Xerox 8560, 8550, 8500 Service Manual

Download

Page 1

Service Manual

701P27910

Phaser® 8400/8500/8550/8560

Color Printer

Page 2

Page 3

Service Manual

701P27910

Phaser®8400/8500/8550/8560

Color Printer

First Printing: January 2007

arning

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.

Page 4

Prepared By:

Xerox Corporation

XOG Worldwide Product Training and Information

26600 SW Parkway

Wilsonville, OR 97070

Copyright © 2007 Xerox C orporation. All Rights Reserved. Unpublished righ ts re served under the copyrigh t law s of th e U nited States. Cont ents of this publication may not be repro duc ed in any form without permission of X erox 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 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.

, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator®, PageMaker®, Photoshop®, PostScript®, Adobe Brilliant® Screens, Adobe

, Adobe Jenson™, Birch®, Carta®, IntelliSe lect®, Mythos®, Quake®, and Tekton® are trademarks of Adob e S ystems Incorporated in the United

States and/or other countries.

Apple

, AppleTalk®, Bonjour®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®, Chicago®, Geneva®,

Monaco HP-GL IBM Windows Novell

, New York® , and QuickDraw® are trademarks of A ppl e Computer, Inc. in the Unit ed States and/or other countries.

, HP-UX®, and PCL®are trademarks of Hewlet t-Packard Corporatio n in the Un it ed States and/or other countries.

and AIX® are trademarks of International Business Machines Corporation in the United States and/or other countries.

, Vista™, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation in the United States and /o r oth er c ountries.

, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™, and Novell Distributed Print Services™are trademar ks of N ovell, Incorporat ed in

the United States and/or other countries.

, Sun Microsystems™, and Solaris™ are trademarks of S un Microsystems, Incorporated in t h e U nited States and/or other countries.

Sun

SWOP

is a trademark of SWOP, Inc.

is a trademark in the U nited States and other countries, licensed exclusively through X/Open Com pany Limited.

UNIX As an E

NERGY STAR

TAR name and logo are re gistered U.S. marks.

partner, Xerox Corporation has determi n e d tha t t his product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY

PANTONE

Colors generated may not match PANTONE-identified standards. Consult c urre nt PANTONE Publications for accurate colo r. PANTONE® and

other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.

ii Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 5

Service Terms

Not

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 Control MCU: Engine Control Board BTR: Bias Transfer Roller NCS: Non-Contact Sensor CRUM: Customer Replaceable Unit

Monitor CTD: Toner Density Control PL: Corresponds to the FRU Parts List. ESD: Electrostatic Discharge ROS: Laser Scanning Unit IDT: Intermediate Transfer Unit RTC: Charge Roller

PHD: Imaging Unit

Product Terms

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 Manual iii

Page 6

Symbols Marked on the Product

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.

iv Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 7

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 Manual v

Page 8

Service Safety Summary

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.

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

vi Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 9

Servicing Mechanical Components

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 Manual vii

Page 10

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.

viii Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 11

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

93/68/EEC

■ January 1, 1996: Electromagnetic Compatibility Directive 89/336/EEC

■ 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 Manual ix

Page 12

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

x Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 13

Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

1 General Information

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

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

Control Panel Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Control Panel Feature Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Menu Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Control Panel Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Parts of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Right Side View with Printer Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

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

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

Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Media and Tray Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Contents

2 Theory of Operation

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

Printer Subsystem Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Process Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Media Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Ink Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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

Drum Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Purge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Drum Assembly And Transfix System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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

Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Paper Pick for Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

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

Transfixing and Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Duplex Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Transfix and Print Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Phaser 8400/8500/8550/8560 Color Printer Service Manual xi

Page 14

Contents

Printer Self-Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Printhead Maintenance Cycle (Eliminate Light Stripes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Paper Preheater Cleaning (Remove Print Smears) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Transfix Roller Oiling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Drum Cleaning - Chase Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Configuration Card Personality Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

3 Error Messages and Codes

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

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

BIST Error Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

POST Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

PEST Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Fault Code Error Message Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Fault Code Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

1,000.4x Errors - 525-Sheet Feeder Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

1,0XX.6x Errors - 525-Sheet Feeder Program Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

2,0XX.4x Errors - I/O Circuit Board Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

2,0XX.6x Errors - I/O Board Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3,0XX.6x Errors - IPC Program Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4,0XX.4x Errors - Process Control System Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4,0XX.6x Errors - Process Control Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

5,0XX.4x Errors - Y-Axis Sub-System Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

5,0XX.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

6,0XX.4x Errors - X-Axis Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

6,0XX.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

7,0XX.4x Errors - Process Motor Gearbox Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

7,0XX.4x Errors- Printhead Tilt Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

7,0XX.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

8,0XX.xx Errors - Wiper/Media Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

8,0XX.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

9,0XX.xx Errors - Ink Loader Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

9,009.44 and 9,00X.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

11,0XX.xx Errors - Electronics Module Interface Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

11,100.60 Errors - Temperature Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

12,000.60 Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

13,0XX.xx Errors - Thermal Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

13,000.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

19,0XX.xx Errors - Printhead Calibration faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

19,0XX.6x Errors - Waveform Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

21,000.69 Errors - Diagnostic Code Version Mismatch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

22,0XX.6x Errors - Jam Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

23,0XX.6x Errors - NVRAM Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

26,0XX.6x Errors - Printing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

26,962.6x Errors - “Fall Out” Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

27,0XX.6x Errors - Profile Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

29,0XX.6x Errors - Jam Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

31,0XX.4x Errors - Mechanical Initialization Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

31,0XX.6x Errors - Program Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

33,0XX.xx Errors - Tray Manager Device Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

34,0XX.xx Errors - Printhead NVRAM Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

36,000.40 Errors - Drum Maintenance Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

36,001.67 Errors - Drum Maintenance Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

36,002.44 Errors - Drum Maintenance Program Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

37,0XX.xx Errors - PEST Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

xii Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 15

Jam Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Jam Code Definition Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Check Menu Definition Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Check / Activators Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Check Shafts Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Check Paper Path Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Check Drive Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

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

Check Motors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Check Misc Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

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

Printer Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Miscellaneous Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Verifying Power Supply Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Measuring AC Power Supply Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

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

Ensuring Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Testing Motor and Solenoid Resistances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Paper Path and Media-Based Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Pick Errors - Trays 2, 3, and 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Paper-Pick Errors - Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Preheater and Transfix Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Checking the Process and Media Path Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Media Skews Passing Through the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

Operating System and Application Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Testing Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Obtaining Serial Back Channel Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

Obtaining a Back Channel Trace with USB to Serial Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74

Contents

Phaser 8400/8500/8550/8560 Color Printer Service Manual xiii

Page 16

Contents

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

Print Too Light or Too Dark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Color is Uneven or Wrong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Streaks or Lines Down the Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Film . . . . . . . . . . . . . . . . . . . . . 5-13

Ink on White Portion of Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Fuzzy Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Poor Primary Color Fills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Poor Small Text Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Vertical Lines Appear Wavy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Oil Streaks on Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Incomplete Image Transfer to Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Ink Smears on First Printed Side of Auto-Duplex Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Repeating Defects on Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

White Stripes (Pinstripes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Wrinkling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Image Is Offset or Cut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Poor Ink Adhesion, Poor Image Durability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Analyzing Service Test Prints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Weak/Missing Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

X-Axis Motion (8400 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Color Bands, RGBK Dither. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Reverse Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Big Bands OHP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Gray Fill, Dot Size Uniformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

YMCKRGB Solid Fills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Primary Solid Fills 10x. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Head-to-Drum Gap (8400 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

Manuf. Skew Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Cleaning Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Other Test and Specialty Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

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

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

Timing the Drum Maintenance Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Jet Substitution Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Enabling Jet Substitution Mode (8400). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Enabling Jet Substitution Mode (8500/8550/8560). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Disabling Jet Substitution Mode (8400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Disabling Jet Substitution Mode (8500/8550/8560) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

xiv Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 17

7 Cleaning and Maintenance

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

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Pick Roller Cleaning Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Drum Maintenance Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Waste Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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 Assembly (PL1.0.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Control Panel Cover (PL1.0.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Control Panel (PL1.0.6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Right Side Cover (PL1.0.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Left Side Cover (PL1.0.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Exit Cover (PL1.0.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Ink Loader (PL1.0.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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

Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Printhead, Right and Left Printhead Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Head Tilt Solenoid (PL4.0.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

X-Axis Bias Spring (PL2.0.19). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Wiper Assembly (PL2.0.17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Stripper Carriage (PL2.0.12) and Transfix Roller (PL2.0.13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Preheater (PL2.0.17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Duplex Roller (PL3.0.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Transfix Load Module (PL2.0.15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

Transfix Camshaft (PL2.0.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Drum Maintenance Camshaft (PL2.0.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Drum Maintenance Pivot Plate (PL2.0.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Drum Assembly (PL2.0.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Purge Pump (PL2.0.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

Exit Module (PL3.0.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

Inner Simplex Guide (PL3.0.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Lower Inner Duplex Guide (PL3.0.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Lower Exit-Guide Assembly with Strip Flag (PL3.0.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Outer Duplex Guide With Safety Interlocks (PL3.0.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Upper Duplex Guide with Solenoid (PL3.0.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Take Away Roller (PL3.0.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Pick Assembly (PL3.0.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Tray Lift Motor and Gear (PL4.0.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Motors, Gears, Solenoids, Clutches, and Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Media Drive with Two Clutches and Solenoid (PL4.0.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Tray 1 Pick Solenoid (PL4.0.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Preheater Lift Solenoid (PL4.0.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Process Drive (PL4.0.14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

X-Axis Motor (PL4.0.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

Head Tilt Gear (PL4.0.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Contents

Phaser 8400/8500/8550/8560 Color Printer Service Manual xv

Page 18

Contents

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Electronics Module (PL5.0.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

Wave Amplifier (PL5.0.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

I/O Board (PL5.0.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Drum Heater Relay Board (PL5.0.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

NVRAM (PL5.0.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

DIMM Memory (PL5.0.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51

Hard Drive (PL5.0.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

9 Parts Lists

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

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

PL 1.0 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

PL 2.0 Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

PL 3.0 Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

PL 4.0 Motors, Gears, Solenoids, Clutches, and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

PL 5.0 Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

PL 6.0 Sensors and Flags (Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

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

10 Wiring Diagrams

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

Main Wiring Diagram (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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

Right-Side Wiring Diagram (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

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

Left-Side Wiring Diagram (Continued). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

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

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

Inside Top - Printhead Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Reference

Menu Map (8400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Menu Map (8500/8550/8560) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Media Margin Specification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Paper Weight Equivalence Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

On-site Printhead Troubleshooting Checklist (8400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Ink Failure Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12

On-site Printhead Troubleshooting Checklist (8500/8550/8560). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

Index

xvi Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 19

General Information

In this chapter...

■ Printer Introduction and Overview

■ Printer Configurations

■ Control Panel Configuration

■ Parts of the Printer

■ Routine Maintenance Items and Consumables

■ Printer Specifications

Chapter

Page 20

General Information

Printer Introduction and Overview

The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.

To ensure understanding of this product, complete the Phaser 8400/8500/ 8550/8560 Service Training and self-study guide.

Back

Left

Front

Right

s8500-002

1-2 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 21

Printer Configurations

General Information

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

Phaser 8400 Printer Configurations

Features 8400B 8400BD 8400N 8400DP 8400DX

Maximum Print Speed 24 24 24 24 24

Memory 128 MB 256 MB 128 MB 256 MB 256 MB

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

No Standard No Standard Standard

Printing

100-Sheet Tray 1 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

Ethernet Connection No No Standard Standard Standard

* 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 Manual 1-3

Page 22

General Information

Phaser 8500/8550 Printer Configurations

Phaser Features 8500N 8500DN 8550DP 8550DT 8550DX

Maximum Print Speed 24ppm 24ppm 30ppm 30ppm 30ppm

Memory 128 MB 128 MB 256 MB 256 MB 512 MB

Hard Drive Optional* Optional* Optional* Optional* Standard

PostScript Fonts 137 137 137 137 137

PCL Fonts 81 81 81 81 81

Job Pipelining No No Yes Yes Yes

Automatic 2-Sided

No Yes Yes Yes Yes

Printing

100-Sheet Tray 1 Standard Standard Standard Standard Standard

525-Sheet Tray 2 Standard Standard Standard Standard Standard

525-Sheet Feeder Tray 3 No No No Yes Yes

525-Sheet Feeder Tray 4 No No No No Yes

USB Connection Standard Standard Standard Standard Standard

Ethernet Connection Yes Yes Yes Yes Yes

* 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 Features 8560N 8560DN 8560DT 8560DX

Maximum Print Speed 30 ppm 30 ppm 30 ppm 30ppm

Memory 256 MB 256 MB 512 MB 512 MB

Hard Drive Optional* Optional* Optional* Standard

PostScript Fonts 137 137 137 137

PCL Fonts 81 81 81 81

Job Pipelining No No Yes Yes

Automatic 2-Sided

No Yes Yes Yes

Printing

100-Sheet Tray 1 Standard Standard Standard Standard

525-Sheet Tray 2 Standard Standard Standard Standard

525-Sheet Feeder Tray 3 No No Yes Yes

525-Sheet Feeder Tray 4 No No No Yes

USB Connection Standard Standard Standard Standard

Ethernet Connection Yes Yes Yes Yes

* 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.

1-4 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 23

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

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

Printing or Power Saver Mode

5 Up Arrow button

Scrolls upward through the menus.

s8500-003

Graphic display indicates status

messages and menus.

6 Down Arrow button

Scrolls downward through the menus.

3 Cancel button

Cancels the current print job.

4 Back button

Returns to the previous menu item.

7 OK button

Accepts the selected setting.

8 Help (?) 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 Manual 1-5

Page 24

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 Menu Shortcut

Service Tools Menu From 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.

1-6 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 25

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.

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

8. Exit Cover

9. Ink Loader/top cover

10.Legal/A4 output tray extension

11.Interface cover

12.Side Door

Right Side View with Printer Interfaces

Phaser 8400/8500/8550/8560 Color Printer Service Manual 1-7

5 6

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

Page 26

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.

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).

1-8 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 27

Routine Maintenance Items and Consumables

Not

Routine Maintenance Items Consumable

General Information

s8500-007

1. Drum Maintenance Kit 3. 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

Routine Maintenance: Consumable:

Extended Drum Maintenance Kit (8400, 8550/8560)

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

Ink (8400) 1140

prints per stick* (8500/8550/

8560) 1080 prints per stick*

Standard Drum Maintenance Kit

10,000 prints (8400/

8560). 5500 color, 10,000 B/W prints (8500/8550).

Waste Tray Empty every 7 purges.

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

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 Manual 1-9

Page 28

General Information

Printer Specifications

Physical Dimensions and Clearances

Print Engine Only Value

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 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 lb.)

Minimum Clearances Supplemental 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 - 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

Required for airflow.

waste tray.

1-10 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 29

Not

Print Engine Only Value

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.)

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 Manual 1-11

Page 30

General Information

Functional Specifications

Characteristic Specification

Printing Process Solid-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

Characteristic Specification

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)

As low as 6 seconds

12 minutes (8400), 15 minutes (8500/8550/8560) 4 minutes

Primary line voltages 90 - 140 VAC 180 - 264 VAC

Primary line voltage frequency range

Power consumption 1250 W (peak) - 1000 typical

Energy Star® 43 W 43 W

Environmental Specifications

Nominal Operating Environment

Temperature 10º - 32º C (50º - 90º F) operating

Humidity 10% - 80% RH Non-Condensing operating

115 Volt 230 Volt

47 - 63 Hz 47 - 63 Hz

1250 W (peak) 1000 typical 180 W (idle) 230 W (average during printing)

20º - 25º C (68º - 77º F) Best jam performance

180 W (idle)

230 W (average during

printing)

1-12 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 31

Media and Tray Specifications

General Information

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.)

Plain Paper or Letterhead

Transparency Phaser Professional Solid Ink

Card Stock

Labels Phaser Color Printing Labels l l

Special Phaser Professional Solid Ink

60–120 g/m2 (16–32 lb. Bond) 121–220 g/m2 (32–59 lb. Bond)

Transparencies

100–120 g/m2 (37–44 lb. Cover) 121–220 g/m2 (44–80 lb. Cover)

Business Cards

Phaser Professional Solid Ink High Resolution Photo Paper

Phaser Premium Postcards l l

Phaser Weatherproof Paper l l

Phaser Trifold Brochures l l

60–120 g/m2 (16–32 lb. Bond)

Any Tray

Tray 1 Only

l l

2-Sided (Duplex)

Single-sided Only

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 5 in.)

Phaser 8400/8500/8550/8560 Color Printer Service Manual 1-13

60–120 g/m2 (16–32 lb. Bond) 121–220 g/m2 (32–59 lb. Bond)

60–120 g/m2 (16–32 lb. Bond)

l l

Page 32

General Information

Paper Size Paper Type Paper Weight/Media Type

Custom

NOTE Print custom size media from Tray 1 only.

Maximum: 216 mm wide x 355

Any Tray

Tray 1 Only

l l l

2-Sided (Duplex)

mm long (8.5 in. wide x 14 in. long)

Minimum: 75 mm wide x 127 mm

l l

long (3 in. wide x 5 in. long)

Minimum: 139.7 mm wide x 210

l l mm long (5.5 in. wide x 8.3 in. long)

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

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

Tray 1 On l y #5-1/2 (Baronial 4.375 x 5.75 in.)

#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)

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).

l l l

Single-sided Only

l l l

l l l l l l l

1-14 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 33

Theory of Operation

In this chapter...

■ Main Printer Subsystems

■ Print Process

■ Printer Self-Maintenance

■ Configuration Card Personality Parameters

Chapter

Page 34

Theory of Operation

Main Printer Subsystems

Preheater

Transfix System

Drum

Drum Maintenance Kit

Wiper Assembly

Ink Loader

Printhead

Electronics Module

Hard Drive

Configuration Card

Waste Tray

Wave Amp

s8500-008

Printer Subsystem Overview

The printer is made up of eight major subsystems, which are described in this section:

■ Process Drive

■ Media Drive

■ Ink Loader

■ Printhead

■ Drum Maintenance Kit

■ Purge System

■ Drum Assembly and Transfix Assembly

■ Electronics Module

The Process Drive:

controls the Transfix Roller loading, and the Drum Maintenance Camshaft actuates the Drum Maintenance Kit and Printhead tilt system.

The Media Drive: Controls each roller in the media transport path. The Media

Drive consists of a drive motor, a gearbox, two clutches, and a solenoid. The Media Drive motor also controls the movement of the Wiper Blade and headlock mechanism through a gear train and solenoid on the Exit Module.

Transmits torque to two camshafts. The Transfix Camshaft

2-2 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 35

Theory of Operation

The Ink Loader: Stores and melts the ink. The melted ink drops into the

Printhead ink reservoirs underneath the ink loader.

The Printhead: Delivers ink onto the drum surface to create an image. The

Printhead includes 1236 interleaved jets (309 of each primary color) to provide the ability to electronically turn off a weak or missing jet to restore image quality.

The Drum Maintenance Kit: Creates a thin layer of silicone oil on the surface of

the Drum prior to printing. The oil keeps the ink from sticking to the Drum’s surface and facilitates image transfer to the media.

The Purge System: Uses air pressure and a wiper blade to remove any debris

or air bubbles that may be obstructing the Printhead nozzles.

The Drum Assembly and Transfix System: Form the key portion of where

imaging takes place. The image is first printed as a "mirror" image on the rotating Drum. A sheet of warmed media feeds from the Preheater and passes between the Drum and the Transfix Roller. The Process Drive gear train then loads the Transfix Module and presses the media to the Drum to adhere the image as the Drum spins in the transfix direction.

The Electronics System: includes the Electronics Module (also known as the E-

can); which contains the main board, the image processor board, the power control board, and the power supply board. Distributed in the print engine are: the Wave Amplifier, I/O board, and Drum Heater Relay Board.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-3

Page 36

Theory of Operation

Process Drive

A small DC servomotor powers the Process Drive gearbox to rotate the gears to specific positions during the printing process. The Process Drive is able to actuate each camshaft system independently through the use of the swing arm in the gear train.

The rotational direction of the motor controls the operation of the transfix and drum maintenance system. When the process motor rotates in one direction, the swing gear engages the lower gears. When the motor rotates in the opposite direction, the upper gears are engaged.

Since the system is open loop, special attention to the home position of the process drive gears and the mating camshaft gears is critical. The Process Drive gearbox is mechanically keyed upon installation via gear orientations. These gear orientations allow the printer subsystems to self-home during operation. If either the gearbox or cam gears is out of home during installation, the printer does not function properly.

Process Drive Swing Gear

Imaging Transfix

Process Motor Gear

Maintenance

Drum Maintenance

Transfix Camshaft

Drum

Camshaft

s8500-009

2-4 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 37

Media Drive

Theory of Operation

The Media Drive assembly drives each roller in the media transport path. A gear train located behind the motor connects it to the Exit Rollers, which are built into the Exit Module. Gear trains located within the Media Drive, along with two clutches and a solenoid, allow the motor to control the Pick, Take Away, Duplex, and Deskew rollers.

A unique swing gear allows the Pick Roller and Take Away Roller to rotate in the same direction regardless of the direction the motor is rotating.

Motor

Media Path Drive

Swing Gear

Duplex Roller

Deskew Roller

Take Away Roller

Pick Roller

s8500-010

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-5

Page 38

Theory of Operation

Ink Loader

The Ink Loader consists of four parallel channels with an ink melting element at the end of each channel. Coil springs exert pressure on four ink sticks to load one unique color in each channel. When the Printhead requires ink, the melting element of the appropriate color melts the end of the ink stick. The melted ink drips into the Printhead ink reservoirs. Sensors in the Ink Loader alert the customer to install more ink sticks before the printer completely consumes the current sticks.

If the ink level sensors inside the Printhead detect that the Printhead has run out of ink, but the ink low/out sensors are not activated, the Control Panel reports an “Ink Jam” error. The Phaser 8400 features a single Ink-Out sensor, which activates when there is no ink stick in any of the four ink channels. This condition activates the sensor flag.

The 8500/8550/8560 features an Ink-Out sensor in each ink stick channel. Each sensor determines if the individual channel is empty. The sensors also determine the count of the ink sticks as they pass by the Ink-Out sensor flag.

Ink Melt Units

Ink Loader Door

Ink Stick

Ink Low Sensor

Ink Out Sensor

Printhead

s8500-011

2-6 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 39

Printhead

Theory of Operation

The Printhead is the heart of the printer, spanning nearly the length of the drum. Using its 1236 jet nozzles (309 jets for each primary color), with a horizontal motion of slightly less than 5 mm (0.2 inches), the Printhead can print the entire image on the rotating drum. The Printhead provides one size ink drop, which is used for all print-quality modes.

Reservoir

Drum

Printhead

Head Driver Board

Purge Tube

Jet Stack

s8500-012

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-7

Page 40

Theory of Operation

Printhead

Ink Loader

Black

Yellow

Level Sense Probe

Funnel Filter

Purge Valve

Ink

Cyan

Magenta

s8500-013

The Printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array. Channels formed by the stacked plates route ink past the 1236 individual, piezo-electric crystal-driven diaphragms, which force the ink in droplets out the 1236 corresponding nozzles. Looking at the Printhead face, the nozzles are arranged in 12 rows, in color order KYKYKYCMCMCM, where K = black, Y = yellow, C = cyan, and M = magenta. During the printing process, the Printhead would only have to travel approximately 14 pixels horizontally to provide complete coverage. However, the Printhead travels much further, depending on print resolution, to interlace each jet with the output of neighboring jets.

The jet array bonds to a cast aluminum ink reservoir, which supplies the molten ink to the jet array. Heaters in the reservoir and the jet array maintain the ink at a printing temperature of about 60 degrees centigrade.

2-8 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 41

Theory of Operation

X-Axis Shaft

X-Axis Hook

Tension Spring

Printhead

X-Axis Shaft

Nose Cone

X-Axis Motor

Gear

Drum

s8500-014

X-Axis or lateral movement of the Printhead is accomplished using a stepper motor driving a fine-thread screw system. The Printhead, mounted to the XAxis shaft, moves laterally across the surface of the drum.

To find the Printhead home position, the X-Axis system drives the Printhead in an open-loop. The Printhead is driven against the left printer frame for a few seconds, and then reversed a set distance. A tension spring links to the Printhead’s left shaft and provides a preloaded tension to allow the Printhead to move smoothly.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-9

Page 42

Theory of Operation

Printhead Tilt

The Printhead is able to rotate into four basic positions:

1. Printhead lock / ship position (19.5 degrees): The Printhead restraint pins

are resting against the right and left locks. In this position, the Printhead tilt arm/follower is free of the tilt cam, and the head is secured for shipping.

2. Wipe position (12 degrees): The Printhead tilt arm/follower is engaged

with the tilt cam, and the head overload spring contact is engaged with the overload spring-plate to provide the correct force for the wiper.

3. Standby position (20.9 degrees): Allows the wiper to clear the Printhead

in order to be in the start wipe Printhead position, and also allow the Printhead locks to pivot and lock or unlock the Printhead. In this position, the Printhead tilt arm/follower is engaged at the standby position of the tilt cam.

4. Print position (0 degrees): The Printhead is forward and resting against

the right and left head-to-drum buttons. The head-to-drum buttons define the space between the jet stack and the drum.

The tilt cam tilts the head into the basic four positions listed above. The cam has five special features and associated functions:

1. The cam is combined with a missing tooth gear that allows the cam to be

inactive in the print position, which frees the process drive to perform other printer operations.

2. The cam has a latching feature to unlatch and latch the missing tooth gear

to engage the Printhead tilt drive train.

3. The cam profile has a standby dwell (the portion of the cam that has a

constant radius), that holds the Printhead back in the standby position.

4. The cam profile has a wipe dwell the holds the Printhead back in the wipe

position.

5. The cam profile increases the power consumption at a specific phase of

rotation. This allows the software to identify a power consumption footprint that alerts the printer to a fault when the head is locked in error.

The Printhead is tilted away from the drum and locked for shipping. The Printhead is locked if the head lock indicator is above the level of the output tray. When the Printhead is locked in the shipping position there are three key restraining elements:

1. The Printhead is restrained from rotating from the shipping position by

pins extending from both ends of the Printhead into a pocket. These pockets are defined by dampening pads that limit motion to the lockarms that pivot into the lock position, limiting forward motion toward the drum. The wiper carriage holds the locks in the lock position, which are normally spring-loaded in the unlocked position.

2. The Printhead is restrained at the X-Axis shafts by the right and left head

restraints that limit motion at both ends of the Printhead.

3. The Printhead is limited to the nominal motion of 1.7 mm in the X-Axis

(left / right side motion when the Printhead is back and locked) by the right lock and the left home stop on the left side frame.

2-10 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 43

DM Cam Gear

Theory of Operation

Printhead Restraint

Drum

Printhead

Tilt Gear (Engaged)

Tilt Gear

s8500-015

In the print position (0 degrees), the Printhead is forward and rests against the right and left head-to-drum buttons. The head-to-drum buttons define the space between the jet stack and the drum. When the Process Drive is activated, it drives the Drum Maintenance Camshaft to engage the tilt gear train. The tilt cam tilts the Printhead into the print position. The cam is combined with a missing tooth gear that allows the cam to be inactive in the print position, freeing the Process Drive to perform other printer operations.

The cam has a latching mechanism to unlatch and latch the missing tooth gear to engage the Printhead tilt drive train. The cam’s latching mechanism also holds the tilt gear in place. A leaf spring applies constant pressure to engage the gear when the latching mechanism is released. The arm of the latching mechanism is inside the frame; the rest is visible, outside the frame. Arrows located on the latching mechanism and on the frame indicate when the Printhead is in print position. When the arrows on the latching mechanism and frame align, the Printhead is in the print position and the tilt gear disengages from the Process Drive. Phaser 8500/8550/8560 printers have a solenoid (Head Tilt Solenoid) that is actuated and deactuated when the tilt cam gear rotates to the respective engaged and disengaged positions.

The latching mechanism is actuated by a small movement of the wiper coupled with the Head Tilt Solenoid. The action of the solenoid ensures that the Head Tilt Gear engages the tilt drive gear. Through a follower gear, the compound gear drives the tilt cam gear clockwise. A cam follower, mounted on the lower end of the tilt arm, follows the rotating tilt cam gear and tilts the Printhead. After one revolution of the tilt gear, the latching mechanism is pulled back into position by the return spring in the 8400, and by the Head Tilt Solenoid in the 8500/8550/8560.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-11

Page 44

Theory of Operation

As viewed from the left side of the printer, when the arrows are not aligned, the tilt gear is engaged.

Head Tilt Compond Gear Tilt Drive Gear

Tilt Gear Engaged

s8500-133

To accommodate Printhead maintenance, the Printhead is tilted back away from the Drum. This creates room for the Wiper Blade to move into position in front of the Printhead faceplate. The Process Drive drives the gears to the tilt compound gear train. The Drum Maintenance Camshaft drives the gear train to tilt the Printhead.

2-12 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 45

Drum Maintenance Kit

The Drum Maintenance Kit creates a thin layer of silicone oil on the surface of the Drum prior to printing. The oil keeps the ink from sticking to the Drum’s surface and facilitates image transfer to the media. The oil is contained in porous foam rollers made from rolled paper/fiber material.

Prior to each print, the Process Motor drives the Drum Maintenance Camshaft to raise the Drum Maintenance Pivot Plate, which raises the oil roller against the rotating Drum. The same camshaft raises a wiper blade to assure that the oil film is smooth and even across the Drum’s surface. The Process Drive rotates in one direction. This rotates the Drum Maintenance Camshaft and raises the drum maintenance system to the Drum. The Process Drive then rotates in the opposite direction to lower the drum maintenance system. The blade removes oil and drains it back into the maintenance kit drawer through a felt filter. The oil roller can then reuse the oil. As the Drum completes one rotation, the rotating cam lowers the oil roller and then lowers the blade.

The Drum has a floating deadband; the narrow section of the drum containing excess oil and other debris. The oil bar is left on the drum surface when the blade is removed from the drum. This oil bar location is controlled to keep it outside of the print area.

An EEPROM chip, built-in to the Drum Maintenance Kit, stores the number of oiling cycles performed and the number of prints remaining to track consumable life. At printer startup, four oiling cycles condition the Drum.

Theory of Operation

Drum

Oil on Drum

Blade

Drum Maintenance Camshaft

After replacing the Process Drive, Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft (or any component requiring removal of the Process Drive), the printer may experience Front Cover jams from Tray occurs with paper in the Preheater and C3T jam errors (strip flag timeout during transfix) recorded in Jam History. In many cases, Tray 1 (MPT) prints with no jams. These symptoms indicate that the Transfix Load Module is incorrectly timed resulting in a late arrival of the leading edge at the strip flag. The likely cause is the position of the Drum Maintenance Camshaft gear in relation to the Process Drive gear. To correct this problem, see Drum Maintenance Camshaft” on page 6-9.

Drum Maintenance Pivot Plate

Maintenance Roller

s8500-016

2. The jam

“Timing the

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-13

Page 46

Theory of Operation

Purge System

Proper Printhead operation is dependant on the correct operation of the purge system. The purge system uses air pressure and a Wiper Blade to purge any debris or air bubbles that may be obstructing the Printhead nozzles. The waste ink that is expelled during the purge is funneled into the Waste Tray. Following the purge, a wipe operation is performed on the faceplate using the Wiper Blade. After the wipe, a Cleaning page is printed.

Wiper Blade

2.5 sec

Printhead

Purge Tube

Purge Pump

s8500-017

To perform a Printhead maintenance cycle, the Printhead is first tilted away from the Drum, to allow the Wiper Blade to pass by. The Wiper Blade is then raised in front of the Printhead. Wiper movement is driven by the Media Path Drive, by engaging a clutch on the exit shaft of the printer. The Purge Pump applies pressure to the ink reservoir for approximately 2.5 seconds. Valves in the reservoir seal when pressure is applied. The pressurization ejects a small amount of ink from the jets. Following the pressure purge, the Printhead is tilted into the wiper assembly and the wipe cycle begins. The pump runs again with the solenoid for approximately 30 seconds, creating a neutral balance between pressure and ink. The Wiper Blade lowers and wipes excess ink from the jets into the ink Waste Tray. A proper purge will layer the length of the Waste Tray with a single layer of ink about 20 mm wide.

The level of the ink in the reservoir is kept at a constant level. If the purge tubing is pinched, the Printhead may not purge properly. In addition, because the purge tubing also acts as a vent to atmosphere when not purging, a more serious failure may occur if the ink overfills. Overfilling may trap air in the reservoir, which would prevent the melted ink from entering the reservoir.

2-14 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 47

Theory of Operation

arning

When servicing the printer be careful of the purge system as it passes the Printhead. If a damaged Wiper Blade catches on the Printhead, it could propel hot liquid ink upward into your face.

30 Sec

Printhead

Solenoid Valve

Purge Pump

(Open During Wiper Action)

Wiper

Drum

Purge Tube

Printhead

s8500-018

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-15

Page 48

Theory of Operation

Not

Drum Assembly And Transfix System

The Drum Assembly and Transfix Module form the key portion of the printer where imaging takes place. The Drum Assembly and Transfix Module are separate, yet interrelated. This section discusses the Drum. The next section provides more detail on the Transfix Module.

In operation, the image is rendered on the rapidly rotating drum. The Preheater heats the media to prepare it for the image transfer process. The heated media is then passed between the Drum (now rotating much more slowly) and the Transfix Roller. The pressure applied by the Transfix Roller transfers the image to the heated media. An encoder disk and sensor on the left end of the Drum monitors the Drum’s speed and position.

Tranfix Roller

Paper Path

Preheater

Drum

Drum Heater

s8500-019

The drum heater heats the surface of the Drum to about 60o C (140o F) for imaging. The drum heater does not rotate. The heater is inside the drum, and is controlled by the Drum Heater Relay Board. The drum heater consists of two resistive heater coils that operate in series for 220 V and in parallel for 110 V operation. The Drum Heater Relay Board controls the series/parallel operation. The Drum Temperature Sensor monitors the drum temperature. The main board interprets the sensor’s signal and turns on the drum heater and Drum Fan to heat the Drum, or turns on the Drum fan alone to cool the Drum.

The Y-Axis Motor drives the Drum. Through a single reduction belt drive, the Y-Axis Motor rotates the Drum at a high speed for imaging and a constant low speed for image transfer. The Y-Axis Belt uses an active tension system to allow the pulley to float while the spring actively adjusts the belt tension.

The drum rotates in different directions for each process.

■ Transfix CW

■ Maintenance CCW

■ Printing CCW

2-16 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 49

Theory of Operation

Single Red

uction Belt Drive

Pulley

Drum Temperature Sensor

Fan

CCW

Air Direction

Tension Spring

Y-Axis Motor

Y-Axis Encoder

8400

8500/8550/

8560

s8500-020

arning

Always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system, which is inherently dangerous. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-17

Page 50

Theory of Operation

Transfix System

The Transfix Roller applies pressure to the back side of the media as it moves between the Transfix Roller and Drum. This pressure transfers the image from the drum to the paper. A set of springs in the Transfix Load Module determines how much pressure the Transfix Roller applies to the Drum. The pressure is uniform across the length of the Transfix Roller to avoid wrinkles and light spots on the prints.

After the Transfix Roller engages, the Drum rotates to advance the media through the transfix process. The Drum continues to advance the media until the Transfix Roller disengages. The action of the Process Drive lifts and lowers the Transfix Roller. The upper gears of the Process Drive move to rotate the Transfix Camshaft to bring the Transfix Roller into contact with the Drum. The gears reverse to rotate the Transfix Roller back to its original position, except when printing from Tray 1 or on envelopes. The transfix load springs and double lever arms increase the force when the Transfix Camshaft engages.

Caution

Never attempt to adjust or increase the transfix pressure on the springs.

s8500-021

2-18 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 51

Electronics Module

Main Board

Theory of Operation

The Electronics Module includes the main board, the power control board, and the power supply. The Electronics Module is a Field Replaceable Unit (FRU).

The main board performs the image processing functions. Communication ports on the board receive the print job image data and convert it to drive signals for the Printhead. The main board also contains the mechanical process controller, which commands the function of the power control board. The main board sends signals through the power control board to the wave amp board, which amplifies the signal that drives the jets on the Printhead. The main board supports Non-Volatile RAM (NVRAM), memory, the hard drive, input/output ports, and the configuration card.

NVRAM: The NVRAM memory device, located on the main board, stores

Control Panel defaults, network settings, calibration data, copy counts, usage profile data, and the printer serial number, which is also referred to as the Engine Tracking Number NVRAM must be transferred to the main board in the replacement electronics module.

Memory: For Phaser 8400 printers, the main board supports two PC 133

compatible SO-DIMM SDRAM memory modules (128 to 256 MB). Phaser 8500/8550/8560 printers support SIMMs instead of DIMMs. Supported sizes are 128, 256, and 512 MB. Printers ship with a minimum of 128 MB and support a maximum of 1024 MB

Hard Drive Support: A hard drive IDE cable plugs into the main board from

the hard drive board. A separate power cable must plug into the power control board from the hard drive board to provide signals and power for the hard drive board.

Input/Output Ports: In the Phaser 8400, the main board provides support for

Ethernet (not supported on the B and BD printer configurations), Parallel, and USB 2.0 external I/O interfaces. For the 8500/8550/8560, the main board provides support for Ethernet (all printer configurations), and USB 2.0 external I/O interfaces. The 8500/8550/8560 configurations do not include parallel interfaces.

(ETN). When the electronics module is replaced, the

Configuration Card

The Configuration Card is a thumbnail-sized device that plugs into the side of the Electronics Module. This device stores printer information and interacts with the printer's NVRAM chip. The Configuration Card supports the transfer of printer model and network configuration information from a failed printer to a replacement printer. When replacing the electronics module, you must transfer the Configuration Card to the replacement electronics module.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-19

Page 52

Theory of Operation

Information stored on the Configuration Card includes the feature value, ethernet address, and personality parameters. The card reads a combination of feature values and the printer hardware capabilities; this will determine the printer model configuration.You can migrate the Configuration Card from one printer to another to transfer the printer configuration. Feature value and ethernet address are configured at the factory, and are “read only”. The feature value is fixed in the Configuration Card and does not change. Ethernet address is stored only on the Configuration Card and cannot be rewritten. The Ethernet address is not written to the NVRAM chip.

Personality parameters are a subset of network configuration parameters, which are populated to the Configuration Card when the customer configures the printer. The personality parameters are copied (“shadowed”), from the main board's NVRAM chip to the Configuration Card during the normal operation of the printer. When the configuration card is inserted into a new printer, the personality parameters on the Configuration Card are written into the NVRAM chip of the new printer. When a printer is powered on, if it contains the Configuration Card of another printer, the personality parameters copy automatically to the NVRAM chip. When removing the Configuration Card for the Phaser 8400, the printer reboots as a B (non-networking) configuration. Refer to the “Configuration Card Personality Parameters” section at the end of this chapter for a detailed list of “shadowed” personality parameters.

Power Control Board

The power control board distributes drive voltages to operate the printer’s various motors, solenoids, and clutches. The power control board also provides the interface that returns information from the printer's sensors to the main board. The sensors track mechanical and thermal functions, such as the position and temperature of the Printhead. The power control board also generates regulated +/- 12 V and 5 V from unregulated +/-15 V power.

Power Supply

There are no field adjustments necessary on the power supply. In general, the power supply has two main sections: the AC section and the DC section. In the AC section, power routes to 10 triacs. Under main board logic control, the triacs supply AC power to the 10 heaters in the printer.

Two fuses provide current protection to the triacs. Fuse F2 and F3 protect the power supply from a shorted triac from a defective heater. If the F2 or F3 fuses blow, it is best to replace the Electronics Module (and, of course, the defective heater), rather than the fuse. With the fuse replaced but the triac shorted, AC power may be applied to the heater. However, each time the main board turns on a triac to activate a heater, it is turned on for only a fraction of a second. The main board must constantly re-address each heater it wants to control. If the print engine firmware should fail, the heaters would automatically shut off.

Thermal fuses also protect the printer. A thermal fuse opens in the unlikely event of a “runaway” heater following a hardware failure. The Drum and the Preheater thermal fuses are located on the Preheater. Additional thermal fuses are located on the Printhead and on the ink melting elements.

2-20 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 53

Theory of Operation

The DC power supply generates + 3.3 V, +/- 15 V, and +/- 50 V. These voltages provide direct or regulated voltage values to various circuits in the printer. The power control board regulates +/- 15 V to +/- 12 and other voltages. The main board also has regulators providing + 5 V, + 2.5 V, and +

1.8 V. The power supply outputs + 3.3 V in ENERGY STAR mode. Fuse F1 provides protection for the switching power supply in the DC section.

arning

Do not touch the power supply; AC line voltages are present. The power switch does not disconnect power from the printer. The power switch signals the supply and the printer logic to begin a shutdown sequence.

AC Line

Switcher

AC Neutral

Low

Vcc

Vss

AC Neutral

I n k

1 1

AC Line

r e s

H 1 0

REG

Line

Gnd Ref

Neutral

r e

jsrjs

H 4

H 2

H 1

s8500-022

e h

H 8

+3.3 V

+15 V

-15 V

+50 V

-50 V

H13 H12 H11 H10

H9 H8 H4 H3 H2 H1

1 3

Serial

Control

Interface

uProcessor

I n k

H 1 2

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-21

Page 54

Theory of Operation

I/O Board

Sensors

All sensor and switch readings are input into the I/O Board. The I/O Board translates these states into encoded information that it sends over a serial data bus (I/O Board data cable) to the Electronics Module. The Electronics Module has no direct connection to sensors, switches, or solenoids. In order to activate a clutch or solenoid, the Electronics Module sends a command to the I/O Board, which processes the command and activates the appropriate device.

Sensors throughout all the major subsystems provide indicators of vital print operations. The following graphic identifies the location of the printer’s sensors.

Ink Low

Paper Exit Sensor

Drum Temperature Sensor

Exit Door Sensor

Strip Sensor

Ink Out

Preheater Sensor

Deskew Sensor

Media Width Sensor

Tray Empty Sensor (Also in Trays 3 & 4)

Pick Sensor (525-sheet Feeder)

Drum Position Encoder

Front Door Sensor

Paper Size Sensor

Tray Lift Sensor (Also in Trays 3 & 4)

s8500-023

2-22 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 55

Print Process

Theory of Operation

Once the printer processes an image and creates a printing bitmap, the print cycle begins. Sensors maintain correct operating temperatures for the Printhead and Drum. Sensors also monitor ink levels in the reservoirs. If necessary, the ink loader adds ink.

At the ready state, the print process consists of the following steps:

■ Drum Preparation

■ Printing

■ Paper Pick

■ Transfixing and Exiting

arning

Keep your fingers away from the Y-Axis Motor while the motor is in operation. The motor’s closed-loop servo system is inherently dangerous.

Drum Preparation

To prepare the Drum, the drum maintenance system applies a thin coating of silicone oil to the surface of the Drum. The Process Drive first rotates the Drum Maintenance Camshaft. As the drum rotates, the cams on the ends of the camshaft push against followers on each side of the drum maintenance system, forcing the oil roller and blade against the Drum. The saturated roller evenly distributes oil on the Drum as it rotates.

Drum

Oil on Drum

Blade

Drum Maintenance Camshaft

Drum Maintenance Pivot Plate

Maintenance Roller

s8500-016

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-23

Page 56

Theory of Operation

Printing

To print, the Drum rotates at a speed dependent upon print resolution. As the Drum reaches the correct speed, the jets begin to fire to deposit the image on the oiled portion of the Drum. As the jets fire, the Printhead moves from right to left to complete the image on the drum.

When printing, the printer performs a “six-jet interlace”, in which each jet lays down a particular number of pixel columns, depending on the print resolution. Each jet lays down one pixel column for each Drum rotation, which varies from eight to 16 rotations, depending on the print resolution. Interlacing “averages out” the variability between jets as it interlaces each jet with other jets. In some test prints, the Printhead moves to the right and lays down 309 parallel bands of ink. Each band is composed of 15 pixel columns of dots from an individual jet.

Jet substitution allows a better performing jet to be used in place of a missing or poorly performing neighboring jet. When the printer is in the jet substitution mode, the Printhead makes a second, right to left movement to deposit the pixel columns of the substituted jets. See page 6-12.

“Jet Substitution Mode” on

2-24 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 57

Paper Pick for Tray 1

To pick a sheet of paper, the Tray 1 solenoid actuates, and the drive gear rotates slightly to engage with the drive train. A bias force from the lift plate against a rotating cam causes the roller to rotate enough so the missing tooth gear engages the drive train. This allows the lift plate and paper stack to rotate against the Pick Roller. The Pick Roller then rotates to pick the paper. A Separator Pad prevents multiple sheets from being picked by the Pick Roller.

Key differences in the Tray 1 pick process include:

■ Increased lift plate force to support heavier paper.

■ 100-sheet capacity.

■ Pick Roller to create the buckle for the deskew process.

■ Pick Roller drive to disengage when the door is opened and closed.

■ Pivoting separator pad to prevent it from binding.

Theory of Operation

Drive Gear

Spring Loaded Lift Plate

Cam

Pick Roller

Separator Pad

s8500-024

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-25

Page 58

Theory of Operation

Not

Paper Pick for Trays 2 - 4

Trays 3 and 4 are 525-Sheet Feeders.

For Trays 2 through 4, the paper pick process is different than the pick process used by Tray 1. To pick a sheet of paper, the Media Path Drive starts, and the pick clutch engages, which turns the Pick Roller and the Nudger Roller. The Nudger Roller advances one sheet of paper forward into the pick nip. The Retard Roller prevents two sheets from advancing. The sheet of paper continues past the Take Away Roller until the sheet completes the deskew process. When using the optional 525-sheet feeder, paper is pre-picked from the tray and staged in the paper path while the printer is printing previous pages.

The deskew process uses a reverse/buckle deskew for all three paper paths. The paper is driven against the non-rotating rollers, which are reversing during simplex, causing a buckle in the paper ensuring the leading edge is straighten to prevent skewing. The deskew rollers do not reverse during duplex printing.

Preheat Exit Sensor

Deskew Roller

Deskew Sensor

Take Away Roller

Retard Roller

Strip Sensor

Exit Sensor

Pick Roller

Nudger Roller

s8500-025

2-26 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 59

Transfixing and Exiting

Transfixing and exiting consists of four major functions:

1. Staging the paper for rendezvous with the image on the drum and transfix

2. Loading the transfix roller and engaging the drum stripper blade

3. Stripping the paper from the drum.

4. Exiting the paper from the printer, or exiting the paper for (2-sided) duplex

Tripping the preheat exit sensor (see previous illustration) sets up a series of events, which take place on a predetermined schedule. Paper is transported through the Preheater to thermally prepare it for transfixing. The preheat sensor detects the paper’s presence, and accurately references the leading edge of the media with the image on the Drum.

Based on the timing information from the Preheater, the leading edge of the media is advanced to the transfix nip.

Once the media is stopped in the transfix nip, the Process Drive gears move to rotate the Transfix Camshaft to bring the Transfix Roller into contact with the Drum. The Transfix Roller nip applies the load necessary to transfer the image to the media from the Drum.

At the point where the Transfix Roller loads, but before the Drum begins to rotate, the Stripper Solenoid engages. The Stripper Solenoid positions the stripper blade. The solenoid mounts on the Upper Inner Duplex guide and activates the strip solenoid lever, which in turn rotates the Stripper Carriage until it hits the transfix ground pins. This action causes the stripper blade to drop onto the deadband of the Drum.

After the Transfix Roller and the stripper engage, the Drum rotates to advance the media and transfix the image. The stripper blade catches the leading edge of the sheet of media and separates it from the Drum. After the leading edge is beyond the stripper blade, the Stripper Solenoid de-energizes.

When the solenoid is de-energized, the solenoid return spring provides a force to move the solenoid plunger out of the solenoid coil which rotates the Stripper Carriage back to its ready position.

Once the entire image is transferred, the Drum stops rotating and the Process Drive lifts the Transfix Roller. The Media Drive now rotates the Exit Rollers in the correct direction to pull the media out. However, the Deskew Clutch is de energized so the deskew rollers are not driven during transfix. The Exit Rollers deposit the media into the Output Tray, ending the print cycle.

Theory of Operation

roller nip.

assembly.

printing.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-27

Page 60

Theory of Operation

Transfix Load Module

Transfix Load Spring

Transfix Load Arm

Transfix Cam

Transfix Roller Gear

Transfer Roller

Drum

Process Drive

Swing Arm Gear

s8500-026

2-28 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 61

Strip Solenoid

Theory of Operation

Release Blade

Preheat Sensor

Transfix Roller

Exit Sensor

Paper Preheater

Strip

Sensor

s8500-027

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-29

Page 62

Theory of Operation

Duplex Printing

When duplex printing, the Exit Rollers pull the media to a predetermined location, such that the trailing edge is adjacent to the Exit Rollers. Then, the Exit Rollers pull the media back into the duplex path. The media deskews against a non-rotating deskew nip. From this point on, the print is processed through the Preheater and transfix system to the Output Tray in the same manner as a single-sided print. Phaser Preheater Lift Solenoid, mounted to the Transfix Load Module, that increases the physical spacing between the Preheater plates when printing the second side of duplex prints. The increased spacing prevents the paper from rubbing as hard against the plates, which can cause smearing to occur. Since the 8400 models operate at a lower temperature, the solenoid is not needed.

8500/8550/8560 models include a

Exit Sensor

Deskew Sensor

Exit Roller

Strip Sensor

Preheat Sensor

Duplex Roller

Preheater Lift Solenoid

Duplex Roller

s8500-028

2-30 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 63

Transfix and Print Speeds

Transfix Speeds

Theory of Operation

Characteristic

Setpoint, Paper Media

Fast Color Standard Enhanced High Res/

Peak Transfix Speed, Simplex tray feed

Peak Transfix Speed, Duplex

Peak Transfix Speed,

20 ips (8400) 25 ips (8500/

8550/8560)

5 ips (8400)

10 ips (8500/

8550/8560)

17 ips (8400) 25 ips (8500/

8550/8560)

5 ips (8400

10 ips (8500/

8550/8560)

20 ips 17 ips 13 ips 7 ips

Legal

Peak Transfix Speed,

13 ips 7 ips 7 ips 7 ips

Tray 1

First Sheet Transfix

7 ips 7 ips 7 ips 7 ips

Speed

Peak Transfix Speed 5 ips

Approximate Print Speeds (8400 Series)

13 ips (8400) 20 ips (8500/ 8550/8560)

5 ips (8400 10 ips (8500/ 8550/8560)

Setpoint, OHP Media

Photo

7 ips (8400)

10 ips (8500/

8550/8560)

5 ips (8400)

10 ips (8500/

8550/8560)

Tray (Source) /

Resolution

Tray 1

Fast Color (300x300 dpi) 10 pages per minute

Simplex, A4 Paper Auto Duplex, A4 Paper

10 sides per minute (spm)

(ppm)

Standard (300x450 dpi) 9 ppm 9 spm

Enhanced (563x400 dpi) 8 ppm 4 spm

High Res/Photo (525 x

6 ppm 3 spm

2400)

PCL 600 x 300 Mode PCL 600 x 600 Mode

Tray 2 - 4

6.5 ppm 3 ppm

Fast Color (300 x 300 dpi) 24 ppm 15 spm

Standard (300 x 450 dpi) 18 ppm 13 spm

Enhanced (563 x 400 dpi) 12 ppm 11 spm

High Res/Photo

7 ppm 7 spm

(525x2400)

PCL 600 x 300 Mode PCL 600 x 600 Mode

13 ppm

6 ppm

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-31

Page 64

Theory of Operation

Approximate Print Speeds (8500/8550/8560)

Tray (Source) /

Resolution

Tray 1

Fast Color (225 x 400 dpi) 12 pages per minute

Simplex, A4 Paper Auto Duplex, A4 Paper

8.5 sides per minute (spm)

(ppm)

Standard (300 x 450 dpi) 9 ppm 7 spm

Enhanced (525 x 450 dpi) 6 ppm 5 spm

High Res/Photo (525 x

3.5 ppm 3 spm

2400 dpi)

PCL 600 x 300 Mode PCL 600 x 600 Mode

Trays 2 - 4

6.5 ppm 3 ppm

Fast Color (225 x 300 dpi) 30 ppm 17 spm

Standard (300 x 450 dpi) 24 ppm 14 spm

Enhanced (525 x 450 dpi) 16 ppm 10 spm

High Res/Photo (525 x

10 ppm 6 spm

2400 dpi)

PCL 600 x 300 Mode PCL 600 x 600 Mode

16 ppm

8ppm

2-32 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 65

Printer Self-Maintenance

Printhead Maintenance Cycle (Eliminate Light Stripes)

Theory of Operation

The printer has several automatic or semi-automatic maintenance functions. These functions may be started automatically after a certain number of prints or during printer startup, or they may be started by the customer if a printquality defect is noted.

■ Printhead Maintenance Cycle (Eliminate Light Stripes)

■ Preheater Cleaning (Remove Print Smears)

■ Transfix Roller Oiling

■ Drum Cleaning (Chase Page)

The Printhead maintenance cleaning cycle removes bubbles or foreign matter that cause a Printhead jet to malfunction. Three basic actions take place during a cleaning cycle:

■ Purging

■ Wiping

■ Printing the Cleaning Page

There is one basic type of cleaning cycle performed by the purge system. The first customer purge and the manufacturing purge consist of two basic cleaning cycles performed sequentially. A cleaning cycle is performed when the printer is first powered on, if the ink reservoir has cooled to the point that a cleaning cycle is triggered. A cleaning cycle is not performed when the printer is coming out of standby mode. Refer to the purge system topic in this chapter for more detail on the Printhead maintenance cycle.

arning

When servicing the printer be careful of the purge system as it passes the Printhead. If a damaged Wiper Blade catches on the Printhead, it could propel hot liquid ink upward into your face.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-33

Page 66

Theory of Operation

Paper Preheater Cleaning (Remove Print Smears)

This customer-initiated cleaning procedure is selected by choosing Remove

Print Smears on the Control Panel’s Print Quality Problems menu. This

procedure cleans ink out of the Preheater that may have been deposited there. Heavier-weight, high-grade quality paper works best for this procedure. Ink can also be deposited if a jammed print, with ink on it, was pulled backwards through the Preheater.

In the Preheater cleaning cycle, these events take place:

1. The customer selects the Remove Print Smears menu item.

2. The printer overheats the Preheater to about 110

trapped inside the Preheater. Ordinarily the Preheater runs at temperatures of between 60

3. The printer picks and passes approximately 12-24 sheets of paper

through the print path. The first few sheets absorb and remove ink from the Preheater. The printer continues to pass sheets of paper though to cool the Preheater until normal operating temperature is reached. If duplex capability is enabled, 5 sheets of paper go through the simplex path and up to 20 sheets go through the duplex path.

4. The printer returns to the Print Quality Problems menu.

Because of the higher paper temperatures involved, this function can clean the Drum of ink deposits caused by a contaminated blade on the Drum Maintenance Kit.

C and 70o C.

C, softening ink

Transfix Roller Oiling

Oiling the Transfix Roller prevents ink from sticking to it. Every 50 prints, the printer performs a Transfix Roller oiling cycle. During this cycle, oil is applied to the Drum as it would be during a print cycle. The Transfix Roller then lowers against the Drum and the Drum rotates, transferring some of the oil to the Transfix Roller. Finally, the Transfix Roller raises to its standby position.

Drum Cleaning - Chase Page

The printer performs a Drum cleaning with a chase page automatically anytime a paper jam occurs. The chase page collects any image, which may not be complete, off the Drum. The printer then attempts to reprint the print that jammed. The chase page is processed the same as a regular print, except that the Drum is not oiled and no image is printed on the drum (since an image is already printed on the Drum).

2-34 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 67

Configuration Card Personality Parameters

Configuration Card “Shadowed” Personality Parameters

Attribute Parameter Size (bytes)

Theory of Operation

N/A “version” not parameter

NEST Base Printer Name 48

NEST SysAdmin Contact 128 (truncated from 256)

NEST Printer Location 128 (truncated from 256)

NEST Asset Identifier 128 (truncated from 256)

IP Host Name 64

IP Domain Name 256

IP Network Mask 4

IP IP Address 4

IP Default Gateway 4

IP BOOTP/DHCP 1

IP DDNS 1

IP SMTP Server 256

IP IP Source 1

IP TCP/IP 1

IP AutoIP 1

version (of the layout of personality parameters)

IP DHCP Vendor Class ID 48

DNS RESOLVER Primary Name Server IP Address 4

DNS RESOLVER Secondary Name Server IP

Address

DNS RESOLVER MulticastDNS 1

NBNS (WINS) Enable 1

NBNS (WINS) WINS Note Type 1

NBNS (WINS) Primary WINS Server 4

NBNS (WINS) Secondary WINS Server 4

Ethernet Speed 1

HTTP On 1

HTTP Information Forwarding 1

HTTP SMTP Server Automatic 1

HTTP Legal Settings 1

HTTP Admin_Password 11

HTTP Admin_Username 11

HTTP KeyUser_Password 11

Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-35

Page 68

Theory of Operation

Configuration Card “Shadowed” Personality Parameters (Continued)

Attribute Parameter Size (bytes)

HTTP KeyUser_Username 11

HTTP Admin_HostAccessList 256

HTTP KeyUser_HostAccessList 256

Notify On 1

IPP Authentication Scheme 1

IPP IPP user name 11

IPP IPP password 11

FTP Login Password 33

Security Print Hosts 256

AppSocket On 1

AppSocket Enabled 1

LPR On 1

LPR Enabled 1

FTP On 1

FTP Enabled 1

IPP On 1

IPP Enabled 1

MIME On 1

MIME Enabled 1

EtherTalk On 1

EtherTalk Enabled 1

PSERVER On 1

PSERVER Enabled 1

PSERVER_IPX Enabled 1

Notes:

1. “Parallel” and “USB”, “On” and “Enabled” parameters have not been identified as personality parameters. They are not tied to networking.

2-36 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 69

Error Messages and Codes

In this chapter...

■ Introduction

■ Power-Up Error Messages and LED Codes

■ BIST Error Reporting

■ POST Error Reporting

■ PEST Error Reporting

■ Fault Code Error Message Troubleshooting

■ Jam Codes

Chapter

Page 70

Error Messages and Codes

Introduction

This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running Service Diagnostics test functions to verify that a specific printer component is operating correctly. For information on Service Diagnostics and all internal printer test functions see

“Service Diagnostics Mode Menu” on page 4-5.

For troubleshooting printer problems not associate with, or displaying, an error code or message, such as startup or power on, media, paper path, printquality or image problems, and electrical failures, see

“General

Troubleshooting” on page 4-1 or “Print-Quality Troubleshooting” on page 5-1.

Check the main menu for current data and historical error data.

■ Status Page

■ Usage Profile

■ Fault History

■ Diagnostic History

3-2 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 71

Power-Up Error Messages and LED Codes

The printer has three sets of tests that are run when first powered on:

■ Built-In Self Tests (BIST)

■ Power On Self Tests (POST)

■ Print Engine Self Tests (PEST)

Note

BIST and POST errors are not stored in the fault history logs.

BIST Error Reporting

BIST verifies basic Electronics Module CPU operation and reports failures by utilizing the rear interface panel PS and PE LEDs. These tests occur immediately at power-up, before POST tests are run or the Control Panel is initialized.

The following table defines the blink patterns associated with a failure.

BIST Error Reporting Blink Pattern Definition Table

Error Messages and Codes

PE LED PS LED Description

Off or 1 Blink, and then off

On Solid (dimly)

Off PS and

1 Rapid

2 Rapid

3 Rapid

Off or 1 Blink, and then off

On Solid (dimly)

Control Panel 1/2 sec. blink

blinking

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

“Miscellaneous Electrical Troubleshooting” on

page 56) and check the power supply fuses.

Initialization failure. The printer is held in reset mode. This can be caused by an Electronics Module fault or a +3.3 V power supply regulation failure (see Electrical Troubleshooting” on page 4-56). See also, “Verifying Power Supply Operation” on page 4-64.

Boot loader memory test failure. Ensure the printers RAM chips are properly seated and that the correct RAM type for this printer is installed.

CPU bridge and/or PCI bus is not communicating. Reboot the printer, if the error still occurs, replace the Electronics Module.

ROM not responding. Reboot the printer, if the error still occurs, replace the Electronics Module.

Printer hangs during code initialization.

1. Unplug all cables from the Electronics Module.

2. Plug in the power cable.

3. Power on the Electronics Module (system).

4. If the problem still occurs, reseat the RAM DIMMs.

5. Replace the Electronics Module. For disassembly, see “Electronics Module (PL5.0.5)” on page 8-46. For replacement, go to the Parts List on page 9-3.

“Miscellaneous

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-3

Page 72

Error Messages and Codes

Not

POST Error Reporting

POST checks the communication paths within the Electronics Module and to other various printer components.

POST testing initializes the Control Panel, and in most cases if an error occurs, a text message is displayed on the Control Panel along with an LED blink code flashing on all three LEDs (Control Panel LED, PS LED and PE LED). If initialization of the Control Panel fails, POST errors will still report using the LED blink patterns. The sum of the flashes equal the error code. If the code has more than 5 flashes, there is a brief pause between each set of 5 flashes to make them easier to count. After all flashes occur within the code, there is a long pause and then the flash pattern repeats.

“Soft” POST errors, that do not prevent the printer from powering up completely, are displayed on the Control Panel for 5 seconds, and then the printer continues through the remainder of POST. There are no rear panel LED codes associated with soft errors. Most soft errors will cause the printer to print a Startup Page with the error message on it.

Before replacing the Electronics Module for any POST errors, do the following:

1. Disconnect all connections to the Electronics Module.

2. Plug in the Power Cord and power on the Electronics Module.

3. If the error blink pattern changes from the original error reported before

Step 1, the problem may not be in the Electronics Module, (see “Miscellaneous Electrical Troubleshooting” on page 4-56).

POST Error Reporting Blink Pattern Definition Table

8400 Error Code

01.01 Flutter then 01 blinks Hard Bad error code. 21.1

02.01 Flutter then 02 blinks Hard Failed machine check. 19.1

02.02 Flutter then 02 blinks Hard Printer panic. 19.2

03.01 Flutter only Soft ID read failure. 31.1

03.02 Flutter then 03 blinks Hard Mismatch. 31.2

03.03 Flutter only. Soft Version mismatch. 31.3

03.04 Flutter then 03 blinks Hard Access failure. 31.4

04.01 Flutter then 04 blinks Hard ID read failure. 23.1

04.02 Flutter then 04 blinks Hard ID mismatch. 23.2

PS, PE and Control Panel LEDs (for

8400)

POST Error Type

Description

8500/ 8550/8560 Error Code

04.03 Flutter then 04 blinks Hard TMVL mismatch, write/read failed. 23.3

04.04 Flutter then 04 blinks Hard TMVH mismatch, write/read failed. 23.4

05.01 Flutter then 05 blinks Hard Communications error. PLD I/O Board serial, link down/bad parity.

05.02 Flutter only Soft Communications error. PLD I/O Board serial, mismatch.

3-4 Phaser 8400/8500/8550/8560 Color Printer Service Manual

32.1

32.2

Page 73

Error Messages and Codes

POST Error Reporting Blink Pattern Definition Table (Continued)

8400 Error Code

6.08 N/A Soft IDE drive general failure. Reseat IDE

PS, PE and Control Panel LEDs (for

8400)

POST Error Type Description

8500/ 8550/8560 Error Code

6.808 cable and power cable. If problem persists, replace the IDE drive. The printer will work without the IDE drive.

07.01 Flutter only Soft Control Panel link is invalid or bad

16.1 parity.

07.02 Flutter only Soft Control Panel version mismatch. 16.2

08.01 Flutter only Soft Control Panel failed to initialize. 16.3

09.01 Flutter only Soft Control Panel data path failure. 16.4

10.01 Flutter then 10 blinks Hard PLD power control link down. 33.1

10.02 Flutter only Soft PLD power control link invalid,

33.2 mismatch error.

11.01 Flutter then 11 blinks Hard EEPROM read failure.

12.1

1. Check EEPROM orientation.

2. Replace EEPROM.

11.02 Flutter then 11 blinks Hard EEPROM write failure.

12.2

1. Check EEPROM orientation.

2. Replace EEPROM.

11.03 Flutter then 11 blinks Hard EEPROM re-read failure.

12.3

1. Check EEPROM orientation.

2. Replace EEPROM.

11.04 Flutter then 11 blinks Hard EEPROM data failure, mismatch error.

12.4

1. Check EEPROM orientation.

2. Replace EEPROM.

12.xx Flutter only Soft Configuration card test failure.

1. Check card orientation.

2. Reseat then replace the

configuration card.

NOTE Printer will work as a base model

(without networking) without the configuration card (8400 only).

13.01 Flutter then 13 blinks Hard PHY reset failure, reset stuck low. 2.1

13.02 Flutter then 13 blinks Hard PHY ID error, mismatch error. 2.2

14.xx Flutter then 14 blinks Hard USB errors, N2280 netchip read, write,

19.1 and mismatch errors, POST hard errors.

15.01 Flutter then 15 blinks Hard CPU interrupt error. 19.3

15.02 Flutter then 15 blinks Hard CPU interrupt error, missing CPU

19.4 interrupts.

15.03 Flutter then 15 blinks Hard CPU interrupt error, IRQ spurious

19.5 assertion.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-5

Page 74

Error Messages and Codes

POST Error Reporting Blink Pattern Definition Table (Continued)

8400 Error Code

15.04 Flutter then 15 blinks Hard CPU interrupt error, timer no assertion. 19.6

15.05 Flutter then 15 blinks Hard CPU interrupt error, spurious

15.06 Flutter then 15 blinks Hard CPU interrupt error, no assertion. 19.8

15.07 Flutter then 15 blinks Hard CPU interrupt error, spurious

15.08 Flutter then 15 blinks Hard CPU interrupt error, no assertion. 19.12

15.09 Flutter then 15 blinks Hard CPU interrupt error, spurious

15.10 Flutter then 15 blinks Hard CPU interrupt error, no assertion.

15.11 Flutter then 15 blinks Hard CPU interrupt error, IRQ spurious

16.01 Flutter only Soft Real time clock read failure. 11.1

16.02 Flutter only Soft Real-time clock write failure. 11.2

16.03 Flutter only Soft Real-time clock re-read failure. 11.3

PS, PE and Control Panel LEDs (for

8400)

POST Error Type Description

assertion.

8500/ 8550/8560 Error Code

19.7

19.11

19.13

16.04 Flutter only Soft Real-time clock does not tick. 11.4

17.01 Flutter then 17 blinks Hard Memory test, less than 128 MB of RAM

18.01 Flutter then 18 blinks Hard IPCB ID read failure.

18.02 Flutter then 18 blinks Hard IPCB ID mismatch.

18.03 Flutter then 18 blinks Hard IPCB PCI configuration failure.

18.04 Flutter only Soft IPCB version mismatch.

19.01 Flutter then 19 blinks Hard Check and reseat cables. Replace Hard

PEST Error Reporting

PEST tests occur after POST tests have been run and PostScript has been initialized. PEST checks the connections and operation of various printer components.

Error codes for PEST tests are displayed on the Control Panel and are all in the 37,XXX.xx series. For troubleshooting PEST error codes, Errors - PEST Faults” on page 3-36.

Soft Trickle charge failure 11.5

13.1 detected. This is the minimum RAM required. Add more RAM. Reseat the RAM, then replace the RAM.

Drive, if necessary.

“37,0XX.xx

3-6 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 75

Fault Code Error Message Troubleshooting

Not

Fault Code Error Reporting

Fault codes are saved to NVRAM and can be retrieved from the printer’s fault history.

All procedures that ask for a test to be run are referencing tests from within the “hidden” Service Diagnostics menu. For more information on Service Diagnostics tests, their results, and how to enter into diagnostic mode, see “Service Diagnostics” on page 4-4.

In normal customer mode, the printer will reboot each time an error occurs. If three of the same errors occur within 72 hours, or 1000 pages, the fault is displayed on the printer’s Control Panel.

Interpreting Fault Codes

■ Failing system (XX,yyy.zz)

Error Messages and Codes

■ Failing subsystem (xx,YYY.zz)

■ Checksum (xx,yyy.zZ

■ Type of problem (xx,yyy.Zx)

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

(xx,yyy.4x) Device faults are indicated by a 4 in the tenths place of the fault code.

This indicates a hardware problem. The most common device faults troubleshooting procedures are documented in this section.

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

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

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

The error code indicates both the PowerPC exception number and the region of firmware that was executing when the exception occurred: Engine, PostScript, Network, or Operating System.

A CPU exception can either be caused by hardware or firmware error. Refer to the infoSMART Knowledge Base for descriptions of the most common faults.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-7

Page 76

Error Messages and Codes

1,000.4x Errors - 525-Sheet Feeder Faults

1,001.46: The upper 525-sheet feeder had an overcurrent condition. The lift

motor or clutch may be shorted.

1,002.47: The lower 525-sheet feeder had an overcurrent condition. The lift

motor or clutch may be shorted.

Troubleshooting Procedure for for 525-Sheet Feeder

Step Questions or Actions

1 1. Unplug all connectors to the feeder.

2. Remove the feeder and inspect the connector.

3. Replace any damaged connectors either on the feeder or engine.

4. Reseat and reconnect the feeder.

Did this correct the problem?

2 Inspect the Pick Rollers in the feeder

tray(s). Are the rollers damaged, dirty, or not moving freely?

3 TRun the Tray [3]/[4] Pick Clutch test.

Does the clutch operate correctly?

4 Run the Tray [3]/[4] Lift Motor test.

Does the motor operate correctly?

5 Check the feeder wiring to the Electronics

Module (J390). Is the wiring defective?

Yes N o

Complete. Go to Step 2.

Replace the Pick Assembly.

Go to Step 4. Replace the

Go to Step 5. Replace the

Replace the wiring and go to Step 3.

Go to Step 3.

feeder.

Replace the feeder.

1,0XX.6x Errors - 525-Sheet Feeder Program Faults

1. Reseat the printer on the feeder.

2. Ensure ground integrity (see “Ensuring Ground Integrity” on page 4-65).

3. Reset NVRAM.

4. Replace the feeder.

3-8 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 77

2,0XX.4x Errors - I/O Circuit Board Fault

2,001.47: The print engine cannot detect the presence of the I/O Board.

Troubleshooting Procedure for I/O Board

Error Messages and Codes

Step Questions or Actions

1 Are all I/O Board connections properly

seated?

2 Reseat the connections and power On the

printer. Does the error persist?

3 Test the wiring from I/O board J840 to the

power control board J800.

2,0XX.6x Errors - I/O Board Program Faults

2,001.69: The Electronics Module failed to initialize.

2,002.61: This fault code indicates a problem with the printer program. The

engine firmware was unable to initialize the queues used for inter-task communication.

2,003.62: This fault code indicates a problem with the printer program. The

engine firmware was unable to start the Service Diagnostics tasks.

2,004.63: Failure to start the print engine in suspend mode.

2,005.64: This fault code indicates a problem with the printer program. ROM

could not be opened for reading (idiags).

2,006.65: This fault code indicates a problem with the printer program. ROM

could not be loaded (idiags).

2,007.66: This fault code indicates a problem with the printer program (idiags)

entry point cannot be found.

a. Reset NVRAM and retest. b. Ensure ground integrity (see “Ensuring Ground Integrity” on

page 4-65).

c. Replace the EEPROM chip.

d. Reboot the printer. 2,008.67: Configuration card is missing.

2,009.68: Configuration card is bad.

2,010.69: Configuration card is blank.

2,011.61: Configuration card is for the wrong product.

2,012.62: Configuration card is an invalid model.

a. Turn off printer.

b. Verify that configuration card is correct card for printer.

c. Insert or replace configuration card.

d. Turn on printer.

e. If problem continues, replace the Electronics Module.

Yes N o

Go to Step 3. Go to Step 2.

Go to Step 3. Complete.

Replace the I/O Board.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-9

Page 78

Error Messages and Codes

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

4,0XX.4x Errors - Process Control System Fault

There is a communication problem between the engine and PostScript regions.

a. Reset NVRAM, and then retest.

b. Replace the EEPROM chip.

4,017.47: This fault code indicates a problem with the process control system.

The ambient temperature is considered too cold to warm up the printer (less

than 10

4,018.48: This fault code indicates a problem with the process control system.

The Printhead temperature dropped below the head cleaning needed threshold.

4,020.41: This fault code indicates a problem with the process control system.

Declared when the printer is booted in FTTR (Fast Time to Ready) mode and the head/wiper contact flag is set in NVRAM. The printer cannot run in FTTR mode with the head/wiper in contact because it would be unwise to separate the two when the printer is cold (could tear wiper.) Service requested that this be a device fault in order to alert the service person to this condition.

4,021.42: This fault code indicates a problem with the process control system.

Declared when the printer is booted in FTTR mode and the Drum is dirty. Cleaning the Drum when very cold could increase the chance of gluing media to the Drum surface around the stripper fingers. Service requested that this be a device fault in order to alert the service person to this condition.

C).

Troubleshooting Procedure for Process Control System

Step Questions and Actions

1 1. Verify the temperature of the room where

the printer is located (see “Environmental Specifications” on page 1-12).

2. Is the room temperature too cold?

3. Ensure the printer is acclimated to the room temperature.

Did this correct the problem?

2 Run the Monitor Heaters tests with all

heaters ON. Are the heaters operating correctly and within specification?

3 Inspect the harness to the failed heater.

Is the harness damaged?

Yes N o

Complete. Go to Step 2.

Replace the Electronics Module.

Replace the harness.

Go to Step 3.

Replace the problem component.

3-10 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 79

Error Messages and Codes

4,024.42: This fault code indicates a problem with the wiper. The wiper is not

aligned properly and engaged the headtilt while in the waste lock position.

Troubleshooting Procedure for 4,024 Error Code

Step Questions and Actions

1 Ensure the Process Drive is correctly homed

as described in

“Homing the Process Drive

Train” on page 6-8.

2 Run the Check Wiper Alignment test.

Did the test fail?

3 Run the Wiper Drive test.

Did the test fail?

4 Inspect the wiper drive and wiper lock

system. Look for ink in the belts. Is the wipe system operating correctly?

5 Inspect the Head Maintenance Clutch.

Is there any oil or contamination?

Yes N o

Is the problem

Go to Step 2.

fixed?

Perform the

Go to Step 3. Wiper Alignment Procedure and test again. Go to Step 3 if the test fails again.

Go to Step 4. Go to Step 6.

Go to Step 5. Replace the

problem

component.

Clean the

Go to Step 6. interior of the system and replace clutch if necessary.

6 Run the Head Maintenance Clutch test.

Is the Head Maintenance Clutch operating correctly?

Replace in this order:

■ Exit Module

■ Media Drive

■ Wiper Blade

Replace the

Head

Maintenance

Clutch.

4,025.46: This fault code indicates a problem with the process control system.

Cannot successfully home the transfix mechanism.

Troubleshooting Procedure for 4,025 Error Code

Step Questions and Actions

1 1. Check for obstructions around the

Yes N o

Complete. Go to Step 2.

Printhead. Look for ink shards in gears of the tilt drive.

2. If the Printhead is obstructed, remove any obstruction from the system and reboot.

Did this fix the problem?

2 Check the Printhead harness routing.

Is the wiring blocking the Printhead?

Re-route all wiring to the

Go to Step 3.

Printhead.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-11

Page 80

Error Messages and Codes

Troubleshooting Procedure for 4,025 Error Code (Continued)

Step Questions and Actions

3 Remove the Waste Tray and Printhead and

look for ink build-up. Is there ink build-up anywhere in the printer?

4 1. Check the Process Drive for damage.

2. Ensure the gears are correctly aligned (see “Homing the Process Drive Train” on page 6-8).

Is the Process Drive damaged?

5 Check the nose cone alignment on the X-

Axis Motor. Is the nose cone misaligned with the Printhead shaft?

6 1. Check the X-Axis Motor connector for

damage.

2. Run the X-Axis Motor test to check the XAxis Motor current.

Did the test fail?

Yes N o

Clean any ink or debris which may be restricting movement of the drive train or Printhead.

Replace the Process Drive.

Correct alignment of the nose cone.

Replace the XAxis Motor.

Go to Step 4.

Go to Step 5.

Go to Step 6.

Go to Step 7.

7 Run the Tilt Drive test.

Did the test fail?

4,0XX.6x Errors - Process Control Software Fault

1. Reset NVRAM and then retest.

2. Ensure ground integrity (see “Ensuring Ground Integrity” on page 4-65).

3. Replace the EEPROM chip.

4. Reboot the printer.

Replace the Process Drive.

3-12 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 81

5,0XX.4x Errors - Y-Axis Sub-System Fault

5,001.41: The Drum turned one full revolution without seeing the Drum home

sensor activate.

5,002.42: The Y-Axis encoder is not working properly or the Drum has stalled.

5,003.43: There is a general problem with the Y-Axis sub-system. 5,004.44: Y-Axis fault_general fail problem with Drum motion sub-system.

Troubleshooting Procedure for Y-Axis Sub-System

Error Messages and Codes

Step Questions and Actions

1 From the Service Diagnostic Monitor Menu,

run the Y-Axis Encoder test. Did the test pass?

2 Inspect the Y-Axis Motor connector.

Is the wiring faulty?

3 Inspect the encoder harness.

Is the harness faulty?

4 1. Run the Y-Axis D r i v e test.

2. Check the current values.

Are the values within normal operating range?

5 1. Run the Y-Axis Belt Tension test.

2. Check the current values.

Are the values within the normal operating range?

6 Run the Y- A x i s Motor test.

Did the tests pass?

Yes N o

Go to Step 2. Go to Step 3.

Replace the harness or YAxis Motor.

Replace the harness.

Go to Step 5. Replace the Y-

Go to Step 6. Replace the

Replace the Drum Assembly.

Go to Step 4.

Replace the Drum Assembly.

Axis Motor.

Y-Axis belt.

Replace the YAxis Motor.

5,0XX.6x Errors - Program Faults

5,001.63: There is a problem with the Y-Axis sub-system.

5,005.67: If not in the home or idle state, the system faults out. Software fault.

5,006.68: Software fault.

5,007.60: Software fault.

5,008.61: PostScript failed to fill the race buffer during imaging. Software fault.

5,009.62: There were errors during imaging. Possible jets on/off outside of the

deadband area. Software fault.

a. Reset NVRAM and retest. b. Ensure ground integrity for the printer (see “Ensuring Ground

Integrity” on page 4-65).

c. Replace the EEPROM chip. d. Reboot the printer.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-13

Page 82

Error Messages and Codes

6,0XX.4x Errors - X-Axis Fault

6,000.41: An X-Axis Motor current error occurred.

Troubleshooting Procedure for X-Axis Motor

Step Questions and Actions

1 1. Inspect the Printhead power cable and

heater wiring.

2. Verify the Printhead travels smoothly from left to right.

3. Ensure the Printhead does not bind due to ink spills.

Is Printhead movement restricted?

2 Clear the obstruction restricting Printhead

movement. Did this correct the problem?

3 Inspect the X-Axis Motor harness.

Is the wiring damaged?

4 Use Service Diagnostics to test the X-Axis

drive.

Did the test fail?

6,0XX.6x Errors - Program Faults

6,001.64: The X-Axis task received an unexpected message.

6,002.65: Attempt to home the X-Axis from a state where homing is not

allowed.

6,008.62: Attempt to use the X-Axis drive without initializing it.

6,011.65: Attempt to service the X-Axis while not in the appropriate state.

6,013.67: Unknown X-Axis program fault.

6,017.62: An attempt was made to drive the X-Axis using the wrong server.

6,018.63: An attempt was made to move with the X-Axis uninitialized.

6,019.64: An attempt was made to move the X-Axis from a homeless state.

6,023.68: Could not allocate memory for X-Axis home parameters.

6,025.66: An attempt was made to home with the X-Axis uninitialized.

6,032.68: Could not find a solution to the described home motion profile.

6,033.60: Could not allocate memory for X-Axis move parameters.

a. Reset NVRAM, and then retest. b. Ensure ground integrity for the printer (see “Ensuring Ground

Integrity” on page 4-65).

Yes N o

Go to Step 2. Go to Step 3.

Complete. Go to Step 3.

Replace the harness.

Replace the XAxis Motor.

Go to Step 4.

Replace the Electronics Module.

3-14 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 83

7,0XX.4x Errors - Process Motor Gearbox Faults

7,002.44: There is a problem with the process motor sub-system. The

process motor stalled during operation.

Troubleshooting Procedure for 7,002 Error Code

Error Messages and Codes

Step Questions and Actions

1 Verify the Process Drive system is properly

homed, see Train” on page 6-8. Did this resolve the problem?

2 Use Service Diagnostics to run the Tilt Axis

Drive test.

Did the test fail?

3 1. Check for and remove any obstructions in

the Process Drive.

2. Ensure the Process Drive gears are correctly aligned.

Are the gears damaged?

4 Use Service Diagnostics to run the Process

Motor test.

Did the test fail?

5 Use Service Diagnostics to run the Tra nsf ix

Drive Slow test.

Did the test fail?

“Homing the Process Drive

Yes N o

Complete. Go to Step 2.

Go to Step 3. Go to Step 4.

Replace the Process Drive.

Verify the transfix cams are not damaged. Replace problem component.

Go to Step 4.

Go to Step 5.

Replace the Process Drive.

7,006.xx: The Head Tilt Solenoid is not activating the Head Tilt Gear, or the

Printhead is not tilting properly.

Troubleshooting Procedure for 7,006 Error Code

Step Questions and Actions

1 Ensure the Process Drive system is

correctly homed as described in the Process Drive Train” on page 6-8.

2 Reboot the printer.

Is the solenoid activating the Head Tilt Gear?

3 Is ink blocking Head Tilt Gear motion?

Is the tilt-head latch properly installed?

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-15

“Homing

Yes N o

Is the problem fixed?

Go to Step 4. Go to Step 3.

Clean or reinstall the head-tilt and start over with Step 1.

Go to Step 2.

Go to Step 4.

Page 84

Error Messages and Codes

Troubleshooting Procedure for 7,006 Error Code (Continued)

Step Questions and Actions

Review instructions for 7,008.xx and 7,010.xx fault codes.

7,0XX.4x Errors- Printhead Tilt Faults

The 7,007.49, 7,008.41, 7009.42, and 7,010.43 errors indicate that the Printhead was unable to tilt normally on its axis. Possible causes include:

■ The printer was powered off in the middle of a cleaning cycle and the

Wiper Blade has frozen to the Printhead.

■ A Drum Maintenance Camshaft lobe is broken and holding the Drum

Maintenance Kit’s oil roller against the Drum when it should be retracted to its home position.

■ Process Drive not being aligned correctly.

■ A damaged Printhead Restraint.

■ Ink spilled in the Roll Block preventing proper Printhead motion.

■ Ink or other debris under the Printhead preventing proper motion.

■ The Wiper Assembly not being aligned correctly or ink spilled in the wiper

tracks.

Yes N o

Follow recommended actions for error codes and reboot the printer.

■ The Head Tilt Gear not being homed correctly.

■ The X-Axis Motor nose cone not being installed correctly.

■ The ferrite torrid on the Printhead interface cable has slipped behind the

Printhead causing the Printhead to bind when it tilts backwards.

■ The black plastic shroud on the back of the Printhead is snapped off and

binding the Printhead when it tilts back.

Caution

After servicing the printer, manually set the following assemblies to their home position before powering on the printer. See Section 6 for instructions on setting these components to their home positions.

■ Printhead (tilted forward and disengaged from Printhead tilt gear)

■ Head Tilt Gear (disengaged from Process Drive train; arrows on left

frame point to each other)

■ Wiper Assembly (bottom of travel)

■ Process Drive (holes on Transfix Camshaft and Drum Maintenance

Camshaft line up with marks on frame, large gears within assembly line up with holes in Process Drive housing)

3-16 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 85

7,007.49: The process motor stalled while tilting the head.

Troubleshooting Procedure for 7,007 Error Code

Error Messages and Codes

Step Questions and Actions

1 1. Check the Printhead wire routing.

Yes N o

Complete. Go to Step 2.

2. Remove the Printhead and inspect the Printhead tilt and drive gears for ink spills.

3. Re-route the wiring.

4. Clean around the gears and Printhead.

Did this correct the problem?

2 To ensure Process Drive is correctly aligned,

homed, and free from damage, see

“Homing

the Process Drive Train” on page 6-8.

Complete. Replace the

Process Drive.

Did this correct the problem?

7,008.41: The head tilt is not engaged, or the Printhead is stuck in the tilt

position by the tilt arms.

Troubleshooting Procedure for 7,008 Error Code

Step Questions and Actions

1 Reboot the printer.

Yes N o

Go to Step 2. Complete.

Did this correct the problem?

2 1. Check the printer for ink spills on the

Complete. Go to Step 3.

HeadTilt Gear and the drive train.

2. Clean and reboot the printer.

Did this correct the problem?

3 Check that the Printhead moves properly left

and right.

4 Ensure the Process Drive is correctly

aligned and homed (see

“Homing the Process Drive Train” on page 6-8). Are the gears damaged?

5 1. Check the Process Drive for obstructions

or damaged.

2. Remove any obstructions. Is the gearbox damaged?

6 Use Service Diagnostics to run the Tilt Axis

Drive test.

Did the test fail?

7 Use Service Diagnostics to run the Head

Maintenance Wiper Clutch test.

Did the test fail?

Go to Step 4. Remove any

obstructions or replace any defective parts.

Replace the

Go to Step 5.

Process Drive.

Replace the

Go to Step 6.

Process Drive.

Replace the

Go to Step 7.

Process Drive.

Replace the

Go to Step 8. Head Maintenance Clutch.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-17

Page 86

Error Messages and Codes

Troubleshooting Procedure for 7,008 Error Code (Continued)

Step Questions and Actions

8 Perform the Wiper Alignment procedure

(see

“Wiper Alignment Procedure” on

Yes N o

Complete. Go to Step 9.

page 6-2). Did this correct the problem?

9 Use Service Diagnostics to run the Wiper

Drive test.

Did the test fail?

Inspect the wiper drive system and

Complete.

replace any defective parts.

7,009.42: The Printhead is tilted back but not properly restrained in the park

arms.

Troubleshooting Procedure for 7,009 Error Code

Step Questions and Actions

1 Check that the right and left Printhead

Yes N o

Complete. Go to Step 2.

Restraints operate correctly and are not damaged.

2 Check that the Wiper Assembly is aligned

correctly (see

“Wiper Alignment Procedure”

Complete. Go to Step 3.

on page 6-2).

3 1. Check the Printhead wire routing.

2. Remove the Printhead and clean around the Printhead tilt gears.

Did this correct the problem?

4 Check that the Process Drive gears are

correctly aligned and homed (see

“Homing the Process Drive Train” on page 6-8). Did this correct the problem?

5 Replace the Process Drive.

Did this correct the problem?

6 Use Service Diagnostics to run the Head

Maintenance Wiper Clutch test.

Did the test fail?

7 Use Service Diagnostics to run the Wiper

Drive test.

Did the test fail?

Complete. Go to Step 4.

Complete. Go to Step 5.

Complete. Go to Step 6

Replace the

Go to Step 7. Head Maintenance Clutch.

Inspect the maintenance

Replace the

Exit Module. drive system, replace any defective parts.

3-18 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 87

Error Messages and Codes

7,010.43: The Printhead is stuck in the tilted position, or is not able to tilt

forward to the print position, due to problems.

7,011.44: This is a soft fault and will not halt the printer.

7,012.45: The Drum transfix is not in home position, after the return home

motion has been completed.

7,014.47: The Printhead is not locked in the head tilt restraint spring.

7,015.48: The head tilt restraint spring is out of place.

Troubleshooting Procedure for 7,010 to 7,015 Error Code

Step Questions and Actions

1 Reboot the printer.

Complete. Go to Step 2.

Did this correct the problem?

2 Do the Printhead Restraints rotate

Go to Step 3. Repair or

correctly?

3 1. Has ink spilled ink around the Printhead

that prevents the Printhead from moving to its center position? You should be able

Clean the Printhead area.

to push the Printhead right to left.

4 Is the Printhead stuck to the Wiper Blade? Start the

printer in diagnostics mode and run idiags test Exercise Heater - toggle Printhead heaters to soften the ink. Manual separate the wiper and Printhead. Set them in their home positions.

Yes N o

replace the

Printhead

Restraints.

Go to Step 5.

Go to Step 4.

5 Does the X-Axis Motor drive the Printhead

to its center position (so it can tilt forward)?

Go to step 6. Troubleshoot

the X-Axis

drive.

6 1. Check the Process Drive for obstructions

Complete. Go to Step 7.

or damaged.

2. Ensure the gears are correctly aligned and homed.

3. Verify the process shaft and drive module shaft are at their home positions.

Did this correct the problem?

7 Has ink spilled on the Head Tilt Gear on its

drive train (near left side of the Printhead)?

Clean the gears.

Go to Step 8.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-19

Page 88

Error Messages and Codes

Troubleshooting Procedure for 7,010 to 7,015 Error Code (Continued)

Step Questions and Actions

Use Service Diagnostics to run the Head Maintenance Wiper Clutch test.

Did the test fail?

9 1. Align the Wiper Assembly (page 6-2).

2. Use Service Diagnostics to run the Wiper Drive Test.

Did the test fail?

10 1. Use Service Diagnostics to run the Load

Maintenance Clutch test.

Did the test fail?

11 Verify the Head Tilt Gear engages. You can

manually set the Head Tilt Gear. Is the gear engaged properly?

12 Use Service Diagnostics to run the Tilt Axis

Drive test.

Did the test fail?

Yes N o

Replace the Head Maintenance Clutch.

Replace the Exit Module.

Inspect the maintenance drive system, replace any defective parts.

Go to Step 12. Set the Head

Replace the Process Drive.

Go to Step 9.

Go to Step 10.

Go to step 11.

Tilt Gear.

Go to Step 13.

13 Use Service Diagnostics to run the Process

Motor test.

Did the test fail?

7,0XX.6x Errors - Program Faults

1. Reset NVRAM and retest.

2. Ensure ground integrity for the printer (see “Ensuring Ground Integrity” on

page 4-65).

Replace the Process Drive.

3-20 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 89

8,0XX.xx Errors - Wiper/Media Drive Faults

8,005.48: The Media Drive stalled while moving the Wiper to home position.

8,006.49: The Wiper cannot verify the home position.

8,007.41: The Wiper stalled finding home.

8,008.42: The Wiper stalled while trying to move away from home position.

8,009.43: The Media Drive stalled while moving without the Head

Maintenance Clutch engaged.

8,015.49: The Media Drive stalled while moving the cap/wipe to park position.

8,025.41: The Media Drive stalled while moving the cap/wipe from park

position.

8,035.42: The Media Drive stalled while moving the cap/wipe Up.

8,045.43: The Media Drive stalled while moving the cap/wipe Down.

8,055.44: The Media Drive stalled while engaging headtilt.

Troubleshooting Procedure for Wiper/Media Gearbox

Error Messages and Codes

Step Questions and Actions

1 Check for obstructions in the Wiper

Assembly path. Is the Wiper Assembly obstructed by the Printhead or wiring?

2 For an 8,005.48 error:

1. Check for paper in the paper path that is adding drag to the rollers. Look for paper or wiring interfering with the take away roller.

2. Remove the Tray 1 Pick Solenoid to view the meshing of the Take Away Roller’s gears to the Media Drive Assembly.

Did this correct the problem?

3 For an 8,007.41 error:

Check for a missing KL-clip securing the Head Maintenance Clutch. Replace if missing. Did this correct the problem?

4 For an 8,009.43 error:

1. Ensure that there is no paper in the paper path adding drag to the rollers.

2. Ensure the Media Drive Assembly is fully seated and correctly installed.

3. Remove the Tray 1 Pick Solenoid to view the meshing of the take away roller’s gears to the Media Drive Assembly.

4. Ensure the feed rollers are properly engaged in the drive gears.

Did this correct the problem?

Yes N o

Clear any obstructions.

Complete. Go to Step 5.

Complete. Replace the

Go to Step 2.

Media Drive Assembly.

5 Run the Wiper Drive test.

Did the test pass?

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-21

Go to Step 6. Go to Step 7.

Page 90

Error Messages and Codes

Troubleshooting Procedure for Wiper/Media Gearbox (Continued)

Step Questions and Actions

Run the Wiper Alignment test (see “Wiper Alignment Procedure” on page 6-2). Did the test pass?

7 1. Inspect the wiper system for improper

operation, obstructions, or damage (broken gear or belt). Look for ink in the Wiper Belt channels.

2. Ensure the wiper system is properly aligned (see “Wiper Alignment Procedure” on page 6-2).

Did this correct the problem?

8 Run the Head Maintenance Clutch test.

Did the test pass?

9 Is the head lock mechanism on the right end

of the Exit Module functioning properly?

10 Are there obstructions or spilled ink on the

Wiper Blade, the Head Tilt Gear drive path, or under the Printhead? Is the Waste Tray overfilled?

Yes N o

Go to Step 8. Go to Step 7.

Complete. Go to Step 8.

Go to Step 9. Replace the

Head Maintenance Clutch.

Go to Step 10. Replace the

Exit Module.

Clean the inside of the printer and retest.

8,0XX.6x Errors - Program Faults

1. Reset NVRAM, and then retest.

2. Ensure ground integrity for the printer (see “Ensuring Ground Integrity” on

page 4-65).

3-22 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 91

9,0XX.xx Errors - Ink Loader Faults

9,000.44: Ink Loader device fault

9,005.49:The cyan ink melt heater is On, but ink is not dripping.

9,006.41: The magenta ink melt heater is On, but ink is not dripping.

9,007.42:The yellow ink melt heater is On, but ink is not dripping.

9,008.43: The black ink melt heater is On, but ink is not dripping.

9,015.4x through 9,018 (8500/8550/8560 only): When the Ink Loader door is

opened to clear an ink jam, the following codes are recorded: 9,01x.41, where x= 5 for cyan, 6 for magenta, 7 for yellow, and 8 for black.

9,025.4x through 9, 028 (8500/8550/8560 only): When the inkloader door is

opened for a second time, the following codes are recorded: 9,02x.41, where x= 5 for cyan, 6 for magenta, 7 for yellow, and 8 for black.

9,035.43 through 9,038 (8500/8550/8560 only): Ink count sensor flags are

stuck after melting 2.5 ink sticks. The following codes are recorded: 9,03x.41, where x= 5 for cyan, 6 for magenta, 7 for yellow, and 8 for black.

Features on the bottom of genuine Xerox ink sticks actuate the Ink Out Sensor located at the forward end of each ink channel of the Ink Loader. The sensor indicates the passage of ink to provide a count of ink consumption.

Damaged or non-genuine ink sticks may not reliably actuate the sensors. This can lead to false Ink Out messages as well as Ink Stick count faults. Using 8400 model ink in a 8500/8550/8560 models will also cause 9,03x.4x ink stick count faults.

Error Messages and Codes

Troubleshooting Procedure for Ink Loader

Step Questions and Actions

1 Is the ink Genuine Xerox? Are they the

correct sticks for the model?

Manually verify that the ink stick is able to advance in the ink loader chute. Check for broken or wrong type ink sticks.

Yes N o

Go to Step 2. 1. Advise customer.

2. Replace the Ink with Xerox Ink.

3. Run Clear ISC Fault test to clear the error. The Clear ISC Fault is located in the Internal Diagnostics Function menu.

Go to Step 3. 1. Remove any

blockage and/or replace the ink stick.

2. Replace the Ink Loader.

3. Run Clear ISC Fault test to clear the error.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-23

Page 92

Error Messages and Codes

Not

Troubleshooting Procedure for Ink Loader (Continued)

Step Questions and Actions

3 Test the Ink Count Sensor by running

the Monitor Sensors test in Service Diagnostics. Insert the clean, eraser end of a pencil thru the lowermost oval slot in the Ink Loader. Actuate the appropriate sensor by sliding the pencil down the white channel guide until the sensor is tripped. If the sensor is functional, a state change appears on the Control Panel as <color> Ink Present H. When released, the reading changes to L. The test only displays a reading when a sensor change occurs. If a flag is stuck, no reading is displayed. Did the test pass?

4 Test the ink melt heaters.

Run the appropriate Ink Melt [1, 2, 3, 4] Heater test.

1 = Yellow 2 = Cyan 3 = Magenta 4 = Black

Did the test pass?

Yes N o

Check for defects in the genuine Ink Sticks. If no defects are found, go to Step 4. Replace ink if necessary.

Replace the Printhead.

Replace the Ink Loader.

1. Replace the Ink Loader.

2. Run Clear ISC Fault test to clear the error.

Xerox is not financially responsible for the incorrect operation of its products caused by the use of non- Xerox ink.

9,009.44 and 9,00X.6x Errors - Program Faults

9,009.44: This fault indicates a device failure attempting to access NVRAM.

a. Reset NVRAM and retest. b. Ensure ground integrity for the printer (see “Ensuring Ground

Integrity” on page 4-65).

11,0XX.xx Errors - Electronics Module Interface Fault

11,001.47: Upper 525-sheet feeder broken serial link detected.

11,002.41: Lower 525-sheet feeder broken serial link detected.

11,002.48: Lower 525-sheet feeder broken serial link detected.

11,003.42: Control Panel broken serial link detected.

11,003.49: Control Panel broken serial link detected.

11,004.41: Control Panel or I/O Board broken serial link detected.

11,004.43: I/O Board broken serial link detected.

11,005.42: Power control broken serial link detected.

11,005.44: Power control broken serial link detected.

3-24 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 93

Error Messages and Codes

11,006.43: Printhead broken serial link detected.

11,006.45: Printhead broken serial link detected.

11,007.44: PCI error detected.

11,008.45: The DMA hardware is not responding.

11,009.46: Communication timeout failure detected.

11,010.47: Hardware version mismatch.

11,010.48: Hardware version mismatch.

11,011.48: Software version mismatch.

11,012.49: The power control PLD does not match the expected version.

11,013.41: I/O PLD version mismatch.

11,014.42: Control Panel version mismatch.

11,015.43: Printhead PLD version mismatch.

11,016.44: Lower 525-sheet feeder PLD version mismatch.

11,017.45: Upper 525-sheet feeder PLD version mismatch.

11,018.46: Titan version mismatch.

Troubleshooting Procedure for Electronic Module Interface

Step Questions and Actions

1 Ensure ground integrity for the printer.

Yes N o

Complete. Go to Step 2.

Did this resolve the error?

2 1. Inspect and reseat all connectors.

Complete. Go to Step 3.

2. Inspect the gray cable between the I/O board and the Electronics Module.

3. Ensure the cables are properly dressed in the wiring raceway as detailed in the wiring diagram section of this manual.

Did this correct the problem?

3 Reset NVRAM and retest.

Complete. Go to Step 4.

Did this resolve the problem?

■ 11, 001.47 and 11,017.45 Replace Tray Lift Motor or the

Electronics Module.

■ 11,002.48 and 11, 016.44 Replace the optional tray (or

check wiring).

■ 11,003.49 and 11,0014.42 Replace the I/O board.

■ 11,004.41 and 11,013.41 Replace the I/O board or the

Control Panel.

■ 11,006.43 and 11,015.43 Replace the Printhead.

■ 11,009.46 Replace the I/O board or the

Electronics Module.

■ For all other 11,000.4x errors: Replace the Electronics

Module.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-25

Page 94

Error Messages and Codes

11,100.60 Errors - Temperature Error

12,000.60 Errors - Program Faults

13,0XX.xx Errors - Thermal Faults

The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Check that the room temperature does not exceed specifications and the fans run correctly. If OK, then replace the Electronics Module.

1. Reset NVRAM and retest.

2. Ensure ground integrity for the printer (see “Ensuring Ground Integrity” on

page 4-65).

13,000.48: Thermal fault.

Troubleshooting Procedures for Error Code 13,000 (Printhead)

Step Questions and Actions

1 Ensure ground integrity for the printer.

Did this correct the problem?

2 Reset NVRAM and retest.

Did this correct the problem?

3 Check and reseat all data cables to the

Printhead. Did this correct the problem?

13,003.42:

13,007.46:

Troubleshooting Procedures for 13,003 to 13,007 Error Code

Step Questions and Actions

1 Ensure ground integrity for the printer.

Did this correct the problem?

2 Reset NVRAM and retest.

Did this correct the problem?

Yes N o

Complete. Go to Step 2.

Complete. Go to Step 3.

Complete. Replace the

Yes N o

Complete. Go to Step 2.

Complete. Replace in

Printhead.

this order:

■ NVRAM

■ Electronics

Module

13,008.47: The Drum heater is too hot.

13,010.49: The Drum heater took too long to reach its setpoint.

3-26 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 95

Error Messages and Codes

Troubleshooting Procedure for 13,008 to 13,010 Error Code (Drum Heater)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see

“Environmental Specifications” on page 1-12). Is the room too cold or too hot?

2 Ensure ground integrity (see “Ensuring

Ground Integrity” on page 4-65). Are all components grounded properly?

3 Is the error code associated with an

overheat condition?

4 Verify clearance for adequate air flow.

Are any of the vents blocked?

5 Using Service Diagnostics, run the Drum

Fan Motor test.

Did the test pass?

6 Check the Electronics Module Fan.

Is the fan operating correctly?

7 Using Service Diagnostics, run the Drum

Temperature Sensor test.

Did the test pass?

Yes N o

Advise

Go to Step 2.

customer.

Go to Step 3. Resolve

ground integrity.

Go to Step 4. Go to Step 6.

Advise

Go to Step 5.

customer.

Go to Step 6. Replace the

Drum Fan and/or the harness.

Go to Step 7. Replace the

Electronics Module Fan.

Go to Step 8. Replace the

Drum Temperature Sensor.

8 Using Service Diagnostics, run the Drum

Heater test.

Did the test pass?

9 Check continuity of the F0130 fuse on the

Preheater. Is the fuse blown?

Replace the Drum Temperature Sensor.

Replace the Preheater.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-27

Page 96

Error Messages and Codes

13,067.43: The Drum Temperature Sensor circuit is open.

13,069.45: The Drum Temperature Sensor circuit is shorted.

13,071.47: The Drum Temperature Sensor returned a bad reading, or the

reading was corrupted by ESD (Electrostatic Discharge).

Troubleshooting Procedure for 13,067 to 13,071 Error Code (Drum Thermistor)

Step Questions and Actions

1 Using Service Diagnostics, run the Drum

Temperature Sensor test.

Did the test pass?

Yes N o

Go to Step 2. Replace the

Drum Temperature Sensor.

2 Inspect the sensor wiring harness.

Is the wiring free from defects? Is the wiring correctly routed through the pass-thru and not pinched against the Drum?

Replace the Drum Temperature Sensor.

Replace the sensor harness.

13,072.48: The Preheater got too hot.

13,074.41: The Preheater took too long to reach its setpoint.

13,131.44: The Preheater thermistor circuit is open.

13,133.46: The Preheater thermistor circuit is shorted.

13,135.48: The Preheater thermistor returned a bad reading, or the reading

was corrupted by ESD.

Troubleshooting Procedure for 13,072 to 13,135 Error Code (Preheater)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see

“Environmental

Yes N o

Advise customer.

Go to Step 2.

Specifications” on page 1-12). Is the room too cold or too hot?

2 Run the Preheater test.

Did the test pass?

3 Check the wiring from the Preheater.

Is the wiring connected and intact?

Replace the I/O Board.

Replace the Preheater.

Go to Step 3.

Replace the harness.

13,136.49: The Printhead left jetstack heater is too hot.

13,138.42: The Printhead left jetstack heater took too long to reach its

setpoint.

13,195.45: The Printhead left jetstack thermistor circuit is open.

13,197.47: The Printhead left jetstack thermistor circuit is shorted.

13,199.49: The Printhead left jetstack thermistor returned a bad reading, or

the reading was corrupted by ESD.

3-28 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 97

Error Messages and Codes

Troubleshooting Procedure for 13,136 to 13,199 Error Code (Printhead)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see

“Environmental

Yes N o

Advise customer.

Go to Step 2.

Specifications” on page 1-12). Is the room too cold or too hot?

2 Ensure ground integrity (see “Ensuring

Ground Integrity” on page 4-65). Are all components grounded properly?

3 Use Service Diagnostics to run the Left

Jetstack Temperature test.

Go to Step 3. Resolve

ground integrity.

Go to Step 4. Replace the

Printhead.

Did the test pass?

4 Check and reseat all wiring to the Printhead.

Did this correct the problem?

Complete. Replace the

Printhead.

13,200.41: The Printhead right jetstack heater is too hot.

13,202.43: The Printhead right jetstack heater took too long to reach its

setpoint.

13,259.46: The Printhead right jetstack thermistor circuit is open.

13,261.48: The Printhead right jetstack thermistor circuit is shorted.

13,263.41: The Printhead right jetstack thermistor returned a bad reading, or

the reading was corrupted by ESD.

Troubleshooting Procedure for 13,200 to 13,263 Error Code (Printhead)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see

“Environmental

Yes N o

Advise customer.

Go to Step 2.

Specifications” on page 1-12). Is the room too cold or too hot?

2 Ensure the ground integrity (see “Ensuring

Ground Integrity” on page 4-65). Are all components grounded properly?

3 Run the Right Jetstack Temperature test.

Did the test pass?

4 Check and reseat all wiring to the Printhead.

Did this correct the problem?

Go to Step 3. Resolve

ground integrity.

Go to Step 4. Replace the

Printhead.

Complete. Replace the

Printhead.

13,264.42: The Printhead reservoir heater got too hot.

13,266.44: The Printhead reservoir heater took too long to reach its setpoint.

13,323.47: The Printhead reservoir thermistor circuit is open.

13,325.49: The Printhead reservoir thermistor circuit is shorted.

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-29

Page 98

Error Messages and Codes

13,327.42: The Printhead reservoir thermistor returned a bad reading, or the

reading was corrupted by ESD.

Troubleshooting Procedure for 13,264 to 13,327 Error Code (Printhead)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see

“Environmental

Yes N o

Advise customer.

Go to Step 2.

Specifications” on page 1-12). Is the room too cold or too hot?

2 Ensure ground integrity (see “Ensuring

Ground Integrity” on page 4-65). Are all components grounded properly?

3 Run the Printhead Reservoir Temperature

test.

Go to Step 3. Resolve

ground integrity.

Go to Step 4. Replace the

Printhead.

Did the test pass?

4 Check and reseat all wiring to the Printhead.

Did this correct the problem?

Complete. Replace the

Printhead.

13,328.43: The ink loader CYAN heater is too hot.

13,330.45: The ink loader CYAN heater took too long to reach its setpoint.

13,387.48: The ink loader CYAN thermistor circuit is open.

13,389.41: The ink loader CYAN thermistor circuit is shorted.

13,391.43: The ink loader CYAN thermistor returned a bad reading, or was

corrupted by ESD.

13,392.44: The ink loader MAGENTA heater is too hot.

13,394.46: The ink loader MAGENTA heater took too long to reach its

setpoint.

13,451.49: The ink loader MAGENTA thermistor circuit is open.

13,453.42: The ink loader MAGENTA thermistor circuit is shorted.

13,455.44: The ink loader MAGENTA thermistor returned a bad reading, or

ESD corruption.

13,456.45: The ink loader YELLOW heater got too hot.

13,458.47: The ink loader YELLOW heater took too long to reach its setpoint.

13,515.41: The ink loader YELLOW thermistor circuit is open.

13,517.43: The ink loader YELLOW thermistor circuit is shorted.

13,519.45: The ink loader YELLOW thermistor returned a bad reading, or

ESD corruption.

13,520.46: The ink loader BLACK heater got too hot.

13,522.48: The ink loader BLACK heater took too long to reach its setpoint.

13,579.42: The ink loader BLACK thermistor circuit is open.

13,581.44: The ink loader BLACK thermistor circuit is shorted.

13,583.46: The ink loader BLACK thermistor returned a bad reading, or ESD

corruption.

3-30 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Page 99

Error Messages and Codes

Troubleshooting Procedure for 13,326 to 13,583 Error Code (Ink Loader)

Step Questions and Actions

1 Check that the ambient room temperature is

within specifications (see Specifications” on page 1-12). Is the room too cold or too hot?

2 Ensure ground integrity (see “Ensuring

Ground Integrity” on page 4-65). Are all components grounded properly?

3 Inspect and reseat the wiring to the ink

loader. Check for open wires. Did this correct the problem?

4 Run the appropriate Ink Melt test.

1 = Yellow 2 = Cyan 3 = Magenta 4 = Black

Did the test pass?

13,000.6x Errors - Program Faults

“Environmental

Yes N o

Advise customer.

Go to Step 3. Resolve

Go to Step 4. Replace the

Go to Step 2.

ground integrity.

I/O board or the Combined Right Cable.

Replace the Ink Loader.

13,001.62: Thermals failed to read from printer NVRAM.

13,002.63: Value is not in valid range.

13,003.64: Thermal control task received an unexpected message.

13,004.65: Thermal control task was expecting initialization message, but

received other.

13,005.66: Thermal code tried to command a segment ID that did not exist.

13,006.67: Thermal code tried to command a segment ID that did not exist.

13,007.68: Thermal power manager task was expecting initialization

message, but received other.

13,008.60: Thermal power manager task received an unexpected message.

a. Reset NVRAM and retest. b. Ensure ground integrity for the printer (see “Ensuring Ground

Integrity” on page 4-65).

Phaser 8400/8500/8550/8560 Color Printer Service Manual 3-31

Page 100

Error Messages and Codes

Not

19,0XX.xx Errors - Printhead Calibration faults.

19,001.46: HFD server failed due to NVRAM operation. This fault only occurs

when the printer is set in manufacturing mode. Program fault.

19,002.47: Attempted to perform a Printhead operation without the Printhead

NVRAM data being loaded.

19,003.48: Scale and offset error is too large. The voltages measured have

more than a 20% error from their expected values. Something is wrong with the Electronics Module or the Wave Amplifier.

19,004.40: The Printhead and the Electronics Module do not match. Contact

escalated Service Support Representative for information to clear fault.

19,005.41: A posssible static discharge from the Pick Clutch to the

Electronics Module.Characterized by:

■ 19,005.41 error code displayed on the Control Panel

■ Printer hangs while printing with the Electronics Module Fan on full

■ Low humidity

■ Occasional Jam Behind the Front Cover messages, usually accompanied

by error 19,005.41 in Fault History

To prevent these discharges, a Grounding Clip (P/N 650442700) was added between the Y-Axis Motor mount and the Pick Clutch. Check that this clip is installed and contacts the metallic portion of the Pick Clutch.

s8560-270

The Grounding Clip is factory installed in later versions of 8500/8550 models and in all 8560 models.

3-32 Phaser 8400/8500/8550/8560 Color Printer Service Manual

Xerox 8560, 8550, 8500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Symbols Marked on the Product

Power Safety Precautions

Electrostatic Discharge (ESD) Precautions

Service Safety Summary

Regulatory Specifications

Manual Organization

Contents

General Information

Printer Introduction and Overview

Printer Configurations

Control Panel Configuration

LED Indicators

Control Panel Feature Descriptions

Menu Maps

Control Panel Shortcuts

Parts of the Printer

Front View

Right Side View with Printer Interfaces

Rear View

Routine Maintenance Items and Consumables

Printer Specifications

Physical Dimensions and Clearances

Functional Specifications

Electrical Specifications

Environmental Specifications

Media and Tray Specifications

Theory of Operation

Main Printer Subsystems

Printer Subsystem Overview

Process Drive

Media Drive

Ink Loader

Printhead

Printhead Tilt

Drum Maintenance Kit

Purge System

Drum Assembly And Transfix System

Electronics Module

I/O Board

Sensors

Print Process

Printing

Paper Pick for Tray 1

Paper Pick for Trays 2 - 4

Transfixing and Exiting

Duplex Printing

Transfix and Print Speeds

Printer Self-Maintenance

Printhead Maintenance Cycle (Eliminate Light Stripes)

Paper Preheater Cleaning (Remove Print Smears)

Transfix Roller Oiling

Drum Cleaning - Chase Page

Configuration Card Personality Parameters

Error Messages and Codes

Introduction

Power-Up Error Messages and LED Codes

BIST Error Reporting

POST Error Reporting

PEST Error Reporting

Fault Code Error Message Troubleshooting

Fault Code Error Reporting

Interpreting Fault Codes

1,000.4x Errors - 525-Sheet Feeder Faults

1,0XX.6x Errors - 525-Sheet Feeder Program Faults

2,0XX.4x Errors - I/O Circuit Board Fault

2,0XX.6x Errors - I/O Board Program Faults

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

4,0XX.4x Errors - Process Control System Fault

4,0XX.6x Errors - Process Control Software Fault

5,0XX.4x Errors - Y-Axis Sub-System Fault

5,0XX.6x Errors - Program Faults

6,0XX.4x Errors - X-Axis Fault

6,0XX.6x Errors - Program Faults

7,0XX.4x Errors - Process Motor Gearbox Faults

7,0XX.4x Errors- Printhead Tilt Faults

7,0XX.6x Errors - Program Faults