Xerox Phaser 8400, Phaser 8500, Phaser 8550 Service Manual

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Phaser® 8400/8500/8550

color printer

Service

Manual

Phaser

8400/8500/8550 Color

Printer

Service Manual

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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.

First Printing: 2005

721P58550

Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.

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

XEROX

Each Other

, The Document Company®, the digital X®, CentreWare®, FinePoint™, infoSMART®, Made For

, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the

United States and/or other countries.

Acrobat

PostScript

IntelliSelect

, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator®, PageMaker®, Photoshop®,

, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™, Birch®, Carta®,

, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the

United States and/or other countries.

, AppleTalk®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple

Apple

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, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple

Computer, Inc. in the United States and/or other countries.

, HP-UX®, and PCL®are trademarks of Hewlett-Packard Corporation in the United States and/or

HP-GL other countries.

IBM

and AIX® are trademarks of International Business Machines Corporation in the United States and/

or other countries.

Windows

, Windows NT®, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation

in the United States and/or other countries.

, NetWare®, NDPS®, NDS®, Novell Directory Services® , IPX™, and Novell Distributed Print

Novell

™

Services

Sun

are trademarks of Novell, Incorporated in the United States and/or other countries.

, Sun Microsystems™, and Solaris® are trademarks of Sun Microsystems, Incorporated in the United

States and/or other countries.

is a trademark of SWOP, Inc.

SWOP

is a trademark in the United States and other countries, licensed exclusively through X/Open

UNIX Company Limited.

NERGY STAR

As an E meets the E

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

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

U.S. marks.

PANTONE

Colors generated may not match PANTONE-identified standards. Consult current PANTONE

Publications for accurate color. PANTONE Pantone, Inc. © Pantone, Inc., 2000.

and other Pantone, Inc. trademarks are the property of

User Safety Summary

Terms in Manual

Caution

Conditions that can result in damage to the product.

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

Power source:

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

Operation of product: Avoid electric shock by contacting a qualified service technician to replace fuses inside the product. Do not operate without the covers and panels properly installed. Do not operate in an atmosphere of explosive gases.

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Turning the power off using the On/Off switch does not de-energize the printer. You must remove the power cord to disconnect the printer from the mains. Keep the power cord accessible for removal in case of an emergency.

Safety instructions: Read all installation instructions carefully before you plug the product into a power source.

Terms on

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A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Also applies to a hazard to property including the product itself.

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

Product

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Personal injury hazard exists in the area where you see the sign.

Care of product: Disconnect the power plug by pulling the plug, not the cord. Disconnect the power plug if the power cord or plug is frayed or otherwise damaged, if you spill anything into the case, if product is exposed to any excess moisture, if product is dropped or damaged, if you suspect that the product needs servicing or repair, and whenever you clean the product.

Service Manual i

Ground the product: Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If necessary, contact a licensed electrician to install a properly grounded outlet.

Symbols as marked on product:

DANGER high voltage:

Protective ground (earth) terminal:

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

WAR NING: If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can cause an electrical shock. Electrical product may be hazardous if misused.

Service Safety Summary

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

Do not service alone:

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

Use care when servicing with power on: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on.

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

Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into contact with dangerous voltages and currents.

Power source: This product is intended to operate from a power source that will not apply more than 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

ii Phaser 8400/8500/8550 Color Printer

Do not perform internal service or adjustment of this

Regulatory Specifications

United States

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.

United States (FCC Regulations)

This equipment has been tested and found to comply 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.

■ Increase the separation between the equipment and receiver.

■ Connect the equipment into an outlet on a circuit different from that to

which the receiver is connected.

■ 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 complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

Service Manual iii

European Union (Declaration of Conformity)

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

Low Voltage Directive 73/23/EEC as amended

EN 60950:2000

Electromagnetic Compatibility Directive 89/336/EEC as amended

EN 55022:1998+A1:2000 +A2:2003

EN 55024:1998+A1:2000 +A2:2003

EN 61000-3-2:2000

EN 61000-3-3:1995+A1:2000

Radio & Telecommunications Terminal Equipment Directive 1999/5/EC as amended

EN 300 330-2 V1.1.1

EN 300 440-2 V1.1.1

EN 301 489-3 V1.3.1

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

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

iv Phaser 8400/8500/8550 Color Printer

Electrostatic Discharge (ESD) Precautions

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

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

■ Immediately before handling any semiconductor components assemblies, drain

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

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

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

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

sufficient to damage some devices.

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

protective package until you are ready to install it.

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

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

■ Minimize body motions when handling unpacked replacement devices. Motion

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

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

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

Printed Circuit Boards (PCB’s).

Service Manual v

vi Phaser 8400/8500/8550 Color Printer

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

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

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

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

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

2 Theory of Operation

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

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

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

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

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

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

Drum Maintenance System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

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

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

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

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

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

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

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

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

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

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

Service Manual vii

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

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

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

Fault Code Error Message Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 3-8

Fault Code Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Interpreting Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

1,000.4x Error - 525-Sheet Feeder Faults . . . . . . . . . . . . . . . . . . 3-9

2,0XX.4x Error - I/O Circuit Board Fault . . . . . . . . . . . . . . . . . . . 3-10

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

4,0XX.4x Errors - Process Control System Fault . . . . . . . . . . . . 3-11

5,0XX.4x Errors - Y-Axis Sub-System Fault . . . . . . . . . . . . . . . . 3-14

6,0XX.4x Errors - X-Axis Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

7,0XX.4x Errors - Process Motor Gearbox Faults. . . . . . . . . . . . 3-16

8,0XX.xx Error - Wiper/Media Path Gearbox Faults . . . . . . . . . . 3-21

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

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

13,0XX.xx Errors - Thermal Faults . . . . . . . . . . . . . . . . . . . . . . . 3-25

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

31,0XX.4x Errors - Mechanical Initialization Jam. . . . . . . . . . . . 3-33

33,0XX.xx Errors - Tray Manager Device Faults. . . . . . . . . . . . . 3-34

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

36,000.40 Errors - Drum Maintenance Faults . . . . . . . . . . . . . . 3-35

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

Jam Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Jam Code Definition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Check / Activators Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

viii Phaser 8400/8500/8550 Color Printer

Check Shafts Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Check Drive Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Check Drum Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Check Motors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Check Misc Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Electronics Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Printer Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Mechanical Initialization (8400) . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Mechanical Initialization (8500/8550). . . . . . . . . . . . . . . . . . . . . 4-62

Miscellaneous Electrical Troubleshooting. . . . . . . . . . . . . . . . . . 4-65

Verifying Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . 4-75

Measuring AC Power Supply Voltages . . . . . . . . . . . . . . . . . . . . 4-75

Measuring DC Power Supply Voltages . . . . . . . . . . . . . . . . . . . . 4-76

Ensuring Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Testing Motor and Solenoid Resistances . . . . . . . . . . . . . . . . . . 4-78

Paper Path and Media-Based Problems . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Media-Based Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Paper-Pick Errors - Trays 2, 3, and 4 . . . . . . . . . . . . . . . . . . . . . 4-79

Paper-Pick Errors - Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Preheater and Transfix Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Checking the Process and Media Path Drive. . . . . . . . . . . . . . . . 4-81

Media Skews Passing Through the Paper Path. . . . . . . . . . . . . . 4-81

Operating System and Application Problems . . . . . . . . . . . . . . . . . . . . . 4-82

Testing Communications Ports. . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

Obtaining Serial Back Channel Trace . . . . . . . . . . . . . . . . . . . . . 4-85

5 Print-Quality Troubleshooting

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

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

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

Smudges or Smears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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

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

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

Streaks or Lines Down the Print . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Scratches or Marks Parallel to the Long Axis of Printing,

Particularly with Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

White Portion of Print is Colored . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Fuzzy Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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 Duplex Print . . . . . . . . . . . . 5-28

Service Manual ix

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

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

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

Image Is Offset or Cut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Poor Ink Adhesion, Poor Image Durability. . . . . . . . . . . . . . . . . 5-32

Analyzing Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Test Print Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

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 Gear Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

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

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

Enabling Jet Substitution Mode (8400) . . . . . . . . . . . . . . . . . . . 6-10

Enabling Jet Substitution Mode (8500/8550) . . . . . . . . . . . . . . 6-10

Disabling Jet Substitution Mode (8400) . . . . . . . . . . . . . . . . . . 6-11

Disabling Jet Substitution Mode (8500/8550) . . . . . . . . . . . . . . 6-11

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

7 Cleaning and Maintenance

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

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

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

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

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

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

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

8 Service Parts Disassembly

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

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

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

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

Front Door (Tray 1) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Control Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Front (Control) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Exit Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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

x Phaser 8400/8500/8550 Color Printer

Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor Assembly . 8-9

Printhead Assembly, Right and Left Printhead Restraints. . . . . . 8-11

Head Tilt Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

X-Axis Bias Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Printhead Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Media Release Blade Carriage Assembly and Transfix Roller . . . 8-21

Paper Preheater and Deskew Assembly . . . . . . . . . . . . . . . . . . . 8-22

Duplex Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Transfix Load Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Transfix Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

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

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

Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

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

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

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

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

Take Away Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

Pick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

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

Motors, Gears, Solenoids, Clutches, and Fans . . . . . . . . . . . . . . . . . . . . 8-47

Media Drive Gearbox with Two Clutches and Solenoid. . . . . . . . 8-47

Tray 1 Pick Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Preheater Lift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

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

X-Axis Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52

Head Tilt Compound Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Wave Amp Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Drum Heater Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

NVRAM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

DIMM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59

Hard Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

Service Manual xi

9 Parts Lists

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

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

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

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

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

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

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

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

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

10 Wiring Diagrams

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

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

A Appendix

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

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

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

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

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

On-site Printhead Troubleshooting Checklist (8500/8550) . . . . A-12

xii Phaser 8400/8500/8550 Color Printer

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

Section

Printer Introduction and Overview

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

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

Back

Left

Right

Front

s8500-002

1-2 Phaser 8400/8500/8550 Color Printer

Printer Configurations

Phaser 8400-Series Printer Configurations

Features 8400B 8400BD 8400N 8400DP 8400DX

Maximum Print Speed 24 24 24 24 24

Memory (Std/Max) 128/512 MB256/512 MB128/512 MB256/512 MB256/512

Hard Drive No No Optional** Optional** Standard

PostScript Fonts 137 137 137 137 137

PCL Fonts 81 81 81 81 81

Japanese Fonts* No No Optional Optional Optional

Job Pipelining No Yes No Yes Yes

Automatic 2-Sided Printing No Standard No Standard Standard

100-Sheet Tray 1 Standard Standard Standard Standard Standard

525-Sheet Tray 2 Standard Standard Standard Standard Standard

525-Sheet Feeder Tray 3 Optional Optional Optional Optional Standard

525-Sheet Feeder Tray 4 Optional Optional Optional Optional Optional

USB, Parallel Connection Standard Standard Standard Standard Standard

10/100 Ethernet

Connection

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

secure print, and collation.

No No Standard Standard Standard

General Information 1-3

Phaser 8500/8550 Series Printer Configurations

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

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

Memory (Std/Max) 128MB/

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 Printing No Yes Yes Yes Yes

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

10/100 Ethernet

Connection

** The following features are not included in the Phaser 8400-series printers, but are included

with the Phaser 8500/8550 printers with a hard drive: proof print, saved print, secure print, personal print, and font storage.

1GB

Ye s Ye s Ye s Ye s Ye s

128MB/

1GB

256MB/

1GB

256MB/

1GB

512MB/

1GB

1-4 Phaser 8400/8500/8550 Color Printer

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

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

■ Flashing Amber = Warning ■ Flashing Red = Error

Processing Data, Printing or Power Saver Mode

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

Up Arrow button Scrolls upward through the menus.

s8500-003

Graphic display indicates status

messages and menus.

Cancel button

Cancels the current print job.

Back button

Returns to the previous menu item.

Down Arrow button

Scrolls downward through the menus.

OK button

Accepts the selected setting.

Help (?) or Information button

Displays a help message with information about the printer, such as printer status, error messages, and maintenance information.

General Information 1-5

Menu Maps

The Customer Menu Map helps you navigate the Control Panel menus. The Menu Map’s are provided in the appendix 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.

Control Panel Shortcuts

Mode or Menu Item Shortcut

Service Tools Menu On the Control Panel, press the Down Arrow button and select

Troubleshooting and press OK.

Then, press the Down Arrow button to select Service Tools and then press OK.

Service (Internal) Diagnostics

Set Control Panel language

Bypass protected menus

Jet Substitution Mode (Phaser 8400 only)To add Jet Substitution Mode to the Print Quality

FTTR (Fast Time To Ready)

(Phaser 8400) Hold the Back and Info button at power up (for about

30 seconds). (Phaser 8500/8550) 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.

Problems menu: From the Print Quality Problems menu: press and hold the Up Arrow button, and then press the Back button . Phaser 8500/8550 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 power-up, 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 Color Printer

Parts of the Printer

This section shows the main external components of the printer, including interfaces, the electronics module, and the internal sensors.

Front View

1. Optional 525-Sheet Feeder Tray 4

2. Optional 525-Sheet Feeder Tray 3

3. Stan. 525-Sheet Feeder Tray 2

4. 100-Sheet Multi-Purpose Tray 1

5. Control Panel

6. Exit cover release

7. Front cover release

8. Exit cover

9. Ink loader/top cover

10.Legal/A4 output tray extension

11.Interface cover

12.Side door

s8500-004

Right Side View with Printer Interfaces

1. Maintenance kit

s8500-005

General Information 1-7

2. Waste tray

3. Power cord connection

4. Power switch

5. Parallel port connection

(8400 series only)

6. USB connection

7. Configuration card

8. Ethernet 10/100 Base-T connection

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 chips. 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 8400 and 8500 series).

1-8 Phaser 8400/8500/8550 Color Printer

Routine Maintenance Items and Consumables

Routine Maintenance Items Consumable

1. Maintenance kit 3. Ink

2. Waste tray

Routine Maintenance: Consumable:

Extended Capacity Maintenance Kit (8400 and 8550 only)

Startup Maintenance Kit

Waste Tray Empty every 7 purges.

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

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

(8500/8550) 10,000 cycles for black and white, 5500 cycles for color. (8400) 10,000 cycles regardless of colors used.

Ink (8400) 1140 prints

per stick* (8500/8550) 1080 prints per stick*

General Information 1-9

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 waste

Required for airflow.

tray.

A. Absolute Mi nimum

6.0 6.0

4.0

Note: All dimensions in inches

28.0

24.0

Front

B. Recommended Minimum

4.0 15.5

4.0

35.5

1-10 Phaser 8400/8500/8550 Color Printer

Functional Specifications

Characteristic Specification

Printing Process Solid-ink

Color Medium

Operating Modes and Resolutions

Maximum Operating Printing Speed

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

Warm-Up Time : From Off (cold start) From Power Saver

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

(8400)

Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced (563x400 dpi), High Resolution/Photo (525x2400) (8500/8550) Fast Color (225 x 400 dpi), Standard (300x450 dpi), Enhanced (525 x 400 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) 4 minutes

Electrical Specifications

Characteristic Specification

115 Volt 230 Volt

Primary line voltages 90 - 140 VAC 180 - 264 VAC

Primary line voltage frequency range

Power consumption 1250 W (peak) - 1000 typical

Energy Star® 43 W 43 W

47 - 63 Hz 47 - 63 Hz

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

180 W (idle)

230 W (average during printing)

Environmental Specifications

Nominal Operating Environment

Temperature

Humidity 10% - 80% RH Non-Condensing operating

General Information 1-11

10º - 32

20 - 25

C (50º - 90º F) operating

C (68º - 77º F) Best jam performance

Media and Tray Specifications

Paper Size Paper Type Paper Weight/Media Type

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

Legal (8.5 x 14 in.)

Executive (7.25 x

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

Statement (5.5 x

8.5 in.)

US Folio (8.5 x 13 in.)

A6 (105 x 148 mm)

B5 ISO (176 x 250 mm)

B5 JIS (182 x 257 mm)

Plain Paper or Letterhead

60–120 g/m

121–220 g/m

Transparency Phaser Professional Solid Ink

Transparencies

Card Stock

100–120 g/m

121–220 g/m

Labels Phaser Color Printing Labels

Special Phaser Professional Solid Ink Business

Cards

Phaser Professional Solid Ink High Resolution Photo Paper

Phaser Premium Postcards

Phaser Weatherproof Paper

Phaser Trifold Brochures

60–120 g/m

121–220 g/m

60–120 g/m

(16–32 lb. Bond)

(32–59 lb. Bond)

(37–44 lb. Cover)

(44–80 lb. Cover)

(16–32 lb. Bond)

(32–59 lb. Bond)

(16–32 lb. Bond)

Any Tray

Tray 1 O n l y

2-Sided (Duplex)

l l

Single-sided Only

1-12 Phaser 8400/8500/8550 Color Printer

Paper Size Paper Type Paper Weight/Media Type

Index Cards (3 x 5in.)

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

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

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

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

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

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

Tra y 1 Only #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).

Any Tray

l l

l ll

l l

l l l

l l l l l l l

Tray 1 O n l y

2-Sided (Duplex)

Single-sided Only

l l l

l l l l l l l

General Information 1-13

1-14 Phaser 8400/8500/8550 Color Printer

Theory of Operation

In this chapter...

■ Main Printer Subsystems

■ Print Process

■ Printer Self-Maintenance

■ Configuration Card Personality Parameters

Section

Main Printer Subsystems

Transfix System

Duplex Print Path

Paper Preheater (and Deskew)

Drum Maintenance Kit

Drum

Printhead

Ink Waste Tray

Wiper Assembly

Ink Loader

*Power Supply

*Main Board

*Hard Drive

*Configuration Card

*Power Control Board

Paper/Media Tray

Wave Amp

*Part of the Electronics Module

s8500-008

Printer Subsystem Overview

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

■ Process Drive

■ Media Path Drive

■ Ink Loader

■ Printhead

■ Drum Maintenance System

■ Purge System

■ Drum Assembly and Transfix Assembly

■ Electronics Module

2-2 Phaser 8400/8500/8550 Color Printer

The Process Drive: is Transmits torque to two main camshaft assemblies. One

camshaft assembly controls the transfix roller loading, and the other controls the drum maintenance system and printhead tilt system.

The Media Path Drive: Controls each roller in the paper transport system. The

paper transport system consists of a drive motor, a gearbox assembly and three solenoids. The media path drive motor also controls the movement of the wiper assembly and the headlock mechanism through a gear train and solenoid on the exit module.

The Ink Loader: Melts the solid ink as ink is required by the printhead. The melted

ink drops into the ink reservoirs of the printhead underneath the ink loader.

The Printhead: Interfaces with the electronics of the printer to jet ink onto the

drum surface to create an image. The print head 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 System: Creates a thin intermediate liquid transfer

surface, a 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 its transfer to the sheet of paper or transparency film.

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 gear train then loads the transfix system and presses the paper to the drum to adhere the image as the drum spins in the transfix direction.

The Electronics Subsystem: 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 board, Input/Output board, and Drum Heater Relay board. In the back frame assembly, there is an additional power supply board.

Theory of Operation 2-3

Process Drive

The process drive is an open loop system that transmits torque to two main camshaft assemblies. One camshaft assembly controls the transfix roller loading, and the other controls the drum maintenance system and printhead tilt system. 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

Transfix Camshaft

Process Motor Gear

Drum

Maintenance

Camshaft

Drum Maintenance

s8500-009

2-4 Phaser 8400/8500/8550 Color Printer

Media Path Drive

The media path drive gearbox and motor assembly controls each roller in the paper transport system. 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 path drive assembly, 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

Takeaway Roller

Pick Roller

s8500-010

Theory of Operation 2-5

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 ink reservoirs of the printhead underneath. 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 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 Loader Door

Ink Stick

Ink Melt Units

Ink Low Sensor (1 Sensor for 8400)

Ink Out Sensors (4 Sensors, One For Each Color For 8500/8550)

Printhead

s8500-011

2-6 Phaser 8400/8500/8550 Color Printer

Printhead

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 printquality modes.

Reservoir

Drum

Printhead

Head Driver Board

Purge Tube

Jet Stack

s8500-012

Theory of Operation 2-7

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 140 degrees centigrade.

2-8 Phaser 8400/8500/8550 Color Printer

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 X-Axis 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.

Theory of Operation 2-9

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 Color Printer

DM Cam Gear

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 printers have a new solenoid that is actuated and deactuated when the tilt cam gear rotates to the respective engaged and disengaged positions.

Theory of Operation 2-11

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 tilt gear solenoid in the 8500/8550.

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

Head Tilt Compond Gear Tilt Drive Gear

Tilt Gear Engaged

s8500-133

To accommodate printhead maintenance, the printhead can be tilted back away from the drum. This creates room for the wiper to be moved 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 Color Printer

Drum Maintenance System

The drum maintenance system creates a thin intermediate liquid transfer surface, a 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 its transfer to the sheet of paper or transparency film. The oil is contained in porous foam rollers made from rolled paper/ fiber material.

Prior to each print, the process motor drives a cam to raise the pivot plate, which raises the oil roller against the rotating drum. The same cam raises the compliant 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 maintenance kit, stores the number of oiling cycles performed by the drum maintenance system. The EEPROM stores the number of prints remaining to track consumable life. At printer startup, four oiling cycles are performed to condition the drum.

Drum

Oil on Drum

Blade

Drum Maintenance Camshaft

Drum Maintenance Pivot Plate

Maintenance Roller

s8500-016

Theory of Operation 2-13

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

To perform a printhead maintenance cycle, the printhead is first tilted away from the drum, to allow the wiper assembly to pass by. The wiper blade is then raised in front of the printhead. Wiper movement is governed 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.

Purge Tube

Purge Pump

s8500-017

2-14 Phaser 8400/8500/8550 Color Printer

The level of the ink in the reservoir is kept at a constant level. If the pressure 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.

arning

When servicing the printer be careful of the purge system as it passes the printhead. If a damaged wiper blade of the purge system 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 Assembly

Drum

Wiper

Purge Tube

Printhead

s8500-018

Theory of Operation 2-15

Drum Assembly And Transfix System

The drum assembly and transfix system form the key portion of the printer where imaging takes place. The drum assembly and transfix system are separate, yet interrelated. This section discusses the drum assembly. The next section provides more detail on the transfix system.

In operation, the image to be printed on paper is first “printed” on the rapidly rotating drum. The paper preheater heats a sheet of paper or transparency film to prepare it for the image transfer process. The heated paper is then passed between the drum (now rotating much more slowly) and the transfix roller. The pressure between the drum and the transfix roller transfers the image to the sheet of paper. An encoder disk and sensor on the left end of the drum monitors the drum’s speed and position.

Tranfix Roller

Paper Path

Paper Preheater

Drum

Drum Heater

The drum heater heats the surface of the drum to about 60 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. A temperature sensor in contact with the drum surface 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.

s8500-019

C (140oF) for imaging.

2-16 Phaser 8400/8500/8550 Color Printer

A closed-loop servomotor drives the drum assembly. Through a single reduction belt

drive, the servomotor rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper. The Y-Axis uses an active tension system to allow the pulley to float while the spring actively adjusts the tension.

Note

The drum rotates in different directions for each process.

■ Transfix CW

■ Maintenance CCW

■ Printing CCW

Single Reduction Belt Drive

Pulley

Drum Temperature Sensor

Fan

CCW

Air Direction

Tension Spring

Y-Axis Motor

Y-Axis Encoder

8400

8500/8550

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.

Theory of Operation 2-17

s8500-020

Transfix System

The transfix roller applies pressure to the back side of the paper as it moves between the transfix roller and drum. This pressure transfers the image from the drum to the paper. A set of springs determines how much pressure the transfix roller applies in the load module against the drum. The pressure must be uniform across the length of the transfix roller to avoid paper wrinkles and light spots on the prints.

After the transfix roller engages, the drum rotates to advance the paper during the transfix process. The drum continues to advance the paper 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 camshaft engages.

arning

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

s8500-021

2-18 Phaser 8400/8500/8550 Color Printer

Electronics Module

The electronics module includes the main board, the power control board, and the power supply. The electronics module is a Field Replaceable Unit (FRU) assembly.

Main Board

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 (ETN). When the electronics module is replaced, the 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 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, the main board provides support for Ethernet (all printer configurations), and USB 2.0 external I/O interfaces. The 8500/ 8550 configurations do not include parallel interfaces.

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.

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

Theory of Operation 2-19

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 readdress 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 paper preheater thermal fuses are located on the paper preheater. Additional thermal fuses are located on the printhead and on the ink melting elements.

2-20 Phaser 8400/8500/8550 Color Printer

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

n k

Vcc

Vss

AC Neutral

I n k

H 1 1

AC Line

r e s

H 1 0

REG

Line

Gnd Ref

Neutral

r e

jsrjs

H 4

H 3

H 2

s8500-022

P r

e h t

H 8

H 9

+3.3 V

+15 V

-15 V

+50 V

-50 V

H13 H12 H11 H10

H9 H8 H4 H3 H2 H1

H 1 3

Serial

Control

Interface

uProcessor

H 1 2

Theory of Operation 2-21

Sensors

Ink Out

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

(x1 for 8400; x4 for 8500/8550)

Strip Sensor

Exit Door Sensor

Ink Low

Paper Exit Sensor

Drum Temperature Sensor

Preheater Sensor

Front Door Sensor

Deskew Sensor

Tray Empty Sensor (Also in Trays 3 & 4)

Pick Sensor (525-sheet Feeder)

Drum Position Encoder

Tray Paper Size Sensor Board

Tray Lift Sensor

(Also in Trays 3 & 4)

s8500-023

2-22 Phaser 8400/8500/8550 Color Printer

Print Process

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 drum rotation drive system; the closed-loop servo drive system is inherently dangerous. Fingers caught in the belts and gears will result in serious injuries.

Theory of Operation 2-23

Drum Preparation

To prepare the drum, the drum maintenance system applies a thin coating of silicone 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

Printing

To print, the drum begins to 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 "Jet Substitution Mode" on page 6-9.

2-24 Phaser 8400/8500/8550 Color Printer

Paper Pick for Tray 1

To pick a sheet of paper, the Tray 1 solenoid is fired, 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 assembly prevents multiple sheets from being picked by the pick roller.

Key differences in the Tray 1 pick process include:

■ Optimized 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.

Drive Gear

Spring Loaded Lift Plate

Cam

Pick Roller

Separator Pad

s8500-024

Theory of Operation 2-25

Paper Pick for Trays 2 - 4

Note

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 nudge 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 rollers 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

Retard Roller

Strip Sensor

Exit Sensor

Pick Roller

Nudger Roller

s8500-025

2-26 Phaser 8400/8500/8550 Color Printer

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 roller

nip.

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

3. Stripping the paper from the drum.

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

printing.

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 paper with the image on the drum.

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

Once the paper is stopped in the transfix nip, the process motor gears move to rotate the transfix camshaft to bring the transfix roller into contact with the drum (see illustrations on following pages). The transfix roller nip applies the load necessary to transfer the image to the paper from the drum.

At the point where the transfix roller loads, but before the drum begins to rotate, the paper stripper solenoid engages. The paper stripper solenoid energizes the paper stripper. 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 paper and transfix the image. The stripper blade catches the leading edge of the sheet of paper and separates it from the drum. After the leading edge of the paper 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 path drive now rotates the exit rollers in the correct direction to pull the paper out. However, the deskew clutch is de energized so the deskew rollers are not driven during transfix. The exit rollers deposit the paper into the output tray, ending the print cycle.

Theory of Operation 2-27

Transfix Load Module

Transfix Load Spring

Transfix Load Arm

Transfix Cam

Transfer Roller

Drum

Transfix Roller Gear

Process Drive

Swing Arm Gear

s8500-026

2-28 Phaser 8400/8500/8550 Color Printer

Strip Solenoid

Release Blade

Preheat Sensor

Transfix Roller

Exit Sensor

Paper Preheater

Strip

Sensor

s8500-027

Theory of Operation 2-29

Duplex Printing

When duplex printing, the exit rollers pull the paper to a predetermined location, such that the trailing edge of the paper is adjacent to the exit rollers. Then, the exit rollers pull the paper back into the duplex path. The paper deskews against a non-rotating deskew nip. From this point on, the print is processed through the paper preheater and transfix system to the exit tray in the same manner as a single-sided print. Phaser 8500/8550 printers include a preheater lift solenoid 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 Phaser 8500/8550 preheater operates at a higher temperature than the Phaser 8400, the solenoid is not needed on Phaser 8400 printers.

Exit Sensor

Strip Sensor

Preheat Sensor

Duplex Roller

Deskew Sensor

Exit Roller

Preheater Lift Solenoid (Phaser 8500/8550 Only)

Duplex Roller

s8500-028

2-30 Phaser 8400/8500/8550 Color Printer

Transfix and Print Speeds

Transfix Speeds

Characteristic Setpoint, Paper Media

Fast Color Standard Enhanced High Res/

Photo

Peak Transfix Speed, Simplex tray feed

Peak Transfix Speed, Duplex

Peak Transfix Speed, Legal

Peak Transfix Speed, Tray 1

First Sheet Transfix Speed

20 ips (8400) 25 ips (8500)

5 ips (8400)

10 ips (8500)

20 ips 17 ips 13 ips 7 ips

13 ips 7 ips 7 ips 7 ips

7 ips 7 ips 7 ips 7 ips

17 ips (8400) 25 ips (8500)

5 ips (8400

10 ips (8500)

13 ips (8400) 20 ips (8500)

5 ips (8400

10 ips (8500)

7 ips (8400)

10 ips (8500)

5 ips (8400)

10 ips (8500)

Setpoint, OHP Media

Peak Transfix Speed 5 ips

Approximate Print Speeds (8400 Series)

Tray (Source) /

Resolution

Tray 1

Fast Color (300x300 dpi) 10 pages per minute (ppm) 10 sides per minute (spm)

Standard (300x450 dpi) 9 ppm 9 spm

Simplex, A4 Paper Auto Duplex, A4 Paper

Enhanced (563x400 dpi) 8 ppm 4 spm

High Res/Photo (525 x

2400)

PCL 600 x 300 Mode PCL 600 x 600 Mode

6 ppm 3 spm

6.5 ppm 3 ppm

Tray 2 - 4

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

Theory of Operation 2-31

Approximate Print Speeds (8400 Series) (Continued)

Tray (Source) /

Resolution

High Res/Photo (525x2400) 7 ppm 7 spm

PCL 600 x 300 Mode PCL 600 x 600 Mode

Simplex, A4 Paper Auto Duplex, A4 Paper

13 ppm

6 ppm

Approximate Print Speeds (8500/8550 Series)

Tray (Source) /

Resolution

Tray 1

Fast Color (225 x 400 dpi) 12 pages per minute (ppm) 8.5 sides per minute (spm)

Standard (300 x 450 dpi) 9 ppm 7 spm

Enhanced (525 x 450 dpi) 6 ppm 5 spm

High Res/Photo (525 x 2400 dpi)

PCL 600 x 300 Mode PCL 600 x 600 Mode

Trays 2 - 4

Simplex, A4 Paper Auto Duplex, A4 Paper

3.5 ppm 3 spm

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 2400 dpi)

PCL 600 x 300 Mode PCL 600 x 600 Mode

10 ppm 6 spm

16 ppm

8ppm

2-32 Phaser 8400/8500/8550 Color Printer

Printer Self-Maintenance

To maintain peak operation, reliability, and print quality, 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 print-quality defect is noted.

■ Printhead Maintenance Cycle (Eliminate Light Stripes)

■ Paper Preheater Cleaning (Remove Print Smears)

■ Transfix Roller Oiling

■ Drum Cleaning (Chase Page)

Printhead Maintenance Cycle (Eliminate Light Stripes)

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

Theory of Operation 2-33

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 paper preheater that may have been deposited there. Heavierweight, 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 paper preheater.

In the paper preheater cleaning cycle, these events take place:

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

2. The printer overheats the paper preheater to about 110

inside the paper preheater. Ordinarily the paper 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 paper 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 paper path and up to 20 sheets go through the duplex paper path.

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

Because of the higher paper temperatures involved, this function can also be used to clean the drum surface of ink deposits caused by a contaminated blade on the drum maintenance system.

C and 70o C for paper or transparency film printing.

C, softening ink trapped

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 transfers 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 Color Printer

Configuration Card Personality Parameters

Configuration Card “Shadowed” Personality Parameters

NCL Subject NCL Item Size (bytes)

N/A “version” not NCL 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 4

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

Theory of Operation 2-35

Configuration Card “Shadowed” Personality Parameters (Continued)

NCL Subject NCL Item Size (bytes)

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

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

2-36 Phaser 8400/8500/8550 Color Printer

Configuration Card “Shadowed” Personality Parameters (Continued)

NCL Subject NCL Item Size (bytes)

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. NCL = Nest Configuration Library

Theory of Operation 2-37

2-38 Phaser 8400/8500/8550 Color Printer

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

Section

Introduction

This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running service diagnostic 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, print-quality 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 Color Printer

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

PE LED PS LED Description

Off or 1 Blink, and then off

On Solid (dimly)

Off PS and

1Rapid

2Rapid

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 65) 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 "Miscellaneous Electrical Troubleshooting" on page 4-65). See also, "Verifying Power Supply Operation" on page 4-75.

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.

Service Manual 3-3

BIST Error Reporting Blink Pattern Definition Table (Continued)

PE LED PS LED Description

3Rapid

blinking

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" on page 8-54. For replacement, go to the Parts List on page 9-3.

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 Complete.ly, 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.

Note

Before replacing the electronics module for any POST errors, do the following:

1. Unplug all wiring and/or cables to the electronics module.

2. Plug in the AC power cable and power on the printer electronics module.

3. If the error blink pattern is now different from the original error reported before

Step 1, the problem may not be in the electronics module, (see "Miscellaneous Electrical Troubleshooting" on page 4-65).

3-4 Phaser 8400/8500/8550 Color Printer

POST Error Reporting Blink Pattern Definition Table

Control Panel Error Code

PS, PE and Control Panel LEDs

POST Error Type Description

01.01 Flutter then 01 blinks

02.01 Flutter then 02 blinks

02.02 Flutter then 02 blinks

03.01 Flutter only Soft ID read failure.

03.02 Flutter then 03 blinks

03.03 Flutter only. Soft Version mismatch.

03.04 Flutter then 03 blinks

04.01 Flutter and then 04 blinks

04.02 Flutter and then 04 blinks

04.03 Flutter and then 04 blinks

04.04 Flutter and then 04 blinks

05.01 Flutter and then 05 blinks

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

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

07.01 Flutter only Soft Control Panel link is invalid or bad parity.

07.02 Flutter only Soft Control Panel version mismatch.

08.01 Flutter only Soft Control Panel failed to initialize, POST soft

09.01 Flutter only Soft Control Panel data path failure, bad data

10.01 Flutter and then 10 blinks

Hard Bad error code.

Hard Failed machine check.

Hard Printer panic.

Hard Mismatch.

Hard Access failure.

Hard ID read failure.

Hard ID mismatch.

Hard TMVL mismatch, write/read failed.

Hard TMVH mismatch, write/read failed.

Hard Communications error. PLD I/O Board serial,

link down/bad parity.

mismatch.

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

error.

returned.

Hard PLD power control link down.

Service Manual 3-5

POST Error Reporting Blink Pattern Definition Table (Continued)

Control Panel Error Code

10.02 Flutter only Soft PLD power control link invalid, mismatch error.

11.01 Flutter and

11.02 Flutter and

11.03 Flutter and

11.04 Flutter and

12.xx Flutter only Soft Configuration card test failure.

13.01 Flutter and

13.02 Flutter and

14.xx Flutter and

15.01 Flutter and

15.02 Flutter and

15.03 Flutter and

15.04 Flutter and

15.05 Flutter and

15.06 Flutter and

PS, PE and Control Panel LEDs

then 11 blinks

then 13 blinks

then 14 blinks

then 15 blinks

POST Error Type Description

Hard EEPROM read failure.

1. Check EEPROM orientation.

2. Replace EEPROM.

Hard EEPROM write failure.

1. Check EEPROM orientation.

2. Replace EEPROM.

Hard EEPROM re-read failure.

1. Check EEPROM orientation.

2. Replace EEPROM.

Hard EEPROM data failure, mismatch error.

1. Check EEPROM orientation.

2. Replace EEPROM.

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).

Hard PHY reset failure, reset stuck low.

Hard PHY ID error, mismatch error.

Hard USB ASIC test errors, N2280 netchip read,

write, and mismatch errors, POST hard errors.

Hard CPU interrupt error, spurious CPU interrupts.

Hard CPU interrupt error, missing CPU interrupts.

Hard CPU interrupt error, IRQ spurious assertion.

Hard CPU interrupt error, timer no assertion.

Hard CPU interrupt error, spurious assertion.

Hard CPU interrupt error, no assertion.

3-6 Phaser 8400/8500/8550 Color Printer

POST Error Reporting Blink Pattern Definition Table (Continued)

Control Panel Error Code

PS, PE and Control Panel LEDs

POST Error Type Description

15.07 Flutter and then 15 blinks

15.08 Flutter and then 15 blinks

15.09 Flutter and then 15 blinks

15.10 Flutter and then 15 blinks

15.11 Flutter and then 15 blinks

16.01 Flutter only Soft Real time clock read failure.

16.02 Flutter only Soft Real-time clock write failure.

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

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

17.01 Flutter and then 17 blinks

18.01 Flutter and then 18 blinks

18.02 Flutter and then 18 blinks

18.03 Flutter and then 18 blinks

18.04 Flutter only Soft IPCB version mismatch.

19.01 Flutter and then 19 blinks

Hard CPU interrupt error, spurious assertion.

Hard CPU interrupt error, no assertion.

Hard CPU interrupt error, spurious assertion.

Hard CPU interrupt error, no assertion.

Hard CPU interrupt error, IRQ spurious assertion.

Hard Memory test, less than 128 MB of RAM

detected. This is the minimum RAM required. Add more RAM. Reseat the RAM SODIMM(s), then replace the RAM SODIMM(s).

Hard IPCB ID read failure.

Hard IPCB ID mismatch.

Hard IPCB PCI configuration failure.

Hard Check and reseat cables. Replace hard drive, if

necessary.

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

Service Manual 3-7

Fault Code Error Message Troubleshooting

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 will be displayed on the printer’s Control Panel.

Interpreting Fault Codes

■ Failing system (XX,yyy.zz)

■ 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.4 fault code. This indicates a hardware problem. The most common device faults

troubleshooting procedures are documented in this section.

(xx,yyy.6 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.7 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.

x) Device faults are indicated by a 4 in the tenths place of the

x) Program faults are indicated by a 6 in the tenths place of the

z) CPU exceptions are indicated by a 7 in the tenths place of the

Note

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.

3-8 Phaser 8400/8500/8550 Color Printer

1,000.4x Error - 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

Step Questions or Actions Yes No

1. Unplug all connectors to the optional

525 sheet feeder.

2. Remove the feeder and inspect the connector.

3. Replace any damaged connectors either on the 525-sheet feeder or engine.

4. Reseat and reconnect the 525-sheet feeder to the printer.

5. Did this correct the problem?

1. Inspect the pick rollers in the 525-sheet

feeder tray(s).

2. Are the pick rollers damaged, dirty, or not moving freely?

1. Run the Tray [3]/[4] Pick Clutch test.

2. Does the pick clutch operate correctly?

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

2. Does the lift motor operate correctly?

1. Check the wiring from the 525-sheet feeder

to the Electronics Module (J390).

2. Is the wiring defective?

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.

525-sheet feeder.

Replace the 525-sheet feeder.

1,0XX.6x Errors: 525-Sheet Feeder program faults

a. Reseat the printer onto the 525-sheet feeder. b. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on

page 4-77).

c. Reset NVRAM. d. Replace the 525-sheet feeder.

Service Manual 3-9

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

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

Troubleshooting Procedure

Step Questions or Actions Yes No

1. Are all wiring connections to and from the

I/O Board properly seated?

1. Reseat the connections.

2. Power on the printer.

3. Did the error reoccur?

1. Test the wiring from the I/O board J840 to

the power control board J800.

Go to Step 3. Go to Step 2.

Go to Step 3. Complete.

Replace the I/O Board.

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 for the printer (see "Ensuring Ground Integrity" on

page 4-77).

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

3,0XX.6x - IPC Program Faults

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

a. Reset NVRAM, and then retest. b. Replace the EEPROM chip.

3-10 Phaser 8400/8500/8550 Color Printer

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

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.

Troubleshooting Procedure

Step Questions and Actions Yes No

C).

1. Verify the temperature of the room where the

printer is located (see "Environmental Specifications" on page 1-11).

2. Is the room temperature too cold for proper operation of the sytem?

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

4. Did this correct the problem?

1. Run the Monitor Heaters tests with all heaters ON.

2. Are the heaters operating correctly and

within specification?

1. Inspect the wiring harness to the failed heater.

2. Is the wiring harness damaged or not working properly?

Complete. Go to Step 2.

Replace the electronics module.

Replace the wiring harness to the failed heater.

Go to Step 3.

Replace the problem component.

Service Manual 3-11

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

Step Questions and Actions Yes No

1. Run the Check Wiper Alignment test.

2. Did the test fail?

1. Run the Wiper Drive test.

2. Did the test fail?

1. Inspect the wiper drive system and wiper

lock system. Look for ink in the belts.

2. Is the wipe system operating correctly?

1. Inspect the head maintenance clutch.

2. Is there the presence of oil or

contamination?

1. Run the Head Maintenance Clutch test.

2. Is the head maintenance clutch operating

correctly?

Perform the Wiper Alignment Procedure and test again. Go to Step 2 if the test fails again.

Go to Step 3. Go to Step 5.

Go to Step 4. Replace the

Clean the interior of the sytem and replace clutch if necessary.

Replace in the following order:

■ Exit module

■ Media drive

gearbox

■ Wiper blade

Go to Step 2.

problem component.

Go to Step 5.

Replace the head maintenance clutch.

3-12 Phaser 8400/8500/8550 Color Printer

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

Cannot successfully home the drum transfix mechanism.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Check for obstructions around the 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.

3. Did this fix the problem?

1. Ensure the wiring around the printhead is

routed properly.

2. Is the wiring blocking the printhead?

1. Remove the waste tray and printhead and

look for ink build-up in the printer.

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

1. Check the process gearbox for damage.

2. Ensure the gears are correctly aligned (see

"Homing the Process Gear Drive Train" on page 6-8).

3. Is the process gearbox damaged?

1. Check the X-axis motor connector for

damage.

2. Run the X-axis Motor test to check the X-axis motor current.

3. Did the test fail?

1. Run the Tilt Drive test.

2. Did the test fail?

Complete. Go to Step 2.

Re-route all wiring to the printhead.

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

Replace the process gearbox.

Replace the Xaxis motor.

Replace the process gearbox.

Go to Step 3.

Go to Step 4.

Go to Step 5.

Go to Step 6.

4,0XX.6x Process Control Software Fault

a. Reset NVRAM and then retest. b. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on

page 4-77).

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

Service Manual 3-13

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.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. From the service diagnostic Monitor Menu,

run the Y-axis Encoder test.

2. Did the test pass?

1. Inspect the Y-axis motor connector.

2. Is the wiring faulty?

1. Inspect the encoder wiring harness.

2. Is the wiring faulty?

1. Run the Y-axis Drive test.

2. Check the current values.

3. Are the values within normal operating

range?

1. Run the Y-axis Belt Tension test.

2. Check the current values.

3. Are the values within the normal operating

range?

1. Run the Y-axis Motor test.

2. Did the tests pass?

Go to Step 2. Go to Step 3.

Replace the wiring harness or Y-axis motor.

Replace the defective wiring.

Go to Step 5. Replace the

Go to Step 6. Replace the

Replace the drum assembly.

Go to Step 4.

Replace the drum assembly.

Y-axis motor.

Y-axis belt.

Replace the Y-axis motor.

5,0XX.6x Errors - Program Faults

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

5,005.67: If not in the homeless 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 4-77).

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

3-14 Phaser 8400/8500/8550 Color Printer

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

6,000.41: An X-axis motor current error occurred.

Troubleshooting Procedure

Step Questions and Actions Yes No

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.

4. Is anything visibly restricting printhead movement?

1. Clear the wiring or ink spill, which is restricting movement of the printhead.

2. Did this correct the problem?

1. Inspect the X-axis wiring harness.

2. Is the wiring damaged or faulty?

1. Use service diagnostics to test the X-axis drive.

2. Did the test fail?

Go to Step 2. Go to Step 3.

Complete. Go to Step 3.

Replace the defective wiring.

Replace the Xaxis motor.

Go to Step 4.

Replace the electronics module.

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 4-77).

Service Manual 3-15

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

Step Questions and Actions Yes No

1. Verify the process drive system is properly

homed, see "Homing the Process Gear Drive Train" on page 6-8.

2. Did this resolve the problem?

1. Use service diagnostics to run the Tilt Axis Drive test.

2. Did the test fail?

1. Check for and remove any obstructions in

the process gearbox.

2. Ensure the process drive gears are correctly aligned.

3. Are the gears damaged?

1. Use service diagnostics to run the Process Motor test.

2. Did the test fail?

1. Use service diagnostics to run the Transfix Drive Slow test.

2. Did the test fail?

Complete. Go to Step 2.

Go to Step 3. Go to Step 4.

Replace the process gearbox.

Replace the process gearbox

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

Go to Step 4.

Go to Step 5.

Replace the process gearbox.

7,006.xx: The head tilt solenoid is not activating the CAM, or the head is not tilting

properly.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Reboot the printer.

2. Is the tilt-head activating the CAM?

1. Is ink blocking the CAM?

2. Is the tilt-head latch properly installed?

1. Review instructions for 7,008.xx and

7,010.xx fault codes.

Go to Step 3. Go to Step 2.

Replace the tilthead solenoid, bracket, or latch and spring.

Follow recommended actions for error codes and reboot the printer.

Remove ink spills or reinstall the head-tilt and start over with Step 1.

3-16 Phaser 8400/8500/8550 Color Printer

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

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Check the printhead wiring for proper

routing.

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.

5. Did this correct the problem?

1. To ensure the gears are correctly aligned,

homed, and free from damage, see "Homing the Process Gear Drive Train" on page 6-8.

2. Did this correct the problem?

Complete. Go to Step 2.

Replace the process gearbox.

Complete.

7,008.41: The head tilt is not engaged, or the printhead is stuck in the tilt position by

the tilt arms.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Reboot the printer.

2. Did this correct the problem?

1. Inspect the printer for ink spills on the head

tilt gear and the drive train.

2. Clean and reboot the printer.

3. Did this correct the problem?

1. Ensure that the printhead moves properly

left and right.

1. Ensure the gears are correctly aligned and homed (see "Homing the Process Gear Drive Train" on page 6-8).

2. Are the gears damaged?

1. Check the process gearbox for obstructions

or damaged.

2. Remove any obstructions.

3. Is the gearbox damaged?

1. Use service diagnostics to run the Tilt Axis

Drive test.

2. Did the test fail?

Go to Step 2. Complete.

Complete. Go to Step 3.

Go to Step 4. Remove any

obstructions or replace any defective parts.

Replace the process gearbox.

Go to Step 5.

Go to Step 6.

Go to Step 7.

Service Manual 3-17

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Use service diagnostics to run the Head

Maintenance Wiper Clutch test.

2. Did the test fail?

1. Perform the Wiper Alignment procedure (see

"Wiper Alignment Procedure" on page 6-2).

2. Did this correct the problem?

1. Use service diagnostics to run the Wiper

Drive Test.

2. Did the test fail?

Replace the wiper drive clutch.

Complete. Go to Step 9.

Inspect the maintenance drive system and replace any defective parts.

Go to Step 8.

Replace the exit module assembly.

7,009.42: The printhead is tilted back but not properly restrained in the park arms.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Ensure that the right and left printhead

restraints work correctly and are not cracked or broken.

1. Ensure that the wiper is aligned correctly (see "Wiper Alignment Procedure" on page 6-2).

1. Check the printhead wiring for proper routing.

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

3. Did this correct the problem?

1. Ensure the gears are correctly aligned and

homed (see "Homing the Process Gear Drive Train" on page 6-8).

2. Did this correct the problem?

1. Replace the process gearbox.

2. Did this correct the problem?

1. Use service diagnostics to run the Head Maintenance Wiper Clutch test.

2. Did the test fail?

1. Use service diagnostics to run the Wiper Drive test.

2. Did the test fail?

Complete. Go to Step 2.

Complete. Go to Step 3.

Complete. Go to Step 4.

Complete. Go to Step 5.

Complete. Go to Step 6

Replace the wiper drive clutch.

Inspect the maintenance drive system, replace any defective parts.

Go to Step 7.

Replace the exit module assembly.

3-18 Phaser 8400/8500/8550 Color Printer

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 home sensor is still in a not homed position, after the

return home motion has been completed.

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

7,015.43: The head tilt restraint spring is out of place.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Reboot the printer.

2. Did this correct the problem?

1. Do the printhead lock arms rotate correctly? Go to Step 3. Repair/replace

1. Has ink spilled ink around the printhead that

prevents the printhead from moving to its center position? You should be able to manually push the printhead right to left.

1. Does the X-axis motor drive the printhead to it’s center position (so it can tilt forward)?

1. Check the process gearbox for obstructions 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.

4. Did this correct the problem?

1. Has ink spilled on the head tilt gear on its

drive train (near left side of the printhead).

1. Use service diagnostics to run the Head Maintenance Wiper Clutch test.

2. Did the test fail?

1. Ensure the wiper is properly aligned.

2. Use service diagnostics to run the Wiper Drive Te st .

3. Did the test fail?

1. Use service diagnostics to run the Load Maintenance Clutch test.

2. Did the test fail?

Complete. Go to Step 2.

the lock arms.

Clean the printhead area.

Go to step 5. Troubleshoot

Complete. Go to Step 6.

Clean the gears.

Replace the wiper drive clutch.

Replace the exit module assembly.

Inspect the maintenance drive system, replace any defective parts.

Go to Step 4.

the X-axis drive.

Go to Step 7.

Go to Step 8.

Go to Step 9.

Go to step 10.

Service Manual 3-19

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Verify the headtilt gear will engage. You can

manually set the headtilt gear.

2. Is the gear engaged properly?

1. Use service diagnostics to run the Tilt Axis Drive test.

2. Did the test fail?

1. Use service diagnostics to run the Process Motor test.

2. Did the test fail?

Go to Step 11. Set the headtilt

gear.

Replace the process gearbox.

Replace the process motor.

Go to Step12.

7,0XX.6x Errors - Program Faults

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

page 4-77).

3-20 Phaser 8400/8500/8550 Color Printer

8,0XX.xx Error - Wiper/Media Path Gearbox Faults

8,005.48: The media path motor gearbox stalled while moving the wiper to the 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 the home position.

8,009.43: The media path motor stalled while moving without the clutch engaged.

8,015.49: The media path motor stalled while moving the cap/wipe to the park

position.

8,025.41: The media path motor stalled while moving the cap/wipe from the park

position.

8,035.42: The media path motor stalled while moving the cap/wipe UP.

8,045.43: The media path motor stalled while moving the cap/wipe DOWN.

8,055.44: The media path motor stalled while engaging headtilt.

Troubleshooting Procedure

Step Questions and Actions Yes No

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 pick solenoid to view the meshing of the take away roller’s gears to the paper path drive module.

3. Did this correct the problem?

For an 8,007.41 error:

1. Check for a missing KL-clip securing the

drum maintenance clutch. Replace if missing.

2. Did this correct the problem?

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 paper drive is fully seated and correctly installed.

3. Remove the pick solenoid to view the meshing of the take away roller’s gears to the paper path drive module.

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

5. Did this correct the problem?

Complete. Go to Step 4.

Service Manual 3-21

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Run the Wiper Drive test.

2. Did the test pass?

1. Run the Wiper Alignment test (see "Wiper

Alignment Procedure" on page 6-2).

2. Did the test pass?

1. Inspect the wiper system for improper

operation, obstructions, or damage (broken gear or belt).

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

3. Did this correct the problem?

1. Run the Head Maintenance Clutch test.

2. Did the test pass?

1. Is the head lock mechanism on the right end

of the exit module assembly is functioning properly?

1. Are there obstructions or spilled ink on the wiper blade, the tilt gear drive path, or under the printhead?

2. Is the waste tray overfilled?

8,0XX.6x Errors - Program Faults

Go to Step 5. Go to Step 6.

Go to Step 7. Go to Step 6.

Complete. Go to Step 7.

Go to Step 8. Replace the

maintenance clutch.

Go to Step 9. Replace the

Clean the inside of the printer and retest.

exit assembly.

Replace the exit module assembly.

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

page 4-77).

3-22 Phaser 8400/8500/8550 Color Printer

9,0XX.xx Errors - Ink Loader Faults

9,000.44: These fault indicate a problem with the ink loader.

9,005.49: Ink loader fault. The cyan ink melt heater is on, but the ink does not

appear to be dripping.

9,006.41: Ink loader fault. The magenta ink melt heater is on, but the ink does not

appear to be dripping.

9,007.42: Ink loader fault. The yellow ink melt heater is on, but the ink does not

appear to be dripping.

9,008.43: Ink loader fault. The black ink melt heater is on, but the ink does not

appear to be dripping.

9,015.4x through 9, 018: When a customer opens and closes the inkloader door 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: When a customer opens and closes the inkloader door

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

9,035.4x through 9, 038: Fault codes associated when ink count 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.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Are the ink sticks all Xerox ink? Go to

1. Manually verify that the ink stick is able to

advance in the ink loader chute.

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

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

2. Did the test pass?

Step 2.

Go to Step 3.

Replace the printhead.

Advise customer. Run clearISCfault test to clear the error.

Remove any blockage and/ or replace the ink stick.Run clearISCfault test to clear the error.

Replace the ink loader assembly. Run clearISCfault test to clear the error.

Service Manual 3-23

9,009.44 and 900X.6x

9,009.44: This fault code 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 4-77).

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

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

11,002.48: Lower 525-sheet feeder 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.

11,005.42: Power control broken serial link detected.

11,006.43: 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.

11,011.48: 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

Step Questions and Actions Yes No

1. Ensure ground integrity for the printer.

2. Did this resolve the error?

1. Inspect and reseat all connectors.

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.

4. Did this correct the problem?

Complete. Go to Step 2.

Complete. Go to Step 3.

3-24 Phaser 8400/8500/8550 Color Printer

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Reset NVRAM and retest.

2. Did this resolve the problem?

■ 11, 001.47 and 11,017.45 Replace tray lift motor or the

■ 11,002.48 and 11, 016.44 Replace lower tray assembly (or

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

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

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

■ For all other 11,000.4x errors: Replace the electronics module.

Complete. Go to Step 4.

electronics module.

check wiring).

11,100.60 - Temperature Error

The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Ensure room temperature is not too high. Ensure also that the electronics fan runs correctly. If OK, then replace the electronics module.

12,000.60 Errors - Program Faults

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

page 4-77).

13,0XX.xx Errors - Thermal Faults

13,000.48: Thermal fault.

Troubleshooting Procedures

Step Questions and Actions Yes No

1. Ensure ground integrity for the printer.

2. Did this correct the problem?

1. Reset NVRAM and retest.

2. Did this correct the problem?

1. Check and reseat all data cables to the

printhead.

2. Did this correct the problem?

13,003.42:

Service Manual 3-25

Complete. Go to Step 2.

Complete. Go to Step 3.

Complete. Replace the

printhead.

13,007.46:

Troubleshooting Procedures

Step Questions and Actions Yes No

1. Ensure ground integrity for the printer.

2. Did this correct the problem?

1. Reset NVRAM and retest.

2. Did this correct the problem?

Complete. Go to Step 2.

Complete. Replace in the

following 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.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printers optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

1. Ensure ground integrity of the printer (see

"Ensuring Ground Integrity" on page 4-77).

2. Are all components grounded properly?

1. Is the error code associated with an

overheat condition?

1. Verify clearance for adequate air flow.

2. Are any of the vents blocked?

1. Using service diagnostics, run the Drum Fan Motor test.

2. Did the test pass?

1. Check the electronics module fan.

2. Is the fan operating correctly?

1. Using service diagnostics, run the Drum Temperature Sensor test.

2. Did the test pass?

Advise customer of specification requirements.

Go to Step 3. Resolve ground

Go to Step 4. Go to Step 6.

Advise customer of clearance specification.

Go to Step 6. Replace the

Go to Step 7. Replace the

Go to Step 8. Replace the

Go to Step 2.

integrity.

Go to Step 5.

drum fan and/or the wiring harness.

electronics module fan.

drum temperature sensor.

3-26 Phaser 8400/8500/8550 Color Printer

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Using service diagnostics, run the Drum

Heater test.

2. Did the test pass?

Replace the drum assembly.

Replace the drum temperature sensor.

13,067.43: The drum thermistor circuit is open.

13,069.45: The drum thermistor circuit is shorted.

13,071.47: The drum thermistor returned a bad reading, or the reading was corrupted

by ESD (Electrostatic Discharge).

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Using service diagnostics, run the Drum

Temperature Sensor test.

2. Did the test pass?

1. Inspect the sensor wiring harness.

2. Is the wiring free from defects?

Go to Step 2. Replace the

drum temperature sensor.

Replace the drum temperature sensor.

Replace the sensor wiring 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

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printers optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

1. Run the Preheater test.

2. Did the test pass?

1. Check the wiring from the preheater.

2. Is the wiring connected properly and sound?

Advise customer of specification requirements.

Replace the I/O board.

Replace the preheater board.

Go to Step 2.

Go to Step 3.

Replace the wiring harness.

Service Manual 3-27

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

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

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

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

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

corrupted by ESD.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printers optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

1. Ensure ground integrity of the printer (see

"Ensuring Ground Integrity" on page 4-77).

2. Are all components grounded properly?

1. Use service diagnostics to run the Left Jetstack Temperature test.

2. Did the test pass?

1. Check and reseat all wiring to the printhead.

2. Did this correct the problem?

Advise customer of environmental specification requirements.

Go to Step 3. Resolve ground

Go to Step 4. Replace the

Complete. Replace the

Go to Step 2.

integrity.

printhead.

3-28 Phaser 8400/8500/8550 Color Printer

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

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

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

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

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

corrupted by ESD.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printer’s optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

1. Ensure the ground integrity of the printer

(see "Ensuring Ground Integrity" on page 4-77).

2. Are all components grounded properly?

1. Run the Right Jetstack Temperature test.

2. Did the test pass?

1. Check and reseat all wiring to the printhead.

2. Did this correct the problem?

Advise customer of specification requirements.

Go to Step 3. Resolve ground

Go to Step 4. Replace the

Complete. Replace the

Go to Step 2.

integrity.

printhead.

13,264.42: The reservoir heater got too hot.

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

13,323.47: The reservoir thermistor circuit is open.

13,325.49: The reservoir thermistor circuit is shorted.

13,327.42: The reservoir thermistor returned a bad reading, or the reading was

corrupted by ESD.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printer’s optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

Advise customer of specification requirements.

Go to Step 2.

Service Manual 3-29

Troubleshooting Procedure (Continued)

Step Questions and Actions Yes No

1. Ensure ground integrity of the printer (see

"Ensuring Ground Integrity" on page 4-77).

2. Are all components grounded properly?

1. Run the printhead Reservoir Temperature

test.

2. Did the test pass?

1. Check and reseat all wiring to the printhead.

2. Did this correct the problem?

Go to Step 3. Resolve ground

integrity.

Go to Step 4. Replace the

printhead.

Complete. Replace the

printhead.

13,328.43: The CYAN heater is too hot.

13,330.45: The CYAN heater took too long to reach its setpoint.

13,387.48: The CYAN thermistor circuit is open.

13,389.41: The CYAN thermistor circuit is shorted.

13,391.43: The CYAN thermistor returned a bad reading, or was corrupted by ESD.

13,392.44: The MAGENTA heater is too hot.

13,394.46: The MAGENTA heater took too long to reach its setpoint.

13,451.49: The MAGENTA thermistor circuit is open.

13,453.42: The MAGENTA thermistor circuit is shorted.

13,455.44: The MAGENTA thermistor returned a bad reading, or ESD corruption.

13,456.45: The YELLOW heater got too hot.

13,458.47: The YELLOW heater took too long to reach its setpoint.

13,515.41: The YELLOW thermistor circuit is open.

13,517.43: The YELLOW thermistor circuit is shorted.

13,519.45: The YELLOW thermistor returned a bad reading, or ESD corruption.

13,520.46: The BLACK heater got too hot.

13,522.48: The BLACK heater took too long to reach its setpoint.

13,579.42: The BLACK thermistor circuit is open.

13,581.44: The BLACK thermistor circuit is shorted.

3-30 Phaser 8400/8500/8550 Color Printer

13,583.46: The BLACK thermistor returned a bad reading, or ESD corruption.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Verify that the ambient temperature of the

room is within the printers optimal environmental specification (see "Environmental Specifications" on page 1-11).

2. Is the room too cold or too hot?

1. Ensure ground integrity of the printer (see

"Ensuring Ground Integrity" on page 4-77).

2. Are all components grounded properly?

1. Run the appropriate Ink Melt test.

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

2. Did the test pass?

1. Inspect and reseat the wiring to the ink

loader.

2. Did this correct the problem?

Advise customer of specification requirements.

Go to Step 3. Resolve ground

Replace the electronics module.

Replace the ink loader.

Go to Step 2.

integrity.

Go to Step 4.

Replace the I/O board.

13,000.6x Errors - Program Faults

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 4-77).

Service Manual 3-31

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.

Troubleshooting Procedure

Step Questions and Actions Yes No

1. Check and reseat all wiring to the printhead.

2. Did this correct the problem?

Complete. Replace in the

following order:

■ Printhead

■ Electronics

Module

19,0XX.6x - Errors

19,001.68 thru 19,039.61: Waveform printhead calibration program faults.

a. Reset NVRAM, and then retest. b. Replace the NVRAM chip.

21,000.69 Errors - Diagnostic Code Version Mismatch

a. The diagnostic firmware does not match the engine firmware. Update the

diagnostic firmware for the printer. If a code updated ROM daughter board is installed on the main board, remove the board so the preheater boots using the main board’s code and diagnostics.

22,0XX.6x Errors - Jam Codes

a. For jam codes, "Jam Codes" on page 3-50.

23,0XX.6x Errors - NVRAM Fault

a. Reset NVRAM, and then retest. b. Replace the NVRAM.

26,0XX.6x Errors - Printing Faults

a. Reboot the printer if one of these faults occur.

3-32 Phaser 8400/8500/8550 Color Printer

Xerox Phaser 8400, Phaser 8500, Phaser 8550 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

United States

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 Path Drive

Ink Loader

Printhead

Printhead Tilt

Drum Maintenance System

Purge System

Drum Assembly And Transfix System

Transfix System

Electronics Module

Main Board

Configuration Card

Power Control Board

Power Supply

Sensors

Print Process

Drum Preparation

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 Error - 525-Sheet Feeder Faults

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

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

3,0XX.6x - IPC Program Faults

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

4,0XX.6x 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.6x Errors - Program Faults

8,0XX.xx Error - Wiper/Media Path Gearbox Faults

8,0XX.6x Errors - Program Faults