Volt 230 Volt

Primary line voltages 90 - 140 VAC 180 - 264 VAC

Primary line voltage frequency range

Power consumption 1250 W (peak)

Energy Star® 43 W 43 W

47 - 63 Hz 47 - 63 Hz

1250 W (peak) 120 W (idle) 230 W (average during printing)

120 W (idle)

230 W (average during printing)

Environmental Specifications

Nominal Operating Environment

Temperature

Humidity 10% - 80% RH Non-Condensing operating

Service Manual 1-11

C / 50º - 90º F operating

10º - 32

Media and Tray Specifications

Paper Size Paper Type Paper Weight/Media Type

Letter (8.5 x 11 in.) or A4 (210 x 297 mm)

Legal (8.5 x 14 in.)

Executive (7.25 x

10.5 in.) or A5 (148 x 210 mm)

Statement (5.5 x

8.5 in.)

US Folio (8.5 x 13 in.)

A6 (105 x 148 mm)

B5 ISO (176 x 250 mm)

B5 JIS (182 x 257 mm)

Index Cards (3 x 5in.)

Plain Paper or Letterhead

Transparency Phaser Professional Solid Ink

Card Stock

Labels Phaser Color Printing Labels

Special Phaser Professional Solid Ink Business

60–122 g/m 123–220 g/m

Transparencies

100–122 g/m 123–220 g/m

Cards

Phaser Professional Solid Ink High Resolution Photo Paper

Phaser Premium Postcards

Phaser Weatherproof Paper

Phaser Trifold Brochures l l

60–122 g/m

60–122 g/m 123–220 g/m

(16–32 lb. Bond)

(32–59 lb. Bond)

(37–44 lb. Cover)

(44–80 lb. Cover)

(16–32 lb. Bond)

(32–59 lb. Bond)

Any Tray

Tray 1 Only

2-Sided (Duplex)

l l

Single-sided Only

1-12 Phaser 8400 Color Printer

Paper Size Paper Type Paper Weight/Media Type

Custom NOTE: Print custom size media from Tray 1 only.

Maximum: 216 mm wide x 355 mm long (8.5 in. wide x 14 in. long)

Minimum: 75 mm wide x 127 mm long (3 in. wide x 5 in. long)

Minimum: 139.7 mm wide x 210 mm long (5.5 in. wide x 8.3 in. long)

Envelopes Any Tray #10 Commercial (4.12 x 9.5 in.)

Tray 1 Only #5-1/2 (Baronial 4.375 x 5.75 in.)

NOTE: Some wrinkling and embossing may occur when printing envelopes. See “Printing” on

the User Documentation CD-ROM for information on how to minimize these occurrences.

NOTE: 2-sided printing can only be used for paper with widths greater than 5.5 in. (139.7 mm)

and lengths greater than 8.3 in. (210.82 mm).

DL (110 x 220 mm) C5 (162 x 229 mm)

#6-3/4 (3.625 x 6.5 in.) Monarch (3.87 x 7.5 in.) Brochure (6 x 9 in.) A7 (5.25 x 7.25 in.) Choukei 3 Gou (120 x 235 mm) Choukei 4 Gou (90 x 205 mm)

Any Tray

l ll

l l

l l l

l l l l l l l

Tray 1 Only

2-Sided (Duplex)

Single-sided Only

l l l

l l l l l l l

Service Manual 1-13

1-14 Phaser 8400 Color Printer

+ 322 hidden pages