Xerox Phaser 8400, Phaser 8500, Phaser 8550 Service Manual
Phaser® 8400/8500/8550
color printer
Service
Manual
Phaser
W
8400/8500/8550 Color
Printer
Service Manual
arning
The following servicing instructions are for use by qualified service
personnel only. To avoid personal injury, do not perform any servicing other
than that contained in the operating instructions, unless you are qualified to
do so.
®
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 Unpublished rights reserved under the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.
®
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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
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Colors generated may not match PANTONE-identified standards. Consult current PANTONE
Publications for accurate color. PANTONE
Pantone, Inc. © Pantone, Inc., 2000.
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User Safety Summary
W
W
W
W
Terms in Manual
Caution
Conditions that can result in damage to the product.
arning
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.
arning
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
arning
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
Contents
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
1
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
MB
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
1
Status Indicator LED:
1
Green: Ready to print.
Yellow: Warning condition, printer
continues to print.
Red: Startup sequence or error
condition.
Blinking: Printer is busy or warming
up.
Phaser 8500
READY TO PRINT
Walk-Up Features
Information
Paper Tray Setup
Printer Setup
Troubleshooting
2
5
5
3
6
4
Up Arrow button
Scrolls upward through the menus.
8
7
s8500-003
Graphic display indicates status
2
messages and menus.
Cancel button
3
Cancels the current print job.
Back button
4
Returns to the previous menu item.
Down Arrow button
6
Scrolls downward through the menus.
OK button
7
Accepts the selected setting.
Help (?) or Information button
8
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
9
8
7
6
5
4
3
2
1
10
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
11
8. Exit cover
9. Ink loader/top cover
10.Legal/A4 output tray extension
12
11.Interface cover
12.Side door
s8500-004
Right Side View with Printer Interfaces
1. Maintenance kit
4
1
3
2
s8500-005
General Information 1-7
2. Waste tray
3. Power cord connection
4. Power switch
5
5. Parallel port connection
6
7
8
(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.
2
4
1
3
1
s8500-006
1. Hard drive (optional) 3. Configuration card (Installed from the
side under the interface cover.)
2. Memory (RAM) DIMM 1 and DIMM 2 4. NVRAM (configuration card handles
NVRAM differences between 8400 and
8500 series).
1-8 Phaser 8400/8500/8550 Color Printer
Routine Maintenance Items and Consumables
3
1
2
3
4
2
1
-
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
º
10º - 32
20 - 25
C (50º - 90º F) operating
º
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
60–120 g/m
121–220 g/m
60–120 g/m
60–120 g/m
60–120 g/m
60–120 g/m
60–120 g/m
2
(16–32 lb. Bond)
2
(32–59 lb. Bond)
2
(37–44 lb. Cover)
2
(44–80 lb. Cover)
2
(16–32 lb. Bond)
2
(16–32 lb. Bond)
2
(32–59 lb. Bond)
2
(16–32 lb. Bond)
2
(16–32 lb. Bond)
2
(16–32 lb. Bond)
2
(16–32 lb. Bond)
2
(16–32 lb. Bond)
Any Tray
Tray 1 O n l y
2-Sided (Duplex)
l
l
l
l l
l
l
l
l l
l l
l l
l l
l l
l l
l l
l
l
l
l l
l l
l l
l l
l l
Single-sided Only
l
l
l
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
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Tray 1 O n l y
2-Sided (Duplex)
Single-sided Only
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General Information 1-13
1-14 Phaser 8400/8500/8550 Color Printer
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