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.
Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter
granted, including wit hout limit ation, mate rial gene rated from th e software pr ograms which are di splayed on the scr een such as styl es, template s, icons, scree n
displays, looks, etc.
Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service par tne rs onl y and are not for
resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation.
XEROX®, The Document Company®, the digital X®, CentreWare®, infoSMA RT®, Made For Each Other®, PagePack™, Phaser®, PhaserSMART®, and
™
Walk-Up
Acrobat
Garamond
are trademarks of Xer ox Corporation in the Unit ed States and/or other countrie s.
iiPhaser 8400/8500/8550/8560 Color Printer Service Manual
Service Terms
Not
W
Manual Terms
Various terms are used throughout this manual to either provide additional
information on a specific topic or to warn of possible danger present during a
procedure or action. Be aware of all symbols and terms when they are used,
and always read Note, Caution, and Warning statements.
Common Acronyms:
The following list defines the acronyms that may be found in this manual.
ADC: Automatic Density ControlMCU: Engine Control Board
BTR: Bias Transfer RollerNCS: Non-Contact Sensor
CRUM: Customer Replaceable Unit
Monitor
CTD: Toner Density ControlPL: Corresponds to the FRU Parts List.
ESD: Electrostatic DischargeROS: Laser Scanning Unit
IDT: Intermediate Transfer UnitRTC: Charge Roller
PHD: Imaging Unit
Product Terms
e
A note indicates an operating or maintenance procedure, practice or
condition that is necessary to efficiently accomplish a task.
A note can provide additional information related to a specific subject or
add a comment on the results achieved through a previous action.
Caution
A caution indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in damage to, or destruction
of, equipment.
arning
A warning indicates an operating or maintenance procedure, practice or
condition that, if not strictly observed, results in injury or loss of life.
Caution: A personal injury hazard exists that may not be apparent. For
example, a panel may cover the hazardous area.
Danger: A personal injury hazard exists in the area where you see the sign.
Phaser 8400/8500/8550/8560 Color Printer Service Manualiii
Symbols Marked on the Product
W
Read and obey all posted warning labels. Throughout the printer, warning
labels are displayed on potentially dangerous components. As you service the
printer, check to make certain that all warning labels remain in place.
Power Safety Precautions
Power Source
For 115 VAC printers, do not apply more than 135 volts RMS between the
supply conductors or between either supply conductor and ground. For 230
VAC printers, do not apply more than 254 volts RMS between the supply
conductors or between either supply conductor and ground. Use only the
specified power cord and connector. This manual assumes that the reader is
a qualified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC
outlet only. If necessary, contact a licensed electrician to install a properly
grounded outlet. If the product loses its ground connection, contact with
conductive parts may cause an electrical shock. A protective ground
connection by way of the grounding conductor in the power cord is essential
for safe operation.
Use caution (or draws attention to a particular component). Refer
to the manual(s) for information.
Hot surface on or in the printer. Use caution to avoid personal
injury.
Disconnecting Power
arning
The power switch does not completely de-energize the printer. You must
also disconnect the power cord from the printer’s AC inlet. Disconnect the
power cord by pulling the plug, not the cord.
Disconnect the power cord in the following cases:
■if the power cord or plug is frayed or otherwise damaged,
■if any liquid or foreign material is spilled into the product,
■if the printer is exposed to any excess moisture,
■if the printer is dropped or damaged,
■if you suspect that the product needs servicing or repair,
■whenever you clean the product.
ivPhaser 8400/8500/8550/8560 Color Printer Service Manual
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 sensitive 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).
Phaser 8400/8500/8550/8560 Color Printer Service Manualv
Service Safety Summary
W
General Guidelines
Warning Labels
For qualified service personnel only: Refer also to the preceding Power Safety
Precautions.
Avoid servicing 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: 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 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.
Read and obey all posted warning labels. Throughout the printer, warning
labels are displayed on potentially dangerous components. As you service the
printer, check to make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning
correctly after you have completed a printer service call. If you bypass an
interlock switch during a service call, use extreme caution when working on or
around the printer.
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug
the power cord from the wall outlet. If you must service the printer with power
applied, be aware of the potential for electrical shock.
arning
Do not touch any electrical component unless you are instructed to do so
by a service procedure.
S7300-02
viPhaser 8400/8500/8550/8560 Color Printer Service Manual
Servicing Mechanical Components
W
W
When servicing mechanical components within the printer, manually rotate
drive assemblies, rollers, and gears.
arning
Do not try to manually rotate or manually stop the drive assemblies while
any printer motor is running.
Servicing Heated Components
arning
This printer uses heat to fuse the image to media. Several components
are heated during operation. Turn the printer power off and wait at least
10 minutes for these components to cool before you attempt to service
the Fuser or adjacent components.
S7300-03
Phaser 8400/8500/8550/8560 Color Printer Service Manualvii
Regulatory Specifications
United States (FCC Regulations)
Xerox has tested this product to electromagnetic emission and immunity
standards. These standards are designed to mitigate interference caused or
received by this product in a typical office environment.
The Phaser 8400/8500/8550/8560 complies with the limits for a Class B
digital device pursuant to Part 15 of the FCC Rules. These limits are designed
to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses, and can radiate radio frequency
energy. If it is not installed and used in accordance with these instructions, it
may cause harmful interference to radio communications. 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 equipment into an outlet on a circuit different from that which
■Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the
user's authority to operate the equipment. To ensure compliance with Part 15
of the FCC rules, use shielded interface cables.
Canada (Regulations)
This Class B digital apparatus comply with Canadian ICES-003.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du
Canada.
the receiver is connected.
viiiPhaser 8400/8500/8550/8560 Color Printer Service Manual
European Union
The CE mark applied to this product symbolizes Xerox’s declaration of
conformity with the following applicable Directives of the European Union as
of the dates indicated:
■January 1, 1995: Low Voltage Directive 73/23/EEC as amended by
■March 9, 1999: Radio & Telecommunications Terminal Equipment
Directive 1999/5/EC
This product, if used properly in accordance with the user's instructions, is
neither dangerous for the consumer nor for the environment.
To ensure compliance with European Union regulations, use shielded
interface cables.
A signed copy of the Declaration of Conformity for this product can be
obtained from Xerox.
Phaser 8400/8500/8550/8560 Color Printer Service Manualix
Manual Organization
The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the
primary document used for repairing, maintaining, and troubleshooting the
printer. Use this manual as your primary resource for understanding the
operational characteristics of the printer and all available options. This manual
describes specifications, theory, and the diagnosis and repair of problems
occurring in the print engine and attached options. Also included are detailed
replacement procedures, parts lists, and wiring diagrams.
The Phaser 8400/8500/8550/8560 Color Printer Service Manual contains
these sections:
Introductory, Safety, and Regulatory Information: This section contains important
safety information and regulatory requirements.
Section 1 - General Information: This section contains an overview of the
printer’s operation, configuration, specifications, and consumables.
Section 2 - Theory of Operation: This section contains detailed functional
information on print engine components.
Section 3 - Error Codes and Messages: This section provides detailed
troubleshooting procedures for error messages and codes generated by
resident diagnostics.
Section 4 - General Troubleshooting: Troubleshooting discussions cover the
operation of Power On Self Test (POST), Service Diagnostics, In addition, this
section includes troubleshooting methods for situations where no error
indicator is available.
Section 5 - Print-Quality Troubleshooting: This section focuses on techniques to
correct image quality problems associated with printer output.
Section 6 - Adjustments and Calibrations: This section provides procedures for
the adjustment of print engine components.
Section 7 - Cleaning and Maintenance: This section provides periodic cleaning
procedures for the printer.
Section 8 - Service Parts Disassembly:
procedures for spare parts listed in the Parts List. A replacement procedure is
included when necessary.
Section 9 - Parts List: This section contains exploded views of the print engine
and option FRUs, as well as part numbers for orderable parts.
Section 10 - Wiring Diagrams: This section contains the plug/jack locations and
the wiring diagrams for the print engine.
Appendix A - Reference: This section provides an illustration of the printer’s
menu structure, a listing of printer status codes, and a list of Service
Diagnostics tests.
This section contains removal
xPhaser 8400/8500/8550/8560 Color Printer Service Manual
* 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.
Phaser 8400/8500/8550/8560 Color Printer Service Manual1-3
General Information
Phaser 8500/8550 Printer Configurations
Phaser Features8500N8500DN8550DP8550DT8550DX
Maximum Print Speed24ppm24ppm30ppm30ppm30ppm
Memory 128 MB 128 MB256 MB256 MB512 MB
Hard DriveOptional*Optional*Optional* Optional*Standard
USB ConnectionStandardStandardStandardStandardStandard
Ethernet ConnectionYesYesYesYesYes
* The following features are included with the Phaser 8500/8550 printers with a hard drive: proof
print, saved print, secure print, personal print, and font storage.
Phaser 8560 Printer Configurations
Phaser Features8560N8560DN8560DT8560DX
Maximum Print Speed30 ppm30 ppm30 ppm30ppm
Memory256 MB 256 MB512 MB512 MB
Hard DriveOptional*Optional*Optional*Standard
PostScript Fonts137137137137
PCL Fonts81818181
Job PipeliningNoNoYesYes
Automatic 2-Sided
NoYesYesYes
Printing
100-Sheet Tray 1StandardStandardStandardStandard
525-Sheet Tray 2StandardStandardStandardStandard
525-Sheet Feeder Tray 3NoNoYesYes
525-Sheet Feeder Tray 4NoNoNoYes
USB ConnectionStandardStandardStandardStandard
Ethernet ConnectionYesYesYesYes
* The following features are included with the Phaser 8560 printers with a hard drive: proof print,
saved print, secure print, personal print, and font storage.
1-4Phaser 8400/8500/8550/8560 Color Printer Service Manual
Control Panel Configuration
The Control 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
General Information
■ Green = Ready to Print■ Flashing Green = Receiving, Processing Data,
■ Flashing Amber = Warning ■ Flashing Red = Error
Control Panel Feature Descriptions
1
1
Status Indicator LED:
Green: Ready to print.
Yellow: Warning condition,
printer continues to print.
Red: Startup sequence or error
condition.
Blinking: Printer is busy or
warming up.
Phaser 8500
READY TO PRINT
Walk-Up Features
Information
Paper Tray Setup
Printer Setup
Troubleshooting
2
Printing or Power Saver Mode
5
3
6
4
8
7
5Up Arrow button
Scrolls upward through the menus.
s8500-003
Graphic display indicates status
2
messages and menus.
6Down Arrow button
Scrolls downward through the
menus.
3Cancel button
Cancels the current print job.
4Back button
Returns to the previous menu
item.
7OK button
Accepts the selected setting.
8Help (?) or Information button
Displays a help message with
information about the printer, such
as printer status, error messages,
and maintenance information.
Phaser 8400/8500/8550/8560 Color Printer Service Manual1-5
General Information
Menu Maps
Control Panel Shortcuts
The Customer Menu Map helps you navigate the Control Panel menus. The
Menu Map’s are provided in the Reference section of this manual, see
page A-2.
To print the Menu Map:
1. On the Control Panel, select Information, and then press the OK button.
2. Select Menu Map, and then press the OK button to print.
The service diagnostic menu map is detailed in Section 4, see “Service
Diagnostics” on page 4-4 for more information.
Mode or MenuShortcut
Service Tools MenuFrom any menu, press and hold the Up Arrow, and then
press OK.
Hidden Service
Menu
Service (Internal)
Diagnostics
Set Control Panel
language
Bypass protected
menus
Jet Substitution
Mode
FTTR (Fast Time To
Ready)
From the Service Tools menu, press and hold the Up Arrow,
and then press the Down Arrow.
(Phaser 8400) Hold the Back and Info button at power up
(for about 30 seconds).
(Phaser 8500/8550/8560) Wait until Control Panel screen
turns black, and then press and hold Back and Help buttons
until the message “Beginning Service Mode” displays.
Press and hold the Cancel button, and then press the Help
button.
Press and hold the Cancel button, and then press the Back
button.
(Phaser 8400 only) To add Jet Substitution Mode to the Print
Quality Problems menu:
From the Print Quality Problems menu: press and hold the Up
Arrow button, and then press the Back button.
Phaser 8500/8550/8560 have Jet Substitution in the main
menu system (under Eliminate Light Stripes).
Printer goes to the ready state without waiting for thermal
temperatures to reach the proper operating values. On powerup, when the Xerox splash screen displays, press and release
the Up Arrow button, then press the Down Arrow button. If
the printer detects ink on the drum, the display indicates a
warming-up status.
1-6Phaser 8400/8500/8550/8560 Color Printer Service Manual
Parts of the Printer
Front View
General Information
This section shows the main external components of the printer, including
interfaces, the electronics module, and the internal sensors.
9
8
7
6
5
4
3
2
1
10
s8500-004
1. Optional 525-Sheet Feeder Tray 4
2. Optional 525-Sheet Feeder Tray 3
3. Tray 2
4.100-Sheet Tray 1 (MPT)
5. Control Panel
6. Exit Cover release
7. Front Door release
11
8. Exit Cover
9. Ink Loader/top cover
10.Legal/A4 output tray extension
11.Interface cover
12
12.Side Door
Right Side View with Printer Interfaces
4
1
Phaser 8400/8500/8550/8560 Color Printer Service Manual1-7
3
2
5
6
7
8
s8500-005
1. Maintenance kit
2. Waste Tray
3. Power Cord connection
4. Power switch
5. Parallel connection (8400 series only)
6. USB connection
7. Configuration Card
8. Ethernet 10/100 Base-T connection
General Information
Rear View
The rear view consists of the printer’s main electronics and power supply,
which are enclosed in a metal case called the Electronics Module. The rear
panel allows access to the Electronics Module, RAM, and NVRAM. The
printer’s Hard Drive is also mounted on the rear panel.
When installing a new electronic module in the printer, the following
components need to be transferred from the old board.
2
4
1
3
1
s8500-006
1. Hard Drive (optional)3. Configuration Card (Installed from
the side under the interface cover.)
2. Memory (RAM) DIMM 1 and DIMM 2 4.NVRAM (Configuration Card
handles NVRAM differences
between models).
1-8Phaser 8400/8500/8550/8560 Color Printer Service Manual
Routine Maintenance Items and Consumables
Not
3
Routine Maintenance ItemsConsumable
General Information
1
2
3
4
2
1
s8500-007
1. Drum Maintenance Kit3. Ink
2. Waste tray
Drum Maintenance Kit life expectancy depends on the kit capacity. For
example, the standard-capacity kits produce 10,000 prints regardless of the
colors used. Extended-capacity Drum Maintenance Kits for 8400 and 8550/
8560 models produce 30,000 pages up to 20% coverage and 20,000 pages
when coverage exceeds 20%. Phaser 8500 models do not support the 8550/
8560 extended-capacity kit
*Consumable capacity is based on 5% coverage per color on plain A4 paper.
e
Phaser 8500 models support only the standard-capacity Drum
Maintenance Kit. Phaser 8400 and 8550/8560 models support both the
standard- and extended-capacity kits. Phaser 8400 kits and Phaser 8500/
8550/8560 kits are not interchangeable.
Phaser 8400/8500/8550/8560 Color Printer Service Manual1-9
General Information
Printer Specifications
Physical Dimensions and Clearances
Print Engine OnlyValue
Width:422 mm (16.6 in.)
Depth: 514 mm (20.24 in.)
Height:368 mm (14.48 in.)
Weight: 26.8 kg (59 lb.)
Optional 525-Sheet FeederValue
Width:422 mm (16.6 in.)
Depth: 514 mm (20.24 in.)
Height:132 mm (5.2 in.)
Weight: 5.4 kg (12 lb.)
Minimum ClearancesSupplemental Information
Left side and 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 - UnrestrictedRequired for media tray and jam access.
Top - 559 mm (22 in.) printer onlyRequired 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
Required for airflow.
waste tray.
1-10Phaser 8400/8500/8550/8560 Color Printer Service Manual
Not
Print Engine OnlyValue
General Information
10 cm
20 cm
(7.5 in.)
(4 in.)
56 cm
(22 in.)
10 cm
(4 in.)
40 cm
(15.5 in.)
60 cm
(24 in.)
60 cm
(24 in.)
e
Check that the printer is on a stable, non-vibrating suface. Advise the
customer to use care not to shake the printer excessively when loading
media or closing the Front Door. During operation, the ink is in liquid form
an can spill from the Printhead reservoir resulting in output defects.
90 cm
(35 in.)
s8500-141
Phaser 8400/8500/8550/8560 Color Printer Service Manual1-11
General Information
Functional Specifications
CharacteristicSpecification
Printing ProcessSolid-ink
Color Medium
Operating Modes and
Resolutions
Maximum Operating
Printing Speed
First-Print-Out
(Letter/A4)
Warm-Up Time:
From Off (cold start)
From Power Saver
Electrical Specifications
CharacteristicSpecification
Yellow, cyan, magenta, and black ink sticks, each shapecoded. The printer uses the subtractive color system to
produce the colors red, green, and blue.
(8400)
Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced
(563x400 dpi), High Resolution/Photo (525x2400)
(8500/8550/8560)
Fast Color (225x400 dpi), Standard (300x450 dpi), Enhanced
(525x400 dpi), High Resolution/Photo (525x2400)
24 ppm (8400 and 8500 series)
30 ppm (8550 series)