How it Works
Xerox
Loading...
Phaser 8510MFP
Advanced Features Manual
100 pgs757.6 Kb0
User Manual
281 pgs5.96 Mb0

Xerox Phaser 8510MFP, Phaser 8560MFP Service Manual

Download
Phaser 8560MFP Multifunction Product Service Documentation
701P01133 October 2006
Phaser 8560MFP Multifunction Product
Service Documentation
Phaser 8560MFP Multifunction Product Service Manual
705P01133
Bus Updated November 1, 2006, Reissue
10/2006
Acrobat®, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator® PageMaker®, Pho­toshop®, PostScript®, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™, Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Sys­tems Incorporated in the United States and/or other countries.
Apple®, AppleTalk®, Bonjour®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, TrueType®, Apple Chancery®, Chicago®, Geneva®, Monaco®, New York® , and Quick­Draw® are trademarks of Apple Computer, Inc. in the United States and/or other countries.
HP-GL®, HP-UX®, and PCL® are trademarks of Hewlett-Packard Corporation in the United States and/or other countries.
Xerox Corporation
XOG Worldwide Product Training & Information
26600 Parkway - Bldg. 60
P.O. Box 1000, M/S 7060-776
Wilsonville, OR 97070-1000
NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is com­plete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, compo­nents or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.
Unpublished rights reserved under the copyright laws of the United States.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.
IBM® and AIX® are trademarks of International Business Machines Corporation in the United States and/or other countries.
Windows®, Vista™, Windows Server™, and Wingdings® are trademarks of Microsoft Corpo­ration in the United States and/or other countries.
Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services®, IPX™, and Novell Distrib­uted Print Services™ are trademarks of Novell, Incorporated in the United States and/or other countries.
SunSM, Sun Microsystems™, and Solaris™ are trademarks of Sun Microsystems, Incorpo­rated in the United States and/or other countries.
SWOP® is a trademark of SWOP, Inc.
UNIX® is a trademark in the United States and other countries, licensed exclusively through X/ Open Company Limited.
PANTONE® Colors generated may not match PANTONE-identified standards. Consult current PANTONE Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are the property of Pantone, Inc. © Pantone, Inc., 2000.
Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation.
XEROX®, The Document Company®, the digital X®, CentreWare®, infoSMART®, Made For Each Other®, PagePack™, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of Xerox Corporation in the United States and/or other countries.
10/2006
Phaser 8510/8560MFP Multifunction Product
Introduction
ii
About This Manual .......................................................................................................... iii
Organization....................................................................................................................iii
Power Safety................................................................................................................... iv
Service Safety Summary................................................................................................. iv
Moving the System.......................................................................................................... vi
Symbology and Nomenclature ........................................................................................ vii
Electrostatic Discharge Precautions ............................................................................... ix
Regulatory Specifications................................................................................................ ix
Phaser 8510/8560MFP Overview ................................................................................... x
System Configurations.................................................................................................... xi
Parts of the Product ........................................................................................................ xii
Control Panel Layout....................................................................................................... xiv
Specifications..................................................................................................................xvi
Introduction
10/2006
iii
Introduction
About This Manual
The Phaser 8510/8560MFP Multifunction Product Service Manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting the system. It is the controlling publication for a service call. Information on its use is found in the Introduction of the Service Documentation. To ensure understanding of this product, complete the Xerox Service Training Program for this particular system.
For manual updates, Service Bulletins, knowledge base, and technical support, visit www.xerox.com/office/support.
Service Manual Revision
Updates are issued as the system changes or as corrections are identified.
Organization
The titles of the sections and a description of the information contained in each section are contained in the following paragraphs:
Introduction and General Information
This section contains documentation organization, symbology and nomenclature, translated warnings, safety symbols, regulatory specifications, and general information about the printer.
Section 1 Service Call Procedures
This section contains procedures to be taken during a service call and in what sequence they are to be completed. This is the entry level for all service calls.
Section 2 Status Indicator RAPs
This section contains descriptions of the diagnostic aids for troubleshooting that include Power On Self Test (POST), Built-in Self Tests (BIST), and Fault Code error procedures.
Section 3 Image Quality
This section contains the diagnostic aids for troubleshooting image quality problems, as well as image quality specifications and image defect samples.
Section 4 Repairs/Adjustments
This section contains all the removal, replacement, and adjustments procedures.
Repairs
Repairs include procedures for removal and replacement of spare parts listed in the Parts List. Use the repair procedures for the correct order of removal and replacement, for warnings, cau­tions, and notes.
Adjustments
Adjustments include procedures for adjusting the parts that must be within specification for the correct operation of the system. Use the adjustment procedures for the correct sequence of operation for specifications, warnings, cautions and notes.
Section 5: Parts Lists
This section contains the illustrated Parts List.
Section 6: Diagnostic Information
This section contains details of the embedded Service Diagnostics test suite, as well as trou­bleshooting procedures for system problems not related to a specific fault code.
Section 7: Wiring Data
This section contains drawings, lists of plug/jack locations, and diagrams of the power distribu­tion wire networks in the machine. Individual wire networks are shown in the Circuit Diagrams contained in Section 2. This section also contains the Block Schematic Diagrams.
Section 8: Theory of Operation
This section contains detailed functional information on the print engine components.
10/2006
v
About This Manual, Organization
Introduction
Power Safety
Power Source
For 115 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. This manual assumes that the reader is a qualified service technician.
Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If neces­sary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock. A protective ground connection by way of the grounding conductor in the power cord is essential for safe
operation.
Disconnecting Power
WARNING
Turning the power off using the power switch does not completely de-energize the sys­tem. You must also disconnect the power cord from the system’s AC inlet. Disconnect the power cord by pulling the plug, not the cord.
Disconnect the power cord in the following cases:
• if the power cord or plug is frayed or otherwise damaged,
• if any liquid or foreign material is spilled into the product,
• if the printer is exposed to any excess moisture,
• if the printer is dropped or damaged,
• if you suspect that the product needs servicing or repair,
• whenever you clean the product.
Service Safety Summary
General Safety
The system and recommended supplies have been designed and tested to meet strict safety requirements. Attention to the following information will ensure the continued safe operation of the system.
Electrical Safety
• Use the Power Cord supplied with the system.
• Plug the Power Cord directly into a properly grounded electrical outlet.
• Do not use a ground adapter plug to connect the system to an electrical outlet that does not have a ground connection terminal.
• Do not use an extension cord or power strip.
• Do not place the system in an area where people might step on the power cord.
• Do not place objects on the power cord
• Do not block the ventilation openings. These openings are provided to prevent overheat­ing of the system.
• Do not drop paper clips or staples into the system.
WARNING
Avoid the potential of electrical shock by ensuring that the system is properly grounded. Electrical products may be hazardous if misused.
The power cord is attached to the system as a plug-in device on the side of the system. If it is necessary to disconnect all electrical power from the system, disconnect the power cord from the electrical outlet.
WARNING
Do not remove the covers or guards that are fastened with screws unless you are installing optional equipment and are specifically instructed to do so. Power should be OFF when performing these installations. Disconnect the power cord when removing covers and guards for installing optional equipment. Except for user-installed options, there are no parts that you can maintain or service behind these covers
WARNING
The following are hazards to your safety:
• Damaged or frayed Power Cord
• Liquid spilled into the system
• Exposure to water or excessive moisture
If any of these conditions occur, do the following:
1. Turn off the Power Switch
2. Disconnect the Power Cord from the electrical outlet.
3. Call an authorized service representative.
Maintenance Safety
• Do not attempt any maintenance procedure that is not specifically described in the docu­mentation supplied with your system.
• Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition.
Introduction
Power Safety, Service Safety Summary
10/2006
vi
Phaser 8510/8560MFP Multifunction Product
• Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com/gwa.
Operational Safety
The system and supplies were designed and tested to meet strict safety requirements. These include safety agency examination, approval, and compliance with established environmental standards.
Pay attention to these safety guidelines to ensure the continued, safe operation of the system.
• Use the supplies specifically designed for your system. The use of unsuitable materials may cause poor performance and a possible safety hazard.
• Follow all warnings and instructions marked on, or supplied with, the system, options and supplies.
CAUTION
Use of other than Genuine Xerox Solid Ink may affect print and copy quality and system reli­ability. It is the only ink designed and manufactured under strict quality controls by Xerox for specific use with this system. The Xerox Warranty, Service Agreements, and Total Satisfaction Guarantee do not cover damage, malfunction, or degradation of performance caused by use of non-Xerox supplies or consumables, or the use of Xerox supplies not specified for this system.
NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Cover­age may vary outside these areas; please contact your local representative for details.
General Guidelines
For qualified service personnel only: Refer also to the preceding Power Safety Precautions.
Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.
Use care when servicing with power: Dangerous voltages may exist at several points in this product. To avoid personal injury, do not touch exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing compo­nents.
Servicing Electrical Components
Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock.
WARNING
Do not touch any electrical component unless you are instructed to do so by a service procedure.
Figure 1 Electrical Components Warning
Servicing Mechanical Components
WARNING
Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents.
Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all
warning labels remain in place.
Safety Interlocks
Make sure all covers are in place and all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.
10/2006
Figure 2 Mechanical Components Warning
Servicing Printhead Components
WARNING
This system uses heat to fuse the image to media. The Printhead is VERY HOT. Turn the printer power off and wait at least 10 minutes for the Printhead to cool before you attempt to service the Printhead or adjacent components.
Introduction
vii
Service Safety Summary
Moving the System
WARNING
Parts of the system are hot. To avoid personal injury or damage to the system, allow the ink to solidify. Run the shut-down procedure to cool the system quickly. Wait at least 30 minutes for the system to cool completely before moving or packing it.
• Allow the system to cool before it is moved to avoid ink spills which can damage the sys­tem.
• Use the shut-down procedure from the Control Panel before moving the system for best results.
• Never move the system if you receive a Power Down Error-Head not Parked message at the system’s control panel. This message means the system is not ready to be moved. If the printhead is not locked, the system can be damaged during shipment.
• Always turn off the system using the power switch, located under the interface cover on the right side of the system, and unplug all cables and cords. Do not turn off the system by pulling the power cord or using a power-strip with an on/off switch.
• Always secure the scanhead shipping restraint on the left side of the scanner to lock the scanhead before removing the scanner portion of the system. Shipping the scanner with the scanhead unlocked can damage the scanner.
Figure 2 System Lifting Technique
• Always move the system separately from optional Trays 3 and 4. When shipping the system, repack the system using the original packing material and boxes or
a Xerox repackaging kit. Additional instructions for repacking the system are provided in the repackaging kit. If you do not have all the original packaging, or are unable to repackage the system, contact your local Xerox service representative
CAUTION
Failure to repackage the system properly for shipment can result in damage to the system. Damage to the system caused by improper moving is not covered by the Xerox warranty, ser­vice agreement, or Total Satisfaction Guarantee.
Figure 1 Locking the Scanhead
• Always remove the document feeder before shipping the system.
• Always remove the scanner before shipping the system.
• The system is heavy and must be lifted by two people. The illustration below shows the proper technique for lifting the system.
Introduction
10/2006
Moving the System
viii
Phaser 8510/8560MFP Multifunction Product
Symbology and Nomenclature
The following reference symbols are used throughout the documentation.
Warnings, Cautions, and Notes
Warnings, Cautions, and Notes will be found throughout the Service Documentation. The words WARNING or CAUTION may be listed on an illustration when the specific component associated with the potential hazard is pointed out; however, the message of the WARNING or
CAUTION is always located in the text. Their definitions are as follows:
WARNING
A Warning is used whenever an operating or maintenance procedure, a practice, condi­tion, or statement, if not strictly observed, could result in personal injury.
CAUTION
A Caution is used whenever an operating or maintenance procedure, a practice, condition, or statement, if not strictly observed, could result in damage to the equipment.
NOTE: A Note is used whenever it is necessary to highlight an operating or maintenance pro­cedure, practice, condition, or statement.
Table 2 Additional Warnings
REP 5.0.2 Scanner Power Supply REP 5.0.19 Drum Heater Relay Board
WARNING
HIGH VOLTAGE! DANGER: HAUTE TENSION! Exercise care when making the voltage check in the following steps. DANGER: Soyez extrêmement vigilant lorsque vous effectuez les tests de tension au
cours des étapes qui suivent.
WARNING
Personal injury may result from grasping hot areas of Printhead. If a hot Printhead must be removed, grasp the Printhead by black plastic frame component.
DANGER: Des blessures peuvent résulter si les zones chaudes du module de four sont touchées. Si un module de four chaud doit être enlevé, le saisir par l'élément en plas­tique noir du bâti.
Common Warnings and Safety Icons
The following common warnings are used throughout the documentation and the safety icons are displayed on the machine. Additional specific warnings are included for the listed sections.
Common Warnings
WARNING
To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.
DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon d'alimentation branché.
The following sections have additional specific warning information.
Table 1 Introduction and Section 4
Introduction - Symbology and Nomenclature Section 4 - Repairs and Adjustments
WARNING
A Warning is used whenever an operating or maintenance procedure, a practice, condi­tioning, or statement, if not strictly observed, could result in personal injury.
DANGER: Une note DANGER est utilisée à chaque fois qu’une procédure de mainte­nance ou qu’une manipulation présente un risque de blessure si elle n’a pas été stricte­ment observée.
The following sections have additional specific warning information.
Table 2 Additional Warnings
REP 2.0.2 Print head Assembly REP 2.0.8 Left and Right Printhead Restraints
Machine Safety Icons
The following precautionary symbols may appear on the system.
This symbol indicates DANGER high voltage.
Figure 1 High Voltage Symbol
Protective ground (earth) symbol.
Figure 2 Protective Ground (earth) Symbol
These symbols indicate hot surface on or in the printer. Use caution to avoid personal injury.
Figure 3 Hot Surface Symbol
10/2006
ix
Introduction
Symbology and Nomenclature
The surface is hot while the printer is running. After turning off the power, wait 30 minutes.
Figure 4 Wait 30 Minutes Symbol
Avoid pinching fingers in the printer. Use caution to avoid personal injury.
Figure 5 Pinch Injury Symbol
Voltage Measurement and Specifications
Measurements of DC voltage must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure. All measurements of AC volt­age should be made with respect to the adjacent return or ACN wire.
Table 3 Voltage Measurement and Specifications
Voltage Specification
INPUT POWER 220 V 198 VAC TO 254 VAC INPUT POWER 100 V 90 VAC TO 135 VAC INPUT POWER 120 V 90 VAC TO 135 VAC +5 VDC +4.75 VDC TO +5.25 VDC +24 VDC +23.37 VDC TO +27.06 VDC
Logic Voltage Levels
Measurements of logic levels must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure.
Use caution (or draws attention to a particular component). Refer to the manual(s) for informa­tion.
Figure 6 Use Caution Symbol
Electrostatic Discharge (ESD) Field Service Kit
The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of electronic components that are handled by the Field Service Personnel. This program is being implemented now as a direct result of advances in microcircuitry technology, as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today.
This program will reduce Field Service costs that are charged to PWB failures. Ninety percent of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will improve product reliability and reduce callbacks.
The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled. This includes activities like replacing or reseating circuit boards or connectors. The kit should also be used in order to prevent additional damage when circuit boards are returned for repair.
The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Procedures section of the Service Documentation.
Table 4 Logic Levels
Voltage H/L Specification
+5 VDC H= +3.00 TO +5.25 VDC
L= 0.0 TO 0.8 VDC
+24 VDC H= +23.37 TO +27.06 VDC L= 0.0 TO 0.8 VDC
DC Voltage Measurements in RAPs
The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP:
There is +5 VDC from TP7 to TP68.
In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.
If a second test point is not given, it is assumed that the black meter lead may be attached to the copier frame.
Introduction
Symbology and Nomenclature
10/2006
x
Phaser 8510/8560MFP Multifunction Product
Electrostatic Discharge Precautions
Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semicon­ductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.
Be sure the power is off to the chassis or circuit board, and observe all other safety precau­tions.
• Immediately before handling any semiconductor components assemblies, drain the elec­trostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.
• After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.
• Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices.
• Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it.
• Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.
• Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device.
• Handle IC’s and EPROM’s carefully to avoid bending pins.
• Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s).
Regulatory Specifications
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 A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protec­tion against harmful interference when the equipment is operated in a commercial environ­ment. 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. Operation of this equipment in a residential area is likely to cause harm­ful interference in which case the user will be required to correct the interference at his/her own expense.
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 A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme
à la norme NMB-003 du Canada.
European Union
This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
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:
10/2006
xi
Electrostatic Discharge Precautions, Regulatory
Introduction
Table 1 Low Voltage Directive 73/23/EEC as amended
EN 60950-1:2001
Table 2 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 61000-3-3:1994 IEC 61000-4-2:1995 IEC 61000-4-3:1995 IEC 61000-4-4:1995 IEC 61000-4-5:1995 IEC 61000-4-6:1996 IEC 61000-4-11:1994
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.
Phaser 8510/8560MFP Overview
The Phaser 8510/8560MFP uses a Printhead and four-color (YMCK) solid-ink sticks, with an image processor supporting PostScript 3 and PCL5c page description languages. The system is a high performance, Letter or A4, 24 (8510MFP) or 30 (8560MFP) page per minute (ppm) multifunction product, supporting resolutions up to 525 x 1200 dots-per-inch (dpi). The product features USB, Fax, and 10/100 base T Ethernet ports, with an optional Foreign Device Inter­face (FDI) for specialized installations. The 8510/8560MFP provides a 100-sheet Tray 1 from which specialty media, card stock, and envelopes are fed. Tray 1 also supports manual feed­ing. Tray 2 provides 525 sheets of capacity. The Output Tray holds 250 sheets facedown. On most configurations an Automatic Document Feeder (DADF) is installed providing enhanced document handling functionality.
Phaser 8510/8560MFP options add memory, media capacity and functionality. RAM memory upgrades are available to raise installed memory to the 1 GB maximum. A 525-Sheet Feeder is also available. Two 525-Sheet Feeders may be installed to raise the maximum media input storage capacity to 1675 sheets. A Configuration Card stores system model identity and con­figuration parameters.
After a predefined period of time since its last activity, the Phaser 8510/8560MFPP enters a power saver standby mode. All communications interfaces remain active and have the ability to wake the system up.
Introduction
Regulatory Specifications, Phaser 8510/8560MFP
10/2006
xii
Figure 1 Phaser 8510/8560MFP Multifunction Product with Optional Trays
Phaser 8510/8560MFP Multifunction Product
System Configurations
Standard Features
The Phaser 8510/8560MFP offers these standard features:
• Maximum print speed (pages per minute) based on letter-size plain paper:
NOTE: Print speeds for media fed from Tray 1 may be up to 50% slower.
Table 1 Phaser 8510/8560MFP Print Speeds
Phaser 8510MFP Multifunction Product Phaser 8560MFP Multifunction Product
PostScript Print Quality Modes: – Fast Color: 24 ppm
– Enhanced: 12 ppm
PCL Print Quality Modes: – 300 x 600 dpi: 13 ppm
– 600 x 600 dpi: 6 ppm
PostScript Print Quality Modes: – Fast Color: 30 ppm
– Standard: 24 ppm – Enhanced: 16 ppm – High Resolution/Photo: 10 ppm PCL Print Quality Modes:
– 300 x 600 dpi: 16 ppm – 600 x 600 dpi: 8 ppm
Product Options
Phaser Multifunction Product options include:
• Additional Trays
• Memory
•System Cart
Additional Trays
Trays 1 and 2 are standard on all configurations. The following additional tray combinations are supported:
• One 525-Sheet Feeder (Tray 3)
• Two 525-Sheet Feeders (Trays 3 and 4)
Memory
All configurations have two memory slots supporting 512 MB, and 1 GB SODIMM modules (up to maximum of 1 GB DDR2).
System Cart
The System Cart supports a fully-optioned system and provides space for media storage.
• First-page-out: 8 seconds for color prints, 15 seconds for color copies
• Copy, Print, Scan, Fax capabilities (options vary according to configuration and memory)
• Connections: USB, Ethernet 10/100/1000 Base-Tx, RJ-11 Fax Modem, Foreign Device Interface
Available Configurations
Table 2 lists the standard configurations.
Table 2 Phaser 8510/8560MFP Standard Configurations
Features 8510MFP/N 8510MFP/D 8560MFP/D 8560MFP/T 8560MFP/X
Memory 512 MB 512 MB
Hard Drive No No Yes Yes Yes Flash Disk Yes Yes No No No Automatic 2-sided
Printing (DADF) 525-Sheet Feeder No* No* No* Yes Yes System Cart No* No* Yes Yes Yes Copy Yes Yes Yes** Yes** Yes** Scan to PC Yes Yes Yes Yes Yes Scan to E-mail Yes Yes Yes Yes Yes Scan to Hard Drive No No Yes Yes Yes Fax Yes Yes Yes** Yes** Yes** * This option can be purchased separately for this configuration.
** Hard Drive enables advanced features on this configuration.
No Yes Yes Yes Yes
(2x256)
512 MB 512 MB 512 MB
Metered Printing
Metered printing (PagePack), involves the combination of control software and specialized Ink Sticks to meter system activity for billing purposes. The Configuration page lists Metered Ink as Enabled when metering is enabled.
Metered Operation
When a metered printer is initialized at first power-up, the customer sets the printer to Metered operation using a unique, factory-supplied, 4-digit PIN. Once set to Metered operation, the con­trol software performs the following:
1. The Mode and PIN-entered values in Engine Control Board NVRAM are set.
2. The Control Panel momentarily displays “Metered Ink is now enabled”, then returns to “Ready” (if no other errors).
3. The First Time Tips pages and the Configuration page are printed.
If an incorrect PIN is entered, “Incorrect numeric password” displays with a prompt “Retry” or “Do not retry.” Retry returns to the enter prompt, “Do not retry” returns to the Replace Ink Stick error message. The error persists until the correct PIN is entered.
NOTE: The Hidden Service menu provides an Enable Metered Ink option to restore the Metered mode parameters to NVRAM should they become lost or corrupt.
Metered Ink
To support metered printing, metered Ink Sticks are available in all four colors. The shape of the metered Ink Stick differs from the non-metered versions.
10/2006
xiii
Introduction
System Configurations
Parts of the Product
Front View
Figure 1 Front View
1. Tray 4 (optional)
2. Tray 3 (optional)
3. Tray 2
4. Tray 1 (MPT)
5. Output Tray
6. Exit Cover
7. Control Panel
8. Duplex Automatic Document Feeder (DADF) Front Cover
9. DADF
10. Interface Cover
11. Drum Maintenance Kit and Waste Tray access
12. Front Door Latch
Open View
Figure 2 Open View
1. Output Tray
2. Short Paper Stop
3. Exit Cover
4. Ink Loader Cover
5. Scan Head Lock
Introduction
Parts of the Product
10/2006
xiv
Phaser 8510/8560MFP Multifunction Product
Side View with Interface Connections
Figure 3 Side View with Interface Connections
1. Drum Maintenance Kit
2. Waste Tray
3. AC Power Cord Connection
4. Power Switch
5. Scanner Cable Connection
6. USB Connection
7. Ethernet Connection
8. Configuration Card
9. RJ-11 Fax Modem Connection
Back View - Electronics Module
The system’s main electronics and power supply are enclosed in a metal case called the Elec­tronics Module. The rear panel allows access to the electronics module, RAM, and NVRAM chips. The system’s Hard Drive is mounted on the rear panel.
Figure 4 Back View
1. RAM Connectors
2. NVRAM Device
3. Hard Drive
4. Printer Stabilizer
NOTE: When replacing the electronics module, transfer these components to the new module.
•RAM
• Configuration Card
• NVRAM Device
• Hard Drive or Flash Disk
10/2006
xv
Introduction
Parts of the Product
Routine Maintenance Items
Control Panel Layout
The Control Panel functions are segregated into three areas.
Figure 1 Control Panel
Table 1 Control Panel Functional Areas
Left Side Center Right Side
Copy, Scan, and Fax functions and indicator LEDs
Control Panel Left
The left side of the control panel contains the following copy, scan, and fax function buttons and LEDs. A lighted LED indicates the current selection. Figure 2 shows each function’s location.
Display, Mode, Navigation but­tons, and status LED’s
Numeric keypad, Stop, Start, Clear, and Clear All buttons
Figure 5 Routine Maintenance Items and Consumables
Table 1 Routine Maintenance Life Expectancy
Routine Maintenance Items
Extended-Capacity Maintenance Kit 30,000 cycles (0-20% coverage)
20,000 cycles (20-100%) coverage. Standard-Capacity Maintenance Kit 10,000 cycles Waste Tray Empty every 7 Purges DADF Pick Rollers and Separator Pad 50,000 scans
Introduction
Parts of the Product, Control Panel Layout
Figure 2 Left Side Control Panel
1. Color Mode selects black and white or color for copy or scan jobs.
2. Document Type selects the type of document (photo, graphic, mixed text and graphics, or text only), for copy or scan jobs.
3. Output Quality selects the output quality mode for copies: fast color, standard, enhanced, or high-resolution/photo.
4. 2-Sided selects either one or 2-sided for the original and one- or 2-sided for the output.
5. Lighten/Darken selects a setting for copy, scan, or fax jobs.
6. Reduce/Enlarge selects scale percentage for output: 25, 50, 100, 150, 200, 400.
10/2006
xvi
Phaser 8510/8560MFP Multifunction Product
7. The Down Arrow reduces the reduce/enlarge percentage in one percent increments.
8. The Up Arrow increases the reduce/enlarge percentage in one percent increments.
9. Reduce/Enlarge Percentage display indicates the current educe/enlarge setting.
Control Panel Center
The center of the Control Panel contains the display, mode and navigation buttons, as well as the status LED. Figure 3 shows each function’s location.
Figure 3 Center Control Panel
1. Copy displays the Copy menu.
2. Scan displays the Scan menu.
3. Print displays the Print menu.
4. Fax displays the Fax menu.
5. System displays the System Setup menu.
6. Help(?) provides additional information about the menu or message displayed.
7. OK accepts the highlighted menu selection.
8. Down Arrow scrolls downward through menu selections.
9. Up Arrow scrolls upward through menu selections.
10. Back returns the previous menu to the display.
11. Control Panel display.
12. Status LED uses color to indicate these states of the current function:
• Green indicates the system is ready to print, copy, scan, or fax.
• Yellow indicates a warning condition. The system continues the operation.
• Red indicates a startup or operational error condition.
• Blinking indicates a warm-up or busy condition.
Control Panel Right
The right side of the Control Panel contains the numeric keypad, Start, Stop, and Clear but­tons, as well as Fax control functions. Figure 4 shows each function’s location.
Figure 4 Right Side Control Panel
1. Numeric keypad for entering numbers for sending a fax, selecting a number of copies, or entering a numeric password.
2. Start initiates the selected function (copy, scan. or fax).
3. Stop pauses a print, copy, scan, or fax job. To cancel the job, follow the instructions indi­cated on the display.
4. Clear All resets all job settings and returns to the top of the default function.
5. Pause enters a pause in a fax number.
6. Delayed Send stores a time for fax transmission.
7. Send List to view or add fax numbers to a list.
8. Speed Dial accesses directories of groups or individual fax numbers.
Control Panel Shortcuts
Table 2 Short Cuts
Mode Press this selection at Power On
Skip execution of POST diagnostics OK Print Service Diagnostics Map INFO Reset PostScript NVRAM BACK+ON Password Bypass UP+DOWN Enter Service Diagnostics BACK+? before the Xerox logo stops scrolling and
until Beginning Service Mode appears.
10/2006
xvii
Introduction
Control Panel Layout
Specifications
Functional Specifications
Table 1 Functional Specifications
Characteristic Specifications
Printing Process Four-color (CMYK) solid ink Printhead architecture. Image System Transfix transfer from oil coated Drum Color Medium Cyan, Magenta, Yellow, and Black Ink Sticks Resolution Fast Color: 225 x 400 dpi
Standard: 300 x 450 dpi Enhanced: 525 x 450 dpi Photo: 525 x 2400 dpi
First Page-Out (from Ready)
Warm-up Time Color and Monochrome: 12 minutes from Power On
Memory Specifications
Characteristic Specifications
Minimum RAM 512 MB Maximum RAM 1 GB Supported RAM Supports up to 1 GB of DDR2 memory using 2 slots Flash Disk 256 MB NAND Flash Storage in 8510MFP
Color: 8 seconds Monochrome: 8 seconds
Table 2 Memory Specifications
Physical Dimensions and Clearances
Table 4 Print Engine
Dimensions Value
Height 620 mm (24.4 in.) Width 530 mm (20.9 in.) Depth 660 mm (26.2 in.) Weight 42 kg (93 lb.)
Table 5 525-Sheet Feeder
Dimensions Value
Height 132 mm (5.2 in.) Width 422 mm (16.6 in.) Depth 514 mm (20.24 in. Weight 5.2 kg (11.5 lb.)
Media Tray Capacity
Table 3 Tray Capacity
Media and Weight Tray 1 Trays 2 and 3 DADF
Standard Paper 100 Sheets 525 Sheets 50 Sheets Transparency 100 Sheets 50 Sheets Envelopes 50 Weight
The DADF accommodates sizes from 114 x 140 mm (4.5 x 5.5 in.) to 216 x 356 mm (8.5 x
14.0 in.). The weight range includes 60-120 g/m2 (16-32 lb. Bond) (22-45 lb. Cover).
Introduction
75-220 g/m
2
75-255* g/m
2
Specifications
10/2006
xviii
Figure 1 Minimum Clearances
Phaser 8510/8560MFP Multifunction Product
Print Engine Specifications
Table 6 Print Engine Functional Specifications
Characteristic Specification
Printing process Solid-ink Controller 500 MHz processor Color medium Yellow, cyan, magenta, and black ink sticks, each shape-
coded. The system uses the subtractive color system to produce the colors red, green, and blue
Color Management Automatic, Black & White,
Office: sRGB, Vivid Color, None, Press: Commercial, Euroscale, SWOP
FPOT, Color Copy < 15 seconds per page/1st copy
subsequent copies at printer speed. Memory 2 slots; minimum 512 MB, maximum 1 GB, PC133 DRAM Fonts 137 PostScript 3
81 PCL5c Warm-up time From Off (cold start): 12 minutes
From power saver: 4 minutes
Table 7 Scanner/DADF Functional Specifications
Characteristic Specification
Noise Standby: < or equal to 45 dB
Scanning: < or equal to 50 dB
Electrical Specifications
Table 8 Electrical Specifications
Characteristic Specification
Primary Line Voltages 90-135 VAC
Primary Line Voltage Fre­quency Range
Power Consumption at Rated Voltage Input
Energy Star 70 W Scanner Power Supply 30 W
180-254 VAC 47 - 63 Hz
300 W (average during printing) 1500 W (peak) - 1000 typical 220 W (idle)
Scanner/DADF Specifications
Table 7 Scanner/DADF Functional Specifications
Characteristic Specification
Printing Process Print Engine Scan to Capabilities Scan to Disk (mailbox) function
Scan/Copy Process Flatbed platen and C-shape ADF
Copies per Minute DADF: 20 ppm simplex, 10 ppm duplex Memory 2 MB (1M x 16 SDRAM) Image Buffer 32 MB SDRAM for Platen
Bit Depth Reading: 48 bits
Optical Resolution 600 x 300 to 600 x 2400 dpi (FS x SS) Output Resolution from Scan-
ner Calibration Time less than 2 seconds (performed prior to copier and scan
Power Saver Mode Scanner and DADF are switched OFF. Also, lamps automati-
Scan to PC
Charge Coupled Device scan head RGB color pack The scan controller provides 16 bit DMA interface for sending image data through the scanner board to the image proces­sor board in the electronics module.
128 MB SDRAM for DADF
Output: 24 bits
Always equals optical resolution
operations)
cally turn off after 20 minutes.
Environmental Specifications
Table 9 Environmental Specifications
Characteristic Specification
Operating Storage
Temperature Humidity 10% - 80% RH Non-Condensing
Altitude 0 to 2,438 meters (8,000 ft.) 0 to 6,092 meters (20,000 ft.) Acoustic Noise (db) Operating Mode Standby Mode
º
- 32º C / 50º - 90º F operating
10
operating
-30°C to 60°C (-22 F to 140 F) 30% to 95% RH, non-condensing
10/2006
xix
Introduction
Specifications
Image Specifications
Table 10 Print Engine Only Skew Specifications
Characteristic Specification
Printed Left Side Margin 5.0 mm + Leading Edge Margin 5.0 mm +
NOTE: To derive the skew specification for a particular media size, measure the width of the leading edge in millimeters. Next, divide the measured length by 1000, then multiply by the appropriate Image Area Tolerance specification in milli-radians. For example, A 5 in. by 7 in. custom page would have a leading edge width, in millimeters, of 127mm (5 in.). Dividing the 127 by 1000 (127/1000), then multiplying the result by the 11 milli-radians specification results in a maximum skew of 1.4 mm (127/1000) x 11 = 1.4 mm.
Table 11 System Skew Specifications Scan, Copy, Print
Characteristic Specification
Printed Left Side Margin 5.0 mm + Leading Edge Margin 5.0 mm + Image Area Tolerance Zone Image Skew, Envelopes 15.5 milli-radians max across the width of the leading edge. Image Skew, Index Card 18.0 milli-radians max across the width of the leading edge. Image Skew, All other sizes 11.0 milli-radians max across the width of the leading edge.
Characteristic Specification
Maximum Print Area 302 mm x 1194 mm Guaranteed Image Area 297 mm x 1194 mm Resolution/Gradation Fast Color: 300 x 300 dpi
Standard: 300 x 450 dpi Enhanced: 563 x 400 dpi Photo/Hi Res: 525 x 1200 dpi
2.0 mm (0.197 in. + .080 in.)
1.3 mm (0.197 in. + .050 in.)
4.0 mm (0.197 in. + .157 in.)
3.3 mm (0.197 in. + .130 in.)
Table 12 Image Specifications
Media and Tray Specifications
The media trays accommodate most sizes and types of paper, transparencies, or other spe­cialty media. Print the Paper Tips page for a list of supported media.
Media that May Damage the System
The system can use a variety of media for print and copy jobs. However, some media can cause poor output quality, increased jams, or damage. Unacceptable media includes:
• Rough, plastic, or porous media
• Paper that has been stapled, folded, photocopied, or wrinkled
• Envelopes with windows, metal clasps, padding, or adhesives with release strips
• CD labels
• Media that is less than 60 g/m2 or more than 220 g/m2
Media Storage Guidelines
If media handling problems are a common occurrence, review the following storage guidelines with the customer.
• Store paper in dark, cool, relatively dry locations. Most paper items are susceptible to damage from ultraviolet (UV) and visible light. UV radiation, which is emitted by the sun and fluorescent bulbs, is particularly damaging to paper items. The intensity and length of exposure to visible light on paper items should be reduced as much as possible.
• Maintain constant temperatures and relative humidity
• Avoid light, heat, and dampness.
• Avoid attics, kitchens, garages, and basements for storing paper. Inside walls are drier than outside walls where moisture can collect.
• Store paper flat. Paper should be stored on pallets, cartons, shelves, or in cabinets.
• Avoid having food or drinks in the area where paper is stored or handled.
• Do not open sealed packages of paper until needed. Leave paper in the original packag­ing. For most commercial grades, the wrapper’s inner lining protects the paper.
• Some specialty media is packaged inside sealed plastic bags. Leave the media inside the bag until needed; return unused media to the bag.
DADF Media Guidelines
The DADF accommodates sizes from 114 x 140 mm (4.5 x 5.5 in.) to 216 x 356 mm (8.5 x 14.0 in.), with weights within the following range: 60–120 g/m2 (16–32 lb. Bond) (22–45 lb. Cover).
Follow these guidelines when loading originals into the document feeder:
• Load originals face-up, so the top of the document enters first.
• Place only loose sheets of paper in the document feeder.
• Adjust the paper guides so they fit against the originals.
• Insert paper in the document feeder only when the ink on the paper is completely dry.
Use the glass rather than the document feeder to copy or scan the following types of originals:
• Paper with paper clips or staples attached
• Paper with wrinkles, curls, folds, tears, or notches
• Coated or carbonless paper, transparencies, or items other such as cloth or metal
• Envelopes
Supported Media
The following sections provide information about paper sizes and weights that can be used in the system trays. For more detailed information about supported paper and other media, print the Paper Tips page:
1. On the Control Panel, press the System button.
2. Select Information, and then press the OK button.
3. Select Information Pages, and then press the OK button.
4. Select Paper Tips, and then press the OK button to print.
See also: Recommended Media List at www.xerox.com/paper
Introduction
Specifications
10/2006
xx
Phaser 8510/8560MFP Multifunction Product
Service Call Procedures.................................................................................................. 1-3
Initial Actions................................................................................................................... 1-4
Routine Maintenance Activities ....................................................................................... 1-5
Cleaning Procedures....................................................................................................... 1-5
Final Actions.................................................................................................................... 1-6
1 Service Call Procedures
10/2006
1-1
Service Call Procedures
Service Call Procedures
This section describes an overview of the steps a service technician should take, using this manual, to service the system and attached options. The system’s diagnostic routines report problems using error messages and fault codes displayed on the Control Panel, logged in the Service Usage Profile, or by flashing LEDs. These error indications serve as the entry point into the troubleshooting process. System problems not directly indicated by or associated with an error message or fault code are covered in Section 6, General Procedures. Print-quality problems are covered in Section 3, Image Quality.
The steps listed here are a guide for performing any service on this system. If you choose not to use these steps, it is recommended that you start at the appropriate troubleshooting proce­dure and proceed from there. When servicing the system, follow the safety measures detailed in Service Safety Summary.
1. Identify the problem.
• Verify the reported problem does exist.
• Check for any error codes and write them down.
• Print normal customer prints and service test prints.
• Make note of any print-quality problems in the test prints.
• Make note of any mechanical or electrical abnormalities present.
• Make note of any unusual noise or smell coming from the printer.
• Print a Service Usage Profile, if the printer is able to print.
• View the Engine Error and Jam Histories under the Service Tools menu.
• Verify the AC input from the wall outlet is within specifications.
2. Inspect and clean the system.
• Follow the cleaning instructions given in Section 6.
• Verify that the power cord is in serviceable condition.
• Restart the system to check if the error reoccurs.
3. Find the cause of the problem.
• Use the troubleshooting procedures to find the root cause of the problem.
• Use Service Diagnostics to check the system and optional components.
• Use the Wiring Diagrams and Plug/Jack Locator to locate test points.
• Take voltage readings as instructed in the troubleshooting procedure.
4. Correct the problem.
• Use the Parts List to locate a part number.
• Use the Repair procedures to replace the part.
5. Final checkout
• Test the printer to verify the problem is corrected and no new problems arose.
Accessing Engine Fault History
Listed below are three ways in which you can access fault history records.
1. Print (if possible) the Status page from the Troubleshooting menu --> Service Tools. The Engine Error History and Jam History are listed on the second page of the report.
2. View the system’s fault history on the Control Panel. Go to Troubleshooting->Service Tools --> Engine Error History.
NOTE: Definitions of the codes that appear in the Fault and Jam History appear in Sec­tion 2.
3. If the system is connected to a network and has a TCP/IP address, view the system’s web page using a web browser.
a. Open a web browser. b. Enter the system’s IP address as the URL. c. Select the Support --> Troubleshooting --> Diagnostics Logs and the fault history dis-
plays.
Technician’s Tool Kit
Table 1 lists required, recommended, and optional tools used to service this and other similar products.
Table 1 Service Tools Description Detail Required Tools
Torx Driver Bits T5, T8, T10, T15, T20 Phillips Drivers Phillips # 2 and # 1 5.0 x 75 mm, 3.0 x 75 mm, 6.0 x 100 mm Flathead Drivers 5.0 x 75 mm, 3.0 x 75 mm Torque Screw Driver Required for this system P/N 003082700 Hex Bit 2.5mm Hex Bit, T-20 P/N 003086600 Driver Extension Small Channel lock Pliers Needle Nose Pliers Wire Cutters Flashlight Assorted Nut Drivers Lint-Free Cloths Lubricant/Grease Reolube P/N 070E00890 Cleaners Multipurpose surface cleaner and Alcohol ESD Strap
Highly Recommended Tools
Nut Driver 5.5mm (magnetic) P/N 600T2123 Network Cross-over cable Tech Scanner Calibration page P/N 109K01910 Toner Vac Toner and general cleaning Multimeter Volts, Ohms, Current
10/2006
1-3
Service Call Procedures
Service Call Procedures
Table 1 Service Tools Description Detail Optional Tools
Canned Air 3 -Prong Claw Part-Retriever Pointer with Magnetized Head Tweezers Utility Knife Dental Mirror Screw Box Soldering Iron Heat Shrink tubing Electrical Tape Jeweler's Screwdriver Kit Precision/Hobby tool set phillips, flathead, pliers, small torx drivers Serial & Parallel Loop Back
Plugs Bootable CDs and Floppy
Disks IC Chip Puller
Initial Actions
Purpose
Use the following procedure to determine the reason for the service call and to identify and organize the actions which must be performed.
Procedure
1. Gather the information about the service call and the condition of the copier/printer. a. Question the operator(s). Ask about the location of most recent paper jams. Ask
about the image quality and the copier/printer performance in general, including any unusual sounds or other indications.
b. After informing the customer that the machine will not be available for copying and
printing, disconnect the machine from the customer’s network. c. If a new installation, be sure all packing material is removed. d. Check that the power cords are in good condition, directly plugged in to the power
source, and free from defects. Repair or replace the power cords as required. Check
that the circuit breaker, if present, is not tripped. e. If the system appears is inoperative, go to Electrical Troubleshooting and repair the
problem. Then continue below. f. Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality
and weight. Print the Paper Tips page for specific media specifications. Look for any
damage to the copies, oil marks, image quality defects, or other indications of an
unreported problem.
NOTE: If a fault code is displayed while performing a diagnostics procedure, go to
that fault code RAP and repair the fault. Return to Diagnostics and continue with the
procedure that you were performing.
g. Display and review the information in the Fault History, Jam History, Service Usage
Profile. Classify this information into categories:
Information that is related to the problem that caused the service call. Information that is related to secondary problems. Information that does not require action, such as a single occurrence of a prob-
lem.
2. Perform any required routine maintenance activities. Refer to the Routine Maintenance Activities section.
3. If any DADF feed jams are reported, or fault codes are logged, replace the Feed Roll Kit.
4. Try to duplicate the problem by running the same jobs that the customer ran once repairs are complete to verify repairs are effective.
5. Go to General Procedures to further investigate the problem.
Service Call Procedures
Service Call Procedures, Initial Actions
10/2006
1-4
Phaser 8510/8560MFP Multifunction Product
Routine Maintenance Activities
Procedure
1. Clean the Pick Rollers on every call.
2. Use the Control Panel to check maintenance item counters.
3. Compare the counter values to those listed in Table 1.
4. Advise the customer of any routine maintenance items that are approaching or over the service limit.
Table 1 Routine Maintenance Item Life Expectancy
Routine Maintenance Items
Extended-Capacity Maintenance Kit 30,000 cycles (0-20% coverage)
20,000 cycles (20-100%) coverage. Standard-Capacity Maintenance Kit 10,000 cycles Waste Tray Empty every 7 Purges DADF Pick Rollers and Separator Pad 50,000 scans
Cleaning Procedures
Purpose
The purpose is to provide cleaning procedures to be performed at every call.
Procedure
CAUTION
Do not use any solvents unless directed to do so in this manual.
General Cleaning
Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise in this manual. Wipe with a dry, lint free cloth if a moistened cloth is used.
1. Feed Components (Rolls and Pads)
Follow the General Cleaning procedure above.
2. Jam Sensors
Clean the sensors with a dry cotton swab.
3. Scanner
a. Using the optical Cleaning Cloth, clean the Document Glass. b. Clean the Document Cover.
4. DADF
Check the paper path for debris or damage. Clean the rolls with a clean cloth and Film Remover as required.
10/2006
1-5
Service Call Procedures
Routine Maintenance Activities, Cleaning Proce-
Final Actions
Purpose
The intent of this procedure is to be used as a guide to follow at the end of every service call.
Procedure
1. Check that the exterior of the system and the adjacent area is clean. Use a dry cloth or a cloth moistened with water to clean the exterior of the system. Do not use solvents.
2. Check the supply of consumables. Ensure that an adequate supply of consumables is available according to local operating procedures.
3. Conduct any operator training that is needed. Ensure the operator understands the peri­odic maintenance procedures in the User Guide.
4. Reconnect the system to the customer network. Verify function by printing one or more test prints. Present these to the customer as examples of system performance.
5. Issue copy credits as needed.
6. Discuss the service call with the customer to ensure that the customer understands what has been done and is satisfied with the results of the service call.
Service Call Procedures
Final Actions
10/2006
1-6
Phaser 8510/8560MFP Multifunction Product
Power On Self Tests ....................................................................................................... 2-3
NVRAM Reset................................................................................................................. 2-5
Error Message Troubleshooting...................................................................................... 2-7
1,00X.4x 525-Sheet Feeder Faults ................................................................................. 2-8
1,000.6x 525-Sheet Feeder Program Faults................................................................... 2-9
2,00X.xx I/O Board Errors............................................................................................... 2-9
2,006.xx I/O Board Program Faults................................................................................. 2-10
2,0XX.6x Configuration Card Faults................................................................................ 2-10
3,0XX.6x IPC Program Faults......................................................................................... 2-11
4,0xx.4x Process Control Errors ..................................................................................... 2-11
4,024.42 Wiper Alignment Fault...................................................................................... 2-12
4,025.46 Drum Transfix Fault.......................................................................................... 2-12
4,0xx.6x Process Control Program Faults....................................................................... 2-13
5,0xx.4x Y-Axis Sub-System Faults................................................................................ 2-13
5,0xx.6x Y-Axis Sub-System Program Faults ................................................................. 2-14
6,0xx.4x X-Axis Fault ...................................................................................................... 2-15
6,0xx.6x X-Axis Program Faults...................................................................................... 2-15
7,002.44 Process Drive Fault.......................................................................................... 2-16
7,006.4x Head Tilt Solenoid Fault................................................................................... 2-16
7,007.49 Process Drive Fault.......................................................................................... 2-17
7,008.41 Printhead Tilt Fault........................................................................................... 2-17
7,009.42 Printhead Restraint Fault ................................................................................. 2-18
7,01X.4x Process Faults ................................................................................................. 2-19
7,0xx.6x Program Faults ................................................................................................. 2-20
8,0XX.4x Wiper or Media Drive Faults............................................................................ 2-21
8,0xx.6x Media Drive Program Faults............................................................................. 2-22
9,0XX.4x Ink Loader Faults............................................................................................. 2-22
9,009.44 and 9,00X.6x Ink Loader Program Faults ........................................................ 2-23
11,0XX.xx Electronics Module Interface Faults............................................................... 2-24
11,100.60 Electronics Module Temperature Fault .......................................................... 2-25
12,000.60 Program Faults............................................................................................... 2-25
13,000.48 Printhead Thermal Fault................................................................................. 2-26
13,003.42 and 13,007.46 Thermal Faults ....................................................................... 2-26
13,008.47 and 13,010.49 Drum Thermal Faults ............................................................. 2-27
13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults ......................................... 2-28
13,XXX.4x Preheater Thermal Faults ............................................................................. 2-28
13,1XX.4x Left Jetstack Thermal Faults ......................................................................... 2-29
13,2XX.4x Right Jetstack Thermal Faults....................................................................... 2-29
13,XXX.xx Printhead Reservoir Thermal Faults.............................................................. 2-30
13,XXX.xx Ink Loader Thermal Faults ............................................................................ 2-30
13,00x.6x Thermal Program Faults................................................................................. 2-31
19,0XX.4x Printhead Calibration Faults .......................................................................... 2-32
19,0XX.6x Waveform Program Faults............................................................................. 2-32
21,000.69 Diagnostic Firmware Version Mismatch......................................................... 2-33
22,0XX.6x Jam Fault....................................................................................................... 2-33
23,0XX.6x NVRAM Faults............................................................................................... 2-34
26,0XX.6x Printing Faults................................................................................................ 2-34
27,0XX.6x Profile Library ................................................................................................ 2-35
2 Error Messages and Codes
29,0XX.6x Jam Manager Faults ...................................................................................... 2-35
31,001.40 Mechanical Initialization Jam.......................................................................... 2-36
31,0XX.6x Program Faults.............................................................................................. 2-36
33,00X.4x Tray 1 Width Sensor Faults............................................................................ 2-37
34,00X.4x Printhead NVRAM Faults ............................................................................... 2-37
36,000.40 Drum Maintenance Faults .............................................................................. 2-38
36,001.67 Drum Maintenance Drive Faults..................................................................... 2-38
36,002.44 Drum Maintenance Kit Fault........................................................................... 2-39
37,0XX.xx PEST Heater Faults....................................................................................... 2-39
37,01X.41 PEST Fan Faults............................................................................................ 2-40
37,016.43 PEST 50 Volt Supply Fault............................................................................. 2-40
37,0XX.4x PEST Clutch/Solenoid Faults ........................................................................ 2-41
37,024.48 PEST Tray 2 Lift Motor Fault.......................................................................... 2-42
37,026.44 PEST Purge Pump Fault................................................................................ 2-42
37,02X.4x PEST Relay Board Faults .............................................................................. 2-43
37,03X.4x PEST X-Axis Motor Faults ............................................................................. 2-43
37,035.44 and 37,036.45 PEST Y-Axis Motor Faults...................................................... 2-44
37,037.46 and 37,038.47 PEST Media Drive Faults....................................................... 2-44
37,039.48 and 37,040.40 PEST Process Drive Faults.................................................... 2-45
37,0XX.4x PEST Power Supply Faults ........................................................................... 2-45
39,002.40 and 39,003.41 Scanner Subsystem Test Faults ............................................ 2-46
39,004.42 Scanhead Locked or Shipping Restraint Faults ............................................. 2-47
39,005.43 Scanner Missing Fault.................................................................................... 2-47
39,010.8 Document Feeder Disconnected or Missing .................................................... 2-48
39,011.40 and 39,012.40 DADF Subsystem Test Faults................................................ 2-49
39,013.42 Document Feeder Jam................................................................................... 2-49
39,014.43 Document Feeder Calibration Fault ............................................................... 2-50
Jam Codes ...................................................................................................................... 2-50
10/2006
2-1
Error Messages and Codes
Power On Self Tests
This section covers the start-up, Power On Self Test (POST), Service Diagnostics, and power supply operations of the system to aid in troubleshooting problems not associated with a reported error. For problems associated with an error message or code, see Error Message Troubleshooting. Troubleshooting tips are available at: www.xerox.com/support.
Check the main menu for current data and historical error data.
• Status Page
• Usage Profile
• Fault History
• Diagnostic History
Power-Up Error Messages and LED Codes
The system 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.
In addition to the numeric error codes appearing on the Control Panel display, the system uses the Control Panel, PS, and PE LEDs to communicate errors. Figure 1 shows location of the PS and PE LEDs on the Electronics Module.
BIST Error Reporting
BIST verifies basic Electronics Module CPU operation and reports failures using PS and PE LEDs. These LEDs are located on the Electronics Module directly above the Scanner Assem­bly connection. BIST 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:
Table 1 BIST Blink Pattern Error Reporting
PE LED PS LED Description
Off or 1 blink, then Off
On solid (dim) On solid (dim) Initialization failure. The system is held in reset mode. This
Off PS and Control
1 Rapid Blinking The CPU and/or PCI bus is not communicating. Reboot the
2 Rapid Blinking ROM not responding. Reboot the system, if the error still
3 Rapid Blinking System hangs during initialization
Off or 1 blink, then Off
Panel blink at 1/ 2 sec. intervals
The power supply could not remain regulated when DC power was applied so it shut down. Follow the troubleshoot­ing procedures for electrical shorts (see Electrical Trouble­shooting) and check the power supply fuses.
can be caused by an Electronics Module fault or a +3.3 V power supply failure. See Electrical Troubleshooting.
Boot loader memory test failure. Ensure the systems RAM is properly seated and that the correct RAM type is installed.
system. If the error persists, replace the Electronics Module (REP 5.0.5).
occurs, replace the Electronics Module (REP 5.0.5).
1. Unplug all connections to the Electronics Module.
2. Plug in the Power Cable.
3. Power on the system.
4. If the problem persists, reseat the RAM Modules.
5. Replace the Electronic Module (REP 5.0.5).
Figure 1 PS and PE LED Locations
POST Error Reporting
POST checks the communication paths within the Electronics Module and to other various sys­tem 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 system from powering up completely, are displayed on the Control Panel for 5 seconds, and then the system continues through the remainder of POST. There are no rear panel LED codes associated with soft errors. Most soft errors will cause the system to print a Startup Page with the error message on it.
10/2006
2-3
Error Messages and Codes
Power On Self Tests
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 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 Electrical Troubleshooting.
Table 2 POST Blink Pattern Error Reporting
Error
PS, PE, and Control
Code
Panel LED s
01.01 Flutter then 01 blinks Hard Bad error code
02.01 Flutter then 02 blinks Hard Failed machine check
02.02 Flutter then 02 blinks Hard System panic
03.01 Flutter only Soft ID read failure
03.02 Flutter then 03 blinks Hard Mismatch
03.03 Flutter only Soft Version mismatch
03.04 Flutter then 03 blinks Hard Access failure
04.01 Flutter then 04 blinks Hard ID read failure
04.02 Flutter then 04 blinks Hard ID mismatch
04.03 Flutter then 04 blinks Hard TMVL mismatch, read/write failed
04.04 Flutter then 04 blinks Hard TMVL mismatch, read/write failed
05.01 Flutter then 05 blinks Hard I/O Board serial communication error.
05.02 Flutter only Soft I/O Board serial mismatch error.
6.08 No indication Soft Hard Drive failure
07.01 Flutter only Soft Control Panel communications error
07.02 Flutter only Soft Control Panel version mismatch
08.01 Flutter only Soft Control Panel failed to initialize
09.01 Flutter only Soft Control Panel data error
10.01 Flutter then 10 blinks Hard Power control link failure
10.02 Flutter only Soft Power control link invalid, mismatch error
11.01 Flutter then 11 blinks Hard EEPROM read failure
11.02 Flutter then 11 blinks Hard EEPROM write failure
11.03 Flutter then 11 blinks Hard EEPROM re-read failure
11.04 Flutter then 11 blinks Hard EEPROM data failure
12.nn Flutter only Soft Configuration Card failure
13.01 Flutter then 13 blinks Hard PHY reset failure (Low)
13.02 Flutter then 13 blinks Hard PHY ID error
14.nn Flutter then 14 blinks Hard USB ASIC error
15.01 Flutter then 15 blinks Hard CPU interrupt error
15.02 Flutter then 15 blinks Hard CPU interrupt error
15.03 Flutter then 15 blinks Hard CPU interrupt error, IRQ
15.04 Flutter then 15 blinks Hard CPU interrupt error
15.05 Flutter then 15 blinks Hard CPU interrupt error
15.06 Flutter then 15 blinks Hard CPU interrupt error
Error Type Description
Table 2 POST Blink Pattern Error Reporting
Error
PS, PE, and Control
Code
Panel LED s
15.07 Flutter then 15 blinks Hard CPU interrupt error
15.08 Flutter then 15 blinks Hard CPU interrupt error
15.09 Flutter then 15 blinks Hard CPU interrupt error
15.10 Flutter then 15 blinks Hard CPU interrupt error
15.11 Flutter then 15 blinks Hard CPU interrupt error
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 failure
17.01 Flutter then 17 blinks Hard Insufficient RAM memory
18.01 Flutter then 18 blinks Hard IPCB ID read failure
18.02 Flutter then 18 blinks Hard IPCB ID mismatch
18.03 Flutter then 18 blinks Hard IPCB PCI configuration failure
18.04 Flutter only Soft IPCB version mismatch
19.01 Flutter then 19 blinks Hard Hard Drive failure
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 system 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, see Error Message Troubleshooting.
Error Type Description
Error Messages and Codes
Power On Self Tests
10/2006
2-4
Phaser 8510/8560MFP Multifunction Product
NVRAM Reset
Many of the troubleshooting procedures in this section include an NVRAM reset as a proce­dural step. Following an NVRAM reset, the system is unable to communicate on the network and has lost several parameters specific to the customer’s configuration. If possible, print a Configuration page to capture networking parameters. and discuss the customer’s configura­tion to document these settings before resetting NVRAM.
Table 1 lists the parameters reset by NVRAM Reset. Required parameters (Yes) must be con­figured to restore default system operation on the network.
Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command
Menu Parameter Default Required
TCP/IP Setup TCP/IP On Yes
DHCP/BOOTP On Yes AutoIP On Yes TCP/IP Address 0.0.0.0 Yes TCP/IP Network Mask 0.0.0.0 Yes TCP/IP Gateway 0.0.0.0 Yes Port 9100 On Yes LPR On Yes IPP On Yes SLP On Yes SSDP On Yes CentreWare IS On Yes
Network Setup Ethernet Speed Auto Yes
EtherTalk On Yes
USB Setup USB Port On Yes
Wait Timeout (USB) 30 Yes Page Description Language (USB) AutoSelect Yes
Control Panel Setup Control Panel Language English No
Control Panel Brightness 5 No Control Panel Contrast 5 No Accessible Control panel Off No
Copy Defaults Setup Color Mode Color No
2-Sided Copying 1-1 No Output Quality Enhanced No Document Type Mixed No Paper Supply Tray 2 No Color Balance -> Cyan Color Balance 0 No Color Balance -> Magenta Color Balance 0 No Color Balance -> Yellow Color Balance 0 No Color Balance -> Black Color Balance 0 No Laser Original Off No Prescan Glass On No
Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command
Menu Parameter Default Required
Copy Main Number of Copies 1 No
Paper Suppy Tray 2 No Original Size Supply No Prescan Glass On No Preset Reduce/Enlarge None No Collate Auto No Edge Erase -> Left 0.0 No Edge Erase -> Right 0.0 No Edge Erase -> Top 0.0 No Edge Erase -> Bottom 0.0 No Margin Shift -> Long Edge 0.0 No Margin Shift -> Short Edge 0.0 No Auto Center Off No Book Copy -> Both Pages ->Gutter Erase 0.0 No Book Copy -> Left Page -> Gutter Erase 0.0 No Book Copy -> Right Page -> Gutter Erase 0.0 No Auto Suppression Off No Covers -> Cover Tray Tray 1 No Blank Separator Off No Blank Separator Tray Tray 2 No Create Booklet (8560MFP Only) Off No Repeat Image (8560MFP Only) Off No Repeat Image -> Rows 1 No Repeat Image -> Columns 1 No N-Up Off No Poster Off No Color Balance -> Cyan Color Balance 0 No Color Balance -> Magenta Color Balance 0 No Color Balance -> Yellow Color Balance 0 No Color Balance -> Black Color Balance 0 No Laser Original Off No
Fax Main Fax To None No
Resolution Standard No Original Size Automatic No Auto Suppression Off No Transmission Report On No Starting Rate Super G3 No
10/2006
2-5
Error Messages and Codes
NVRAM Reset
Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command
Menu Parameter Default Required
Fax Send Setup Transmission Report Never No
Reduced Image (8560 only) Off Yes Redial Count 3 No Redial Time Interval 15 No Auto Resend Policy Unsent Pg Yes Auto Resend Count 3 Yes Document Type Mixed No Resolution Standard No Transmission Header (8560 only) On No
Fax Receive Setup Paper Suplly Tray 2 Yes
Fax Receive On Yes Answer Delay 0 Yes Secure Receive (8560 only) Off Yes Secure Receive Password (8560 only) None Yes Junk Fax Prevention Off Yes 2-Sided Fax Printing 1-1 No
Fax Configuration Line Name None Yes
Dial Type Tone Yes Line Monitor Volume 2 No Auto Activity Report Off No Starting Rate Super G3 Yes Error Correction Mode On Yes
Fax Configuration Dial Pause 3 No
Dial Delay 0 No Max Compression JBIG/MMR No
File Security Daily Removal Off Yes
Remove At 00:00 Yes Age-based Removal Off Yes Remove at Age 24 Yes
Paper Handing Setup Load Paper Timeout 3 min. No
Tray 1 Mode Dynamic No Tray 1 Prompt 30 sec. No Tray 2 ~ [N] Mode Dynamic No Tray 2 ~ [N] Prompt None No Letter/A4 Substitution On No Custom Units Inches/mm No Cleaning Page Source Highest No
Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command
Menu Parameter Default Required
System Controls Startup Page On No
Auto Clear Timeout 60 sec. No Power Saver Timeout 4 hours No Date and Time None No Intelligent Ready On No Default Function Copy No Color Copy Password Disabled No Print Job Interrupt (8560 only) On No
Paper Tray Setup Tray 1 Paper - Media Size Guide Size No
Tray 1 Paper - Media Type Plain No Tray 2 Paper - Media Type Plain No Tray 3 Paper - Media Type (if installed) Plain No Tray 4 Paper - Media Type (if installed) Plain No
Print Defaults Setup Paper Source Auto No
2-Sided Printing Disabled No
PS-PCL Setup Pitch 10.00 No
Point Size 12.00 No Symbol Set PC8 No Oreientation Portrait No Form Length 6 No Line Termination On No Draft Mode Off No Color Mode Color No
Scan Default Setup Color Mode Color No
Document Type Mixed No Scan Resolution 100x100 No Laser Original Off No
Scan Main Scan To Public No
Scan Resolution 100x100 No Original Size Automatic No Auto Suppression Off No Laser Original Off No
Table 2 summarizes system parameters not affected by an NVRAM Reset.
Table 2 System Parameters Not Affected by an NVRAM Reset
Parameter Comment
Metric Defaults MAC Address Set by the Configuration Card Serial Number Model number
Error Messages and Codes
NVRAM Reset
10/2006
2-6
Phaser 8510/8560MFP Multifunction Product
Table 2 System Parameters Not Affected by an NVRAM Reset
Parameter Comment
License Number PostScript Version PostScript Revision Activation Date The activation date is stored in Usage Profile NVRAM. Adobe Serial Number System Date and Time Fax Country Fax Configuration Fax Line ID Fax Configuration Overwrite Removals File Security Speed Dial Individual Directory Fax Send Speed Dial Group Directory Fax Send Tray Media Types and Sizes Unconfirmed following NVRAM Reset. Metered Supplies Metered operation Print Counter System Print Count Billing Meters Substituted Jets Jet Substitution Mode Warm-up Mode Set in CWIS Warm-up Settings Set in CWIS Stand-by Settings Set in CWIS
Error Message Troubleshooting
This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running Service Diagnostic test functions to verify that a com­ponent is operating correctly. Procedures that direct a test to be run are referencing tests from within the Hidden Service menu. For information on Service Diagnostics, see Service Diagnos­tics.
For troubleshooting problems not associate with 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.
Fault Code Error Reporting
Fault codes are saved to NVRAM and can be retrieved from the printer’s fault history.
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 page count when the error occurred (xx,yyy.zz:123) Device faults are indicated by a 4 in the tenths place of the fault code (xx,yyy.4x). This indicates
a hardware problem. The most common device faults troubleshooting procedures are docu­mented in this section.
Program faults are indicated by a 6 in the tenths place of the fault code (xx,yyy.6x). 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.
CPU exceptions are indicated by a 7 in the tenths place of the fault code (xx,yyy.7z). The error code indicates both the Power PC exception number and the region of firmware that was exe­cuting when the exception occurred: Engine, PostScript, Network, or Operating System.
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.
10/2006
2-7
NVRAM Reset, Error Message Troubleshooting
Error Messages and Codes
1,00X.4x 525-Sheet Feeder Faults
The following troubleshooting procedure applies to these errors:
525-Sheet Feeder Errors
1,001.46 An over current condition was detected in the upper 525-Sheet Feeder.
The lift motor or clutch may be shorted.
1,002.47 An over current condition was detected in the lower 525-Sheet Feeder.
The lift motor or clutch may be shorted.
Initial Actions
• Check the tray to ensure it is free of obstructions or debris.
• Check the operation of the Tray Lift Plate.
• Check the condition of the Feed and Pick Rollers.
• Reseat the optional tray connection to the system.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 1,000.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Tray Feeder, PL 3.0 Left Side Harness (1/2) Figure 4 Pick Assy and Retard
Roller Kit, PL 3.0 Left Side Harness, PL 5.0 Left Side Wire Routing (1/2) P/J204
Table 2 525-Sheet Troubleshooting Procedure
Step Questions or Actions Yes No
5 Check the wiring from the feeder to Elec-
tronics Module. Is the wiring defective?
6 Check ground integrity.
Are the system grounds connected?
Replace the har­ness. If the error per­sists, go to Step 6.
Reset NVRAM. If the error persists, replace the feeder.
Replace the feeder.
Reconnect the sys­tem grounds.
Troubleshooting Procedure
Table 2 525-Sheet Troubleshooting Procedure
Step Questions or Actions Yes No
1 Remove the 525-Sheet Feeder and check
the connections for damage. Are the connectors damaged?
2 Check the Pick Assembly for dirt, damage,
or wear. Are the rollers damaged or worn?
3 Test the Pick Clutch.
Run the Service Diagnostics Pick Clutch test for the affected tray. Does the Pick Clutch operate correctly?
4 Test the Lift Motor.
Run the Service Diagnostics Lift Motor test for the affected tray. Does the Lift Motor operate correctly?
Error Messages and Codes
Replace the dam­aged connections.
Replace the Pick Assembly (REP
3.0.18). Go to Step 3. Replace the feeder.
1,00X.4x
Go to Step 2.
10/2006
2-8
Phaser 8510/8560MFP Multifunction Product
1,000.6x 525-Sheet Feeder Program Faults
A firmware error has occurred. The following troubleshooting procedure applies to these errors:
2,00X.xx I/O Board Errors
The following troubleshooting procedure applies to these errors:
525-Sheet Feeder Program Errors
1,006.x The 525-Sheet Feeder has encountered a program fault.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 1,000.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 525-Sheet Feeder Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
I/O Circuit Board Errors
2,001.47 The Print Engine does not detect the I/O Board
Initial Actions
• Check the I/O Board for obvious signs of damage.
• Check that all connections to the board are secure by reseating each connection.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 2,00X.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
I/O Board, PL 5.0 Right Side Harness / I/O Control Figure 8 Right Side Harness, PL 5.0 Right Side Wire Routing (1/2) Figure 2 I/O Board Power Control
Cable, PL 5.0
Right Side Wire Routing (1/2) Figure 2
Troubleshooting Procedure
Table 2 I/O Board Error Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the I/O Board for damage.
Are the connectors damaged?
2 Reseat all I/O Board connections.
Does the problem persist?
3 Check I/O Power Control Cable continuity
between P/J840 on the I/O Board and P/ J10 on the Electronics Module. Is the wiring defective?
Repair the damaged connections.
Go to Step 3. Complete.
Replace the cable. If the error persists, replace the I/O Board.
Go to Step 2.
Replace the I/O Board (REP 5.0.13).
10/2006
2-9
Error Messages and Codes
1,000.6x, 2,00X.xx
2,006.xx I/O Board Program Faults
The following troubleshooting procedure applies to these errors:
2,0XX.6x Configuration Card Faults
The following troubleshooting procedure applies to these errors:
I/O Board Program Faults 2,001.69 The Electronics Module Failed to initialize. 2,002.61 Firmware program fault 2,003.62 Firmware program fault 2,004.63 Failure to start the Print Engine in Suspend Mode. 2,005.64 ROM read error 2,006.65 ROM read error 2,007.66 idiags entry point access error
Initial Actions
• Reset NVRAM and retest.
• Check that all connections to the Electronics Module and I/O Board are secure by reseat­ing each connection.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 2,006.xx Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
I/O Board, PL 5.0.13 NVRAM, PL 5.0.9
Troubleshooting Procedure
Table 2 I/O Board Error Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all I/O Board connections.
Does the problem persist?
2 Reseat all Electronics Module connec-
tions. Does the problem persist?
3 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Go to Step 3. Complete.
Replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
I/O Board Program Faults 2,008.67 The Configuration Card is Missing 2,009.68 The Configuration Card is Bad 2,010.69 The Configuration Card is Blank 2,011.61 The Configuration Card is for the wrong product 2,012.62 The Configuration Card is an invalid model
Initial Actions
• Turn Off the system.
• Check that the Configuration Card is correct for the system.
• Turn the system On.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 2,006.xx Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0 Configuration Card, PL 5.0
Troubleshooting Procedure
Table 2 Configuration Card Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Replace the Configuration Card, restart
the system, and retest. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
3 Replace the Electronics Module.
Does the problem persist?
Go to Step 2. Complete.
Go to Step 3. Reconnect the sys-
tem grounds. Complete.
Error Messages and Codes
2,006.xx, 2,0XX.6x
10/2006
2-10
Phaser 8510/8560MFP Multifunction Product
3,0XX.6x IPC Program Faults
A firmware communications error has occurred. The following troubleshooting procedure applies to these errors:
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 3,000.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
4,0xx.4x Process Control Errors
The following troubleshooting procedure applies to these errors:
Process Control Errors
4,017.47 The ambient temperature is too low ( < 10°C). 4,018.48 The Printhead temperature is too low. 4,020.41 Fast Time To Ready (FTTR) mode with head/cap flag set in NVRAM. 4,021.42 Fast Time To Ready (FTTR) mode with a dirty Drum.
Initial Actions
• Check the ambient air temperature.
• Check that the system is located in a suitable environment.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 2 I/O Board Error Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Table 1 4,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0 Right Side Wire Routing (2/2), Figure 3 Printhead, PL 2.0 Electronics Module, Figure 6 Drum Assembly, PL 2.0 Electronics Module Power, Figure 7 Drum Heater Relay Board, PL 5.0 Right Side Wire Routing (1/2), Figure 2 Drum Temperature Sensor, PL 6.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
Table 2 Process Control Error Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the heaters.
Run the Service Diagnostics Monitor Heaters tests with all heaters On. Do the heaters function properly?
2 Check the harness to the failed heater.
Is the harness damaged?
Replace the Elec­tronics Module (REP
5.0.5).
Replace the har­ness.
Go to Step 3.
Replace the failed component.
10/2006
2-11
Error Messages and Codes
3,0XX.6x, 4,0xx.4x
4,024.42 Wiper Alignment Fault
The following troubleshooting procedure applies to this error:
4,025.46 Drum Transfix Fault
The following troubleshooting procedure applies to this error:
Wiper Blade Misalignment Errors
4,024.42 Printhead Wiper Blade misaligned
Initial Actions
• Check Wiper Alignment.
• Check damage, debris, or Ink build-up near the Printhead.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 4,024.42 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Head Maintenance Clutch, PL 4.0 I/O Board (2/2), Figure 10 Media Drive Assembly, PL 4.0 Left Side Harness (2/2), Figure 5 Wiper Blade, PL 2.0
Troubleshooting Procedure
Table 2 4,024.42 Wiper Alignment Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Wiper alignment.
Run the Service Diagnostics Check Wiper Alignment test. Did the test Fail?
2 Test the Wiper drive.
Run the Service Diagnostics Wiper Drive test. Did the test fail?
3 Check the Wiper drive and lock systems
for ink, obstructions, or damage. Is the Wiper drive function correctly?
4 Check the Head Maintenance Clutch.
Is there any oil, contamination, or obvious damage?
5 Test the Head Maintenance Clutch.
Run the Service Diagnostics Head Main­tenance Clutch test. Does the clutch function correctly?
Perform (ADJ 2.5.1) and retest. If the test fails again, go to Step 2.
Go to Step 3. Go to Step 5.
Go to Step 4. Clear any ink or
Clean the interior of the system or replace the clutch if necessary.
Replace in order: Exit Module Media Drive Assy Wiper Blade
Go to Step 2.
obstructions or replace any dam­aged components.
Go to Step 5.
Replace the Head Maintenance Clutch (REP 4.0.4).
Drum Transfix Fault
4,025.46 Drum Transfix does not reach home position.
Initial Actions
• Check for dirt, debris, or obstructions around the Printhead.
• Check that the Waste Tray is correctly installed.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 4,025.46 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 5.0 Right Side Harness / I/O Control, Figure 8 X-Axis Motor, PL 2.0 Right Side Harness / I/O Control, Figure 8 Head Tilt Solenoid, PL 5.0 Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 4,025.46 Drum Transfix Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check for ink build up in the Head Tilt
drive, Waste Tray, or wires interfering with Printhead motion. Is the Printhead clear of obstructions?
2 Check the Process Drive for damage.
Ensure the gears are correctly aligned (see ADJ 4.7.1). Is the process gearbox damaged?
3 Check the X-Axis Motor connection (P/
J150). Run the Service Diagnostics X-Axis Motor test. Did the test fail?
4 Test the Printhead Tilt Drive.
Run the Service Diagnostics Tilt Drive test. Did the test fail?
Go to Step 11. Clear any obstruc-
Replace the Pro­cess Drive (REP
4.0.7).
Replace the X-Axis Motor (REP 4.0.5).
Replace the Pro­cess Drive (REP
4.0.7).
tions to Printhead movement. If the error persists, go to Step 2.
Go to Step 3.
Go to Step 4.
Error Messages and Codes
4,024.42, 4,025.46
10/2006
2-12
Phaser 8510/8560MFP Multifunction Product
4,0xx.6x Process Control Program Faults
A firmware communications error has occurred. The following troubleshooting procedure applies to these errors:
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 4,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Process Control Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
5,0xx.4x Y-Axis Sub-System Faults
The following troubleshooting procedure applies to these errors:
Y-Axis Sub-System Faults 5,001.41 The Drum rotated once without a Drum Home Position Sensor activation. 5,002.42 The Y-Axis Encoder is faulty, or the Drum has stalled. 5,003.43 Problem in the Y-Axis sub-system. 5,004.44 Problem with the Y-Axis motion sub-system.
Initial Actions
• Check for obstructions or debris.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 5,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Y-Axis Belt, PL 2.0 Y--Axis Motor, PL 4.0 Electronics Module Power, Figure 7 Drum Assembly (Encoder) Right Side Harness / /O Control, Figure 8
Troubleshooting Procedure
Table 2 Y-Axis Sub-System Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Y-Axis Encoder.
Run the Service Diagnostics Y-Axis Encoder test from the Monitor menu. Did the test pass?
2 Check the Y-Axis Motor connection (P/
J18). Is the wiring faulty?
3 Check the Y-Axis Encoder wiring.
Is the wiring faulty?
4 Test the Y-Axis Drive.
Run the Service Diagnostics Y-Axis Drive test. Did the test pass?
5 Test Y-Axis Belt tension.
Run the Service Diagnostics Y-Axis Belt Tension test. Did the test pass?
Go to Step 2. Go to Step 3.
Replace the wiring. Go to Step 4.
Replace the wiring. Replace the Drum
Assy (REP 2.0.3).
Go to Step 5. Replace the Y-Axis
Motor (REP 4.0.11).
Go to Step 6. Replace the Y-Axis
Belt (REP 2.0.4).
10/2006
2-13
Error Messages and Codes
4,0xx.6x, 5,0xx.4x
Table 2 Y-Axis Sub-System Faults Troubleshooting Procedure
Step Questions or Actions Yes No
6 Test the Y-Axis Motor.
Run the Service Diagnostics Y-Axis Motor test. Did the test pass?
Replace the Drum Assembly (REP
2.0.3).
Replace the Y-Axis Motor (REP 4.0.11).
5,0xx.6x Y-Axis Sub-System Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Y-Axis Sub-System Program Faults 5,001.63 Y-Axis sub-system general fault. 5,005.67 Sub-system not in homeless or idle state, software fault. 5,006.68 Software fault. 5,007.60 Software fault. 5,008.61 PostScript failed to fill the buffer. 5,009.62 Imaging errors. Possible jets On/Off outside the deadband area.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 5,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Y-Axis Sub-System Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
5,0xx.4x, 5,0xx.6x
10/2006
2-14
Phaser 8510/8560MFP Multifunction Product
6,0xx.4x X-Axis Fault
An X-Axis drive error has occurred. The following troubleshooting procedure applies to this error:
X-Axis Motor Error
6,000.41 X-Axis Motor current error.
Initial Actions
• Check for Ink build-up or other obstructions around the Printhead.
• Check the Printhead power (P/J4) connection and related wiring.
• Verify the Printhead travels smoothly from left to right.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 6,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
X-Axis Motor, PL 4.0 Right Side Harness / I/O Control, Figure 8 Electronics Module, PL 5.0 Right Side Wire Routing (2/2), Figure 3
6,0xx.6x X-Axis Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
X-Axis Program Faults 6,001.64 The X-Axis task received an unexpected message. 6,002.65 Attempt to home X-Axis drive from wrong state. 6,008.62 Attempt to use X-Axis drive without initialization. 6,011.65 Attempt to service X-Axis drive in wrong state. 6,013.67 Unknown X-Axis program fault. 6,017.62 Attempt to drive X-Axis using wrong server. 6,018.63 Attempt to move with the X-Axis not initialized. 6,019.64 Attempt to move with the X-Axis not at home position. 6,023.68 Could not allocate memory for X-Axis parameters. 6,025.66 Attempt to home the X-Axis drive without initialization. 6,032.68 Unrecognized X-Axis motion. 6,033.60 Could not allocate memory for X-Axis move parameters.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Troubleshooting Procedure
Table 2 Process Control Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the X-Axis Motor wiring.
Is the wiring faulty?
2 Test the X-Axis Motor.
Run the Service Diagnostics X-Axis Motor test. Did the test pass?
Replace the wiring. Go to Step 2.
Replace the X-Axis Motor (REP 4.0.5).
Replace the Elec­tronics Module (REP
5.0.5).
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 6,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
10/2006
2-15
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
6,0xx.4x, 6,0xx.6x
7,002.44 Process Drive Fault
A Process Drive error has occurred. The following troubleshooting procedure applies to this error:
7,006.4x Head Tilt Solenoid Fault
A Printhead tilt error has occurred. The following troubleshooting procedure applies to this error:
Process Faults
7,002.44 The Process Drive stalled during operation.
Initial Actions
• Check that the Process Drive gear train is properly homed.
• Check for obstructions in or around the Process Drive gearbox.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,002.44 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8
Troubleshooting Procedure
Table 2 Process Drive Fault 7,002.44 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the Process Drive is properly
aligned (ADJ 4.7.1). Is the Process Drive misaligned?
2 Test the Tilt Axis Drive.
Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?
3 Check the Process Drive for damage,
debris, or obstructions. Is there any damage?
4 Test the Process Drive Motor.
Run the Service Diagnostics Process Motor Test. Did the test fail?
5 Test the Transfix Cams
Run the Service Diagnostics Transfix Drive Slow test. Do the Transfix Cam operate correctly?
Perform ADJ 4.7.1. Go to Step 2.
Go to Step 3. Go to Step 4.
Replace the Pro­cess Drive (REP
4.0.7). Replace the Pro-
cess Drive (REP
4.0.7).
Replace the Pro­cess Drive (REP
4.0.7).
Go to Step 4.
Go to Step 5.
Verify the transfix cams are not dam­aged. If the error persists, replace the Transfix Cam Shaft (REP 2.0.10).
Process Faults
7,006.xx The Head Tilt Solenoid is not activating the Head Tilt Cam, or the Print-
head is not tilting properly.
Initial Actions
• Check for obstructions or ink spills around the Printhead.
• Verify the Printhead travels smoothly from left to right.
• Check the Printhead Restraint Arms.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Head Tilt Gear, PL 4.0 Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2), Figure 5 Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8
Troubleshooting Procedures
The Head Tilt Solenoid is not activating the Head Tilt Gear, or the Printhead is not tilting prop­erly
Table 2 Head Tilt Solenoid Faults 7,006.xx Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the Process Drive is properly
aligned (ADJ 4.7.1). Is the Process Drive misaligned?
2 Reboot the system.
Is the tilt-head activating the Head Tilt Gear.
3 Check for Ink spills on or near the Head
Tilt Gear.
4 Review instructions for 7,008.xx and
7,010.xx fault codes.
Perform ADJ 4.7.1. Go to Step 2.
Go to Step 4. Go to Step 3.
Remove ink spills or reinstall the head-tilt and start over with Step 1.
Follow recom­mended actions for error codes and reboot the printer.
Go to Step 4.
Error Messages and Codes
7,002.44, 7,006.4x
10/2006
2-16
Phaser 8510/8560MFP Multifunction Product
7,007.49 Process Drive Fault
A Process Drive or Printhead error has occurred. The following troubleshooting procedures applies to this error:
7,008.41 Printhead Tilt Fault
A Process Drive or Printhead error has occurred. The following troubleshooting procedure applies to this error:
Process Drive Fault
7,007.49 The Process Drive stalled while tilting the Printhead.
Initial Actions
• Check that the Process Drive gear train is properly homed.
• Check for obstructions or ink spills around the Printhead.
• Verify the Printhead travels smoothly from left to right.
• Check the Printhead Restraint Arms.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,007.49 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8
Troubleshooting Procedure
Table 2 Process Drive Faults 7,007.49 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the Process Drive is properly
aligned (ADJ 4.7.1). Is the Process Drive misaligned?
2 Remove the Printhead and inspect the
Head Tilt Gear, Spring, and Process Drive gears for ink spills. Clean if necessary. Does the error persist?
3 Realign the Process Drive (ADJ 4.7.1).
Does the error persist?
Perform ADJ 4.7.1. Go to Step 2.
Go to Step 3. Complete.
Replace the Pro­cess Drive (REP
4.0.7).
Complete.
Process Faults
7,008.41 Printhead tilt is not engaged, or the Printhead is stuck in the tilt position.
Initial Actions
• Check that the Process Drive gear train is properly homed.
• Check for obstructions or ink spills around the Printhead.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,008.41 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8 Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2), Figure 5 Head Tilt Gear, PL 4.0
Troubleshooting Procedure
The Head Tilt Solenoid is not activating the head tilt cam, or the head is not tilting properly
Table 2 Head Tilt Solenoid Faults 7,008.41 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reboot the system.
Does the error persist?
2 Check for Ink spills on or near the Head
Tilt Gear. Clean and reboot the system. Does the error persist?
3 Check that the Printhead moves properly
to the left and right. Does the Printhead move correctly?
4 Realign the Process Drive (ADJ 4.7.1).
Does the error persist?
5 Check the Process Drive for damage,
debris, or obstructions. Is there any damage?
6 Test the Tilt Axis Drive.
Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Remove any
obstructions or replace any defec­tive parts.
Go to Step 5. Complete.
Replace the Pro­cess Drive (REP
4.0.7). Go to Step 7. Replace the Pro-
Go to Step 6.
cess Drive (REP
4.0.7).
10/2006
2-17
Error Messages and Codes
7,007.49, 7,008.41
Table 2 Head Tilt Solenoid Faults 7,008.41 Troubleshooting Procedure
Step Questions or Actions Yes No
7 Test the Head Maintenance Clutch.
Run the Service Diagnostics Head Main­tenance Wiper Clutch test. Does the clutch operate correctly?
8 Check the Printhead Wiper alignment.
Is the Printhead Wiper properly aligned?
9 Test the Wiper Drive.
Run the Service Diagnostics Wiper Drive test. Does the Wiper Drive operate correctly?
Go to Step 8. Replace the clutch
Go to Step 9. Perform ADJ 2.5.1.
Replace the Exit Module (REP 3.0.7).
(REP 4.0.4).
Repair or replace the Wiper Drive.
7,009.42 Printhead Restraint Fault
A Process Drive or Printhead error has occurred. The following troubleshooting procedure applies to this error:
Process Faults
7,009.42 Printhead is tilted back, but not properly restrained.
Initial Actions
• Check for obstructions or ink spills around the Printhead.
• Check the Printhead Restraint Arms.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,009.42 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8 Restraint Arms, PL 2.0 Head Maintenance Clutch, PL 4.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
The Printhead is tilted back, but not properly restrained in the Printhead Restraints.
Table 2 Printhead Restraint Fault 7,009.42 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the restraints for damage or debris.
Are the restraints damaged?
2 Check the Printhead Wiper alignment.
Is the Printhead Wiper properly aligned?
3 Check Printhead wire routing and the Tilt
Gear. Does the Printhead move freely?
4 Check that the Process Drive is aligned
(ADJ 4.7.1). Is the Process Drive misaligned?
5 Replace the Process Drive (REP 4.0.7).
Does the error persist?
6 Test the Head Maintenance Clutch
Run the Service Diagnostics Head Main­tenance Wiper Clutch test. Does the clutch operate correctly?
Replace damaged parts (REP 2.0.8).
Go to Step 4. Perform ADJ 2.5.1.
Remove ink spills or reinstall the Print­head.
Perform ADJ 4.7.1. Go to Step 5.
Go to Step 6. Complete.
Go to Step 7. Replace the clutch
Go to Step 2.
Go to Step 4.
(REP 4.0.4).
Error Messages and Codes
7,008.41, 7,009.42
10/2006
2-18
Phaser 8510/8560MFP Multifunction Product
Table 2 Printhead Restraint Fault 7,009.42 Troubleshooting Procedure
Step Questions or Actions Yes No
7 Test the Wiper Drive.
Run the Service Diagnostics Wiper Drive test. Does the Wiper Drive operate correctly?
Replace the Exit Module (REP 3.0.7).
Repair the Wiper Drive.
7,01X.4x Process Faults
A Process Drive or Printhead error has occurred. The following troubleshooting procedures apply to these errors:
Process Faults 7,010.43 Printhead is stuck or is not tilting properly over the cam. 7,011.44 Soft fault. System continues to operate. 7,012.45 Transfix Home Sensor does not indicate home position. 7,014.47 The Printhead is not locked in the restraint spring. 7,015.48 The Head Tile Restraint Spring is out of place.
Initial Actions
• Check that the Process Drive gear train is properly homed.
• Check for obstructions or ink spills around the Printhead.
• Verify the Printhead travels smoothly from left to right.
• Check the Printhead Restraint Arms.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,010.4x through 7,015.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8 Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2), Figure 5 Head Tilt Gear, PL 4.0 Restraint Arms, PL 2.0 Head Maintenance Clutch, PL 4.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
The Printhead is stuck, or incorrectly positioned.
Table 2 Printhead Restraint Fault 7,010.xx through 7,015.xx Troubleshooting Procedure Step Questions or Actions Yes No
1 Reboot the system.
Does the error persist?
2 Check the Printhead Lock Arms.
Do the arms rotate correctly?
3 Check for ink spills around the Printhead
and Printhead Tilt Gears. The Printhead should move when pushed left or right. Is the area around the Printhead clean and unobstructed?
10/2006
2-19
Go to Step 2. Complete.
Go to Step 3. Repair or replace the
Printhead Restraints (REP 2.0.8).
Go to Step 4. Remove ink spills or
obstructions.
Error Messages and Codes
7,009.42, 7,01X.4x
Table 2 Printhead Restraint Fault 7,010.xx through 7,015.xx Troubleshooting Procedure
Step Questions or Actions Yes No
4 Check the X-Axis Motor.
Does the X-Axis Motor drive the Printhead to the center position?
5 Check that the Process Drive is properly
aligned (ADJ 4.7.1). Check that the Process Shaft and Drive Module Shaft are at their home positions. Is the Process Drive misaligned?
6 Check for ink spilled on the Head Tilt Gear
or its drive train. Are the gears clean?
7 Test the Head Maintenance Clutch
Run the Service Diagnostics Head Main­tenance Wiper Clutch test. Does the clutch operate correctly?
8 Test the Wiper Drive.
Run the Service Diagnostics Wiper Drive test. Does the Wiper Drive operate correctly?
9 Test the maintenance drive.
Run the Service Diagnostics Load Mainte­nance Clutch test. Does the drive operate correctly?
10 Check that the Head Tilt Gear engages.
Manually engage the Head Tilt Gear. Does the gear engage the drive?
11 Test the Tilt Axis Drive.
Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?
12 Test the Process Drive.
Run the Service Diagnostics Process Motor test. Does the Process Drive operate correctly?
Go to Step 5. Check the X-Axis
Realign the Process Drive (ADJ 4.7.1).
Go to Step 7. Clean the gears.
Go to Step 8. Replace the clutch
Replace the Exit Module (REP 3.0.7).
Go to Step 9. Check the mainte-
Go to Step 11. Set the Head Tilt
Go to Step 12. Replace the Pro-
Complete. Replace the Pro-
Drive (6,0xx.4x).
Go to Step 6.
(REP 4.0.4).
Repair the Wiper Drive.
nance drive system and replace any defective parts.
Gear.
cess Drive (REP
4.0.7).
cess Drive (REP
4.0.7).
7,0xx.6x Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Process Program Faults
7,0xx.6x The system detected a program fault during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 7,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Process Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
7,01X.4x, 7,0xx.6x
10/2006
2-20
Phaser 8510/8560MFP Multifunction Product
8,0XX.4x Wiper or Media Drive Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Wiper or Media Drive Faults 8,005.48 The media path motor 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 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 head tilt.
Initial Actions
• Check for paper in the paper path.
• Check the condition of the Pick and Retard Rollers.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 8,0XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Media Drive Assembly, PL 4.0 Left Side Harness (2/2), Figure 5 Head Maintenance Clutch, PL 4.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
Table 2 Media Drive Troubleshooting Procedure
Step Questions or Actions Yes No
1 For an 8,005.48 error:
1. Check the area surrounding the Take Away Roller.
2. Remove the Tray 1 Pick Solenoid (REP 4.0.12) to view the meshing of the roller gears to the Media Drive.
Did this correct the problem?
2 For an 8,007.41 error:
Check for a missing KL-clip securing the drum maintenance clutch. Replace if missing. Did this correct the problem?
Complete. Go to Step 4.
Complete. Go to Step 4.
Table 2 Media Drive Troubleshooting Procedure
Step Questions or Actions Yes No
3 For an 8,009.43 error:
1. Check for paper in the paper path.
2. Ensure the Media Drive Assembly is fully seated and correctly installed.
3. Remove the Tray 1 Pick Solenoid to view the meshing of the Take Away Roller’s gears to the Media Drive Assembly.
4. Ensure the feed rollers are properly engaged in the drive gears.
Did this correct the problem?
4 Check the Wiper drive.
Run the Service Diagnostics Wiper Drive test. Does the Wiper operate correctly?
5 Align the Printhead Wiper (ADJ 2.5.1).
Does the Wiper align?
6 Inspect the wiper system for improper
operation, obstructions, or damage (bro­ken gear or belt). Look for ink in the wiper belt channels. Did this correct the problem?
7 Check the Wiper Clutch.
Run the Service Diagnostics Head Main­tenance Clutch test. Does the clutch operate correctly?
8 Check the right side Wiper Lock.
Does the lock operate correctly?
9 Check for obstructions or spilled ink on the
Wiper Blade, Head Tilt Gear drive, and under the Printhead. Is the Wiper, Media Drive, and Printhead clear or ink or obstructions?
Complete. Replace the Media
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 clutch
Go to Step 9. Replace the Exit
Replace the Exit Module (REP 3.0.7).
Drive Assembly (REP 4.0.14).
(REP 4.0.4).
Module (REP 3.0.7). Clean the system
and retest.
10/2006
2-21
Error Messages and Codes
8,0XX.4x
8,0xx.6x Media Drive Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Media Drive Program Faults
8,0xx.6x The system detected a program fault during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 8,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Media Drive Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
9,0XX.4x Ink Loader Faults
An Ink Loader error has occurred. The following troubleshooting procedure applies to these errors:
Ink Loader Faults 9,000.44 The Ink Loader failed during operation. 9,005.49 The Cyan Ink Melt Heater is on, but no ink is detected. 9,006.41 The Magenta Ink Melt Heater is on, but no ink is detected. 9,007.42 The Yellow Ink Melt Heater is on, but no ink is detected. 9,008.43 The Black Ink Melt Heater is on, but no ink is detected. 9,015.41 Ink Loader Door opened to clear Cyan Ink Stick Jam. 9,016.41 Ink Loader Door opened to clear Magenta Ink Stick Jam. 9,017.41 Ink Loader Door opened to clear Yellow Ink Stick Jam. 9,018.41 Ink Loader Door opened to clear Black Ink Stick Jam. 9,025.41 Ink Loader Door opened twice to clear Cyan Ink Stick Jam. 9,026.41 Ink Loader Door opened twice to clear Magenta Ink Stick Jam. 9,027.41 Ink Loader Door opened twice to clear Yellow Ink Stick Jam. 9,028.41 Ink Loader Door opened twice to clear Black Ink Stick Jam. 9,035.41 Ink count flag stuck after melting 2.5 Cyan Ink Sticks. 9,036.41 Ink count flag stuck after melting 2.5 Magenta Ink Sticks. 9,037.41 Ink count flag stuck after melting 2.5 Yellow Ink Sticks. 9,038.41 Ink count flag stuck after melting 2.5 Black Ink Sticks.
Initial Actions
• Check that the Ink Sticks are genuine Xerox.
• Check for obstructions in the Ink Wells.
• Check the Ink Loader data (P/J0150) and power (P/J5) connections.
• Verify the Ink Sticks advance in the Ink Loader.
• If the problem persists, follow the procedure below.
Error Messages and Codes
8,0xx.6x, 9,0XX.4x
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 9,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Ink Loader Assy, PL 2.0 I/O Board (2/2), Figure 10
NOTE: Following Ink Loader Assembly replacement, or for Ink count flag stuck errors, clear the Ink Stick Count (ISC) fault using the Clear ISC Fault menu item located in the Service Diagnos­tics Function menu.
10/2006
2-22
Phaser 8510/8560MFP Multifunction Product
Troubleshooting Procedure
Table 2 Process Drive Faults 9,0XX.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the ink stick is able to advance
in the ink loader chute. Check for broken or wrong type ink sticks. Are the Ink Sticks loading properly?
2 Test the appropriate Ink Melt Heater.
Run the Service Diagnostics Ink Melt [1,2,3,4] test.
• 1 = Yellow
•2 = Cyan
• 3 = Magenta
•4 = Black Did the test pass?
Go to Step 2. Remove any block-
Replace the Print­head (REP 2.0.2).
age and/or replace the ink stick. Run clear ISC Fault test to clear the error. This must be per­formed following an ink loader replace­ment.
Replace the Ink Loader (REP 2.0.1).
9,009.44 and 9,00X.6x Ink Loader Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Ink Loader Program Faults 9,009.44 Communications error in NVRAM. 9,0xx.6x The system detected a program fault during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 9,009.44 and 9,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Ink Loader Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device. (REP 5.0.9).
Reconnect the sys­tem grounds.
10/2006
2-23
Error Messages and Codes
9,0XX.4x, 9,009.44 and 9,00X.6x
11,0XX.xx Electronics Module Interface Faults
A communications error has occurred. The following troubleshooting procedure applies to these errors:
Ink Loader Faults 11,001.47 The Upper 525-sheet feeder broken serial link detected. 11,002.48 The 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.
Initial Actions
• Check that all system grounds are secured.
• Check or reseat all connections to the Electronics Module.
• Check the condition of all harnesses.
• If the problem persists, follow the procedure below.
Troubleshooting Procedure
Table 2 Process Drive Faults 11,0xx.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check ground integrity for the printer.
Does the error persist?
2 Reseat all system interconnections and
check that the cables are properly dressed. Does the error persist?
3 Reset NVRAM.
Does the error persist? For errors 11, 001.47 and 11,017.45
Replace the Tray Lift Motor. Does the error persist?
For errors 11,002.48 and 11, 016.44 Check the Option Tray connection. Does the error persist?
For errors 11,003.49 and 11,0014.42 Replace the I/O
For errors 11,004.41 and 11,013.41 Replace the I/O Board (REP 5.0.13). Does the error persist?
For errors 11,006.43 and 11,015.43 Replace the Print-
For error 11,009.46 Replace the I/O Board (REP 5.0.13). Does the error persist?
For all other 11,000.4x errors: Replace the Elec-
Go to Step 2. Complete.
Go to Step 3. Complete.
Locate the error code below.
Replace the Elec­tronics Module (REP
5.0.5). Replace the optional
tray.
Board (REP 5.0.13) Replace the Control
Panel (REP 1.0.9).
head (REP 2.0.2). Replace the Elec-
tronics Module (REP
5.0.5).
tronics Module (REP
5.0.5).
Complete.
Complete.
Complete.
Complete.
Complete.
Complete.
Complete.
Complete.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 11,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
I/O Board, PL 2.0 Right Side Harness / I/O Control, Figure 8 Right Side Harness, PL 5.0 Right Side Harness / I/O Control, Figure 8 I/O Board Power Control Cable, PL 5.0 Right Side Harness / I/O Control, Figure 8 Left Side Harness, PL 5.0 Left Side Harness (1/2), Figure 4 Electronics Module, PL 5.0 Electronics Module, Figure 6 Optional Feeder, PL 3.0 Left Side Harness (1/2), Figure 4
Error Messages and Codes
11,0XX.xx
10/2006
2-24
Phaser 8510/8560MFP Multifunction Product
11,100.60 Electronics Module Temperature Fault
The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting procedure applies to this error:
Program Faults
11,100.60 The system reports an overheat condition.
Initial Actions
• Check the ambient room temperature.
• Check for obstructions in the Air Vents. If obstructions are cleared, allow time for the sys­tem to cool.
• If the problem persists, follow the procedure below.
12,000.60 Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Program Faults
12,000.60 The system detected a program fault during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 11,100.60 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0 Electronics Module Power, Figure 7 Electronics Module Fan, PL 4.0 Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 Temperature Fault 11,100.60 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the air ducts are free of
obstructions and the fans are operating correctly. Are the fans operating correctly?
Replace the Elec­tronics Module (REP
5.0.5).
Replace the defec­tive fan.
Table 1 12,000.60 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 12,000.60 Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
10/2006
2-25
Error Messages and Codes
11,100.60, 12,000.60
13,000.48 Printhead Thermal Fault
A thermal error is detected in the Printhead. The following troubleshooting procedure applies to this error:
Process Thermal Faults
13,000.48 A thermal fault was detected in the Printhead.
13,003.42 and 13,007.46 Thermal Faults
A thermal error has occurred. The following troubleshooting procedures apply to these errors:
Thermal Faults 13,003.42 Thermal fault 13,007.46 Thermal fault
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Printhead, PL 2.0 Electronics Module, Figure 6 NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 13,000.48 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check ground integrity for the printer.
Does the error persist?
2 Reset NVRAM.
Does the error persist?
3 Reseat all system connections to the
Printhead and check that the harnesses are properly dressed. Does the error persist?
Go to Step 2. Complete.
Replace the NVRAM device (REP 5.0.9).
Replace the Print­head (REP 2.0.2).
Complete.
Complete.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,003.42 and 13,007.46 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0 Electronics Module, PL 5.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 13,003.42 and 13,007.46 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check ground integrity for the printer.
Does the error persist?
2 Reset NVRAM.
Does the error persist?
Go to Step 2. Complete.
Replace in the NVRAM device (REP 5.0.9). If the error persists, replace the Electron­ics Module (REP
5.0.5).
Complete.
Error Messages and Codes
13,000.48, 13,003.42 and 13,007.46
10/2006
2-26
Phaser 8510/8560MFP Multifunction Product
13,008.47 and 13,010.49 Drum Thermal Faults
A Drum Assembly thermal error has occurred. The following troubleshooting procedures apply to these errors:
Drum Thermal Faults 13,008.47 The Drum Heater is too hot 13,010.49 The Drum Heater took too long to reach the setpoint temperature.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,008.47 and 13,010.49 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Drum Fan, PL 4.0 Right Side Harness / I/O Control, Figure 8 Drum Assembly Electronics Module Power, Figure 7 Drum Temperature Sensor, PL 6.0 I/O Board (2/2), Figure 10 Electronics Module Fan Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 13,008.47 and 13,010.49 Troubleshooting Procedure
Step Questions or Actions Yes No
7 Test the Drum Temperature Sensor.
Run the Service Diagnostics Drum Tem­perature Sensor test. Does the sensor operate correctly?
8 Test the Drum Heater.
Run the Service Diagnostics Drum Heater test. Does the heater operate correctly?
Go to Step 8. Replace the Drum
Replace the Drum Assembly (REP
2.0.3).
Temperature Sen­sor. (REP 6.0.4).
Replace the Drum Temperature Sen­sor. (REP 6.0.4).
Table 2 13,008.47 and 13,010.49 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature is
within environmental specifications. Is the room within operating parameters?
2 Check ground integrity for the printer.
Does the error persist?
3 Is the error code associated with an over-
heat condition?.
4 Check airflow at the vents.
Is there adequate clearance, and are the vents clean?
5 Test the Drum Fan
Run the Service Diagnostics Drum Fan Motor test. Does the fan operate correctly?
6 Test the Electronics Module Fan.
Does the Fan operate correctly?
Go to Step 2. Advise the customer
Go to Step 2. Complete.
Go to Step 4. Go to Step 6.
Go to Step 5. Clean the vents.
Go to Step 6. Replace the Drum
Go to Step 7. Replace the Elec-
of operational requirements.
Fan (REP 4.0.6).
tronics Module Fan (REP 4.0.15).
10/2006
2-27
Error Messages and Codes
13,008.47
13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults
A Drum Temperature Sensor error has occurred. The following troubleshooting procedures apply to these errors:
13,XXX.4x Preheater Thermal Faults
A Preheater thermal error has occurred. The following troubleshooting procedures apply to these errors:
Drum Temperature Sensor Faults 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 faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Drum Temperature Sensor, PL 6.0 I/O Board (2/2), Figure 10
Troubleshooting Procedures
Table 2 13,067.43, 13,069.45 and 13,071.47 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Drum Temperature Sensor.
Run the Service Diagnostics Drum Tem­perature Sensor test. Does the sensor operate correctly?
2 Check the Drum Heater Sensor harness.
Is the harness free from defects or dam­age?
Go to Step 2. Replace the Drum
Replace the Drum Temperature Sen­sor. (REP 6.0.4).
Temperature Sen­sor. (REP 6.0.4).
Repair the wiring.
Preheater Thermal Faults 13,072.48 The Preheater is too hot. 13,074.41 The Preheater took too long to reach the setpoint temperature. 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 faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,XXX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Preheater, PL 2.0 I/O Board, Figure 9 I/O Board, PL 5.0 I/O Board, Figure 9 Right Combined Cable, PL 5.0
Troubleshooting Procedures
Table 2 Preheater Thermal Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature of the
room is within the system’s environmental specifications. Is the room within operating parameters?
2 Test the Preheater.
Run the Service Diagnostics Preheater test. Does the Preheater operate correctly?
3 Check Preheater connections and wiring.
Are the connections secure and the wiring undamaged?
Go to Step 2. Advise the customer
Replace the I/O Board (REP 5.0.13).
Replace the Pre­heater (REP 2.0.17).
of operational requirements.
Go to Step 3.
Repair or replace the wiring.
Error Messages and Codes
13,067.43, 13,069.45, 13,071.47, 13,XXX.4x
10/2006
2-28
Phaser 8510/8560MFP Multifunction Product
13,1XX.4x Left Jetstack Thermal Faults
A thermal error in the Printhead jetstack has occurred. The following troubleshooting proce­dures apply to these errors:
13,2XX.4x Right Jetstack Thermal Faults
A thermal error in the Printhead jetstack has occurred. The following troubleshooting proce­dures apply to these errors:
Left Jetstack Thermal Faults 13,136.49 The left jetstack heater is too hot. 13,138.42 The left jetstack heater took too long to reach the setpoint temperature. 13,195.45 The left jetstack heater thermistor circuit is open. 13,197.47 The left jetstack heater thermistor circuit is shorted. 13,199.49 The left jetstack heater thermistor returned faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,1XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Printhead, PL 2.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 Left Jetstack Thermal Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature of the
room is within the system’s specifications. Is the room within operating parameters?
2 Check ground integrity for the printer.
Does the error persist?
3 Test the Left Jetstack.
Run the Service Diagnostics Left Jet­stack Temperature test. Does the Preheater operate correctly?
4 Check Printhead connections and wiring.
Are the connections secure and the wiring undamaged?
Go to Step 2. Advise the customer
Go to Step 3. Complete.
Go to Step 4. Replace the Print-
Replace the Print­head (REP 2.0.2).
of operational requirements.
head (REP 2.0.2).
Repair the wiring.
Right Jetstack Thermal Faults 13,200.41 The right jetstack heater is too hot. 13,202.43 The right jetstack heater took too long to reach the setpoint temperature. 13,259.46 The right jetstack heater thermistor circuit is open. 13,261.48 The right jetstack heater thermistor circuit is shorted. 13,263.41 The right jetstack heater thermistor returned faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,2XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Printhead, PL 2.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 Right Jetstack Troubleshooting Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature of the
room is within the system’s specifications. Is the room within operating parameters?
2 Check ground integrity for the printer.
Does the error persist?
3 Test the Right Jetstack.
Run the Service Diagnostics Right Jet­stack Temperature test. Does the Preheater operate correctly?
4 Check Printhead connections and wiring.
Are the connections secure and the wiring undamaged?
Go to Step 2. Advise the customer
Go to Step 3. Complete.
Go to Step 4. Replace the Print-
Replace the Print­head (REP 2.0.2).
of operational requirements.
head (REP 2.0.2).
Repair the wiring.
10/2006
2-29
Error Messages and Codes
13,1XX.4x, 13,2XX.4x
13,XXX.xx Printhead Reservoir Thermal Faults
A Printhead Reservoir thermal error has occurred. The following troubleshooting procedures apply to these errors:
Printhead Reservoir Thermal Faults 13,264.42 The Printhead reservoir heater is too hot. 13,266.44 The Printhead reservoir heater took too long to reach setpoint temp. 13,323.47 The Printhead reservoir heater thermistor circuit is open. 13,325.49 The Printhead reservoir heater thermistor circuit is shorted. 13,327.42 The Printhead reservoir heater thermistor returned faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 13,XXX.xx Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Printhead, PL 2.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 Printhead Reservoir Thermal Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature of the
room is within the system’s specifications. Is the room within operating parameters?
2 Check ground integrity for the printer.
Does the error persist?
3 Test the Printhead Reservoir temperature.
Run the Service Diagnostics Reservoir Temperature test. Does the Printhead operate correctly?
4 Check Printhead connections and wiring.
Are the connections secure and the wiring undamaged?
Go to Step 2. Advise the customer
Go to Step 3. Complete.
Go to Step 4. Replace the Print-
Replace the Print­head (REP 2.0.2).
of operational requirements.
head (REP 2.0.2).
Repair the wiring.
13,XXX.xx Ink Loader Thermal Faults
A thermal error has occurred. The following troubleshooting procedures apply to these errors:
Ink Loader Thermal Faults 13,328.43 The Cyan heater is too hot. 13,330.45 The Cyan heater took too long to reach the setpoint temperature. 13,387.48 The Cyan heater thermistor circuit is open. 13,389.41 The Cyan heater thermistor circuit is shorted. 13,391.43 The Cyan heater thermistor returned faulty reading. 13,392.44 The Magenta heater is too hot. 13,394.46 The Magenta heater took too long to reach the setpoint temperature. 13,451.49 The Magenta heater thermistor circuit is open. 13,453.42 The Magenta heater thermistor circuit is shorted. 13,455.44 The Magenta heater thermistor returned faulty reading. 13,456.45 The Yellow heater is too hot. 13,458.47 The Yellow heater took too long to reach setpoint temp. 13,515.41 The Yellow heater thermistor circuit is open. 13,517.43 The Yellow heater thermistor circuit is shorted. 13,519.45 The Yellow heater thermistor returned faulty reading. 13,456.45 The Black heater is too hot. 13,458.47 The Black heater took too long to reach setpoint temp. 13,515.41 The Black heater thermistor circuit is open. 13,517.43 The Black heater thermistor circuit is shorted. 13,519.45 The Black heater thermistor returned faulty reading.
Initial Actions
• Check that all system grounds are secured.
• Check the ambient room temperature.
• Check the fan operation and vents.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.
Table 1 Ink Loader Thermal Fault Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Ink Loader, PL 2.0 Electronics Module, Figure 6 I/O Board, PL 5.0 I/O Board (2/2), Figure 10 Electronics Module, PL 5.0 Electronics Module, Figure 6 Right Combined Cable, PL 5.0
Error Messages and Codes
13,XXX.xx Printhead Reservoir, 13,XXX.xx
10/2006
2-30
Phaser 8510/8560MFP Multifunction Product
Troubleshooting Procedures
Table 2 Ink Loader Ink Melt Heater 13,328.43 through 13,581.44 Procedure
Step Questions or Actions Yes No
1 Verify that the ambient temperature of the
room is within the system’s specifications. Is the room within operating parameters?
2 Check ground integrity for the printer.
Does the error persist?
3 Test the appropriate Ink Melt heater.
Run the Service Diagnostics Ink Melt test.
1. Yellow
2. Cyan
3. Magenta
4. Black Does the Ink Melt Heater operate cor-
rectly?
4 Check Ink Loader connections and wiring.
Are the connections secure and the wiring undamaged?
Go to Step 2. Advise the customer
Go to Step 3. Complete.
Replace the Elec­tronics Module (REP
5.0.5).
Replace the Ink Loader (REP 2.0.1).
of operational requirements.
Go to Step 4.
Repair or replace the wiring. If the error persists, replace the I/O Board (REP
5.0.13).
13,00x.6x Thermal Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
X-Axis Program Faults 13,001.62 Thermals failed to read system NVRAM. 13,002.63 Value 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 expected an initialization message, but received other. 13,008.60 Thermal power manager task received an unexpected message.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 6,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
10/2006
2-31
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
13,XXX.xx, 13,00x.6x
19,0XX.4x Printhead Calibration Faults
The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting procedure applies to this error:
Printhead Calibration Faults
19,001.46 The HFD server failed due to NVRAM operation. THis fault should only occur
when the system is in manufacturing mode.
19,002.47 The system attempted a Printhead operation without position data in NVRAM. 19,003.48 Scale and offset voltage error too large. Something is wrong with the Electron-
ics Module or Wave Amplifier.
19,004.40 The Printhead and Electronics Module do not match.
19,0XX.6x Waveform Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
X-Axis Program Faults 19,001.68
to 19,039.61
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Waveform Printhead calibration program faults.
Initial Actions
• Check electrical connections to the Printhead.
• Check for obstructions or damage near the Printhead. If obstructions are cleared, retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 19,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0 Electronics Module, Figure 6 Printhead, PL 2.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 Process Drive Faults 7,0xx.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check and reseat all connections to the
Printhead. Does the problem persist?
Replace the Print­head (REP 2.0.2). If the error persists, replace the Electron­ics Module (REP
5.0.5).
Complete.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 6,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Check that the ground straps are place between the Media Drive Motor and Y­Axis Assembly. Also check the ground clip at the Tray 2 Pick Clutch. Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
19,0XX.4x, 19,0XX.6x
10/2006
2-32
Phaser 8510/8560MFP Multifunction Product
21,000.69 Diagnostic Firmware Version Mismatch
A software error has occurred. The following troubleshooting procedure applies to these errors:
X-Axis Program Faults
21,000.69 The diagnostics firmware doesn’t match the engine firmware.
22,0XX.6x Jam Fault
A jam has occurred. The system generates a four-digit, alphanumeric code associated to a particular area of the paper path, followed by the value of the system page counter when the jam occurred <jam code><page count>. Jam code syntax is defined in Table 1. A listing of common Jam Codes appears at the end of this section.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 6,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Update the Diagnostic firmware.
Does the problem persist?
2 Replace the Electronics Module (REP
5.0.5).
Go to Step 2. Complete.
Complete.
Table 1 Jam Code Key
Process Event Basis for Jam System State Media Supply
A Deskew Flag B Preheater Flag C Strip Flag D Exit Flag E Tray 1 Width F Front Door G Exit Door H Tray 2 Media J Tray 3 Media K Tray 4 Media M Media Drive N Y-Axis Motor P Process Drive V Tray 2 Event W Tray 3 Event X Tray 3 Pick Flag Y Tray 4 Event Z Tray 4 Pick Flag
As an example, the Jam Code W2Q1 indicates a Tray 3 Paper Size Switch unexpectedly acti­vated while a paper pick operation occurred from Tray 1. See Jam Codes for a listing of the most commonly seen codes.
2 Sensor Event 3 Timeout 4 Motor Stall 5 Motor Position 6 Length Short 7 Length Long
A Abnormal shutdown B Normal shutdown C Mechanical recovery D Warmup E Ready F Fault G Auto Drum Maintenance H Printhead Maintenance J Printhead purge K Oil Transfix Roller L Standby M Pick from Tray 2 N Pick from Tray 3 P Pick from Tray 4 Q Pick from Tray 1 R Pick from DUplex S Stage for transfix T Transfix V Pint Drum Maintenance W Imaging X Exit Z Shutdown
1 Tray 1 2 Tray 2 3 Tray 3 4 Tray 4 5 Chase Page 6 Duplex
Initial Actions
• Clear the paper path of obstructions or debris.
• Check that the media meets specifications and is loaded correctly.
• Check that the Pick Rollers are clean and in good condition.
Troubleshooting Procedure
Locate the code in the Jam Codes listing and follow the procedure, if available
10/2006
2-33
21,000.69, 22,0XX.6x
Error Messages and Codes
23,0XX.6x NVRAM Faults
An NVRAM error has occurred. The following troubleshooting procedure applies to these errors:
26,0XX.6x Printing Faults
A printing process error has occurred. The following troubleshooting procedure applies to these errors:
NVRAM Faults
23,0xx.6x The system detected an NVRAM fault during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 23,0XX.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Printing Faults 26,0xx.6x A printing process fault occurred during operation. 26,962.64 A fall out code fault.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Troubleshooting Procedure
Check the fault history and troubleshoot the error listed immediately prior to these codes. Oth­erwise, reboot the system to clear these error conditions.
Error Messages and Codes
23,0XX.6x, 26,0XX.6x
10/2006
2-34
Phaser 8510/8560MFP Multifunction Product
27,0XX.6x Profile Library
A profile library error has occurred. The following troubleshooting procedure applies to these errors:
Profile Library Faults
27,0xx.6x A printing process fault occurred during operation.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Troubleshooting Procedure
Check system ground integrity.
29,0XX.6x Jam Manager Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Jam Manager Faults
29,0XX.6x Jam Manager program faults.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 29,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Jam Manager Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
10/2006
2-35
Error Messages and Codes
27,0XX.6x, 29,0XX.6x
31,001.40 Mechanical Initialization Jam
A software error has occurred. The following troubleshooting procedure applies to this error:
31,0XX.6x Program Faults
A software error has occurred. The following troubleshooting procedure applies to these errors:
Mechanical Initialization Fault
31,001.40 Mechanical initialization jam fault.
Initial Actions
• Check routing of tray sensor harnesses.
• Check that the Take Away Rollers are free of obstructions.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 31,0xx.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Media Drive Assy, PL 4.0 Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 X-Axis Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the Take Away Rollers.
Do the rollers show signs of excessive wear or damage?
2 Test the Media Drive.
Run the Service Diagnostics Paper Path Drive test. Does the Media Drive operate correctly?
3 DId the Media Drive run extremely fast? Replace the Media
4 Check the rollers.
Remove the Media Drive Assembly and check each roller for binding or drag. Do the rollers rotate correctly?
Replace the affected roller.
Go to Step 4. Go to Step 3.
Drive Assembly (REP 4.0.14).
Replace the Media Drive Assembly (REP 4.0.14).
Go to Step 2.
Go to Step 4.
Repair or replace rollers.
Program Faults
31,0XX.6x Program faults.
Initial Actions
• Reset NVRAM and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 31,0xx.6x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
NVRAM, PL 5.0
Troubleshooting Procedure
Table 2 Program Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat all Electronics Module connec-
tions. Does the problem persist?
2 Check ground integrity.
Are the system grounds connected?
Go to Step 2. Complete.
Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).
Reconnect the sys­tem grounds.
Error Messages and Codes
31,001.40, 31,0XX.6x
10/2006
2-36
Phaser 8510/8560MFP Multifunction Product
33,00X.4x Tray 1 Width Sensor Faults
The Paper Width Sensor, located in the Tray 1/Front Door Assembly is reporting out of range values. The following troubleshooting procedure applies to these errors:
34,00X.4x Printhead NVRAM Faults
The Printhead is unable to access system NVRAM. The following troubleshooting procedure applies to these errors:
Tray Manager Device Faults 33,001.42 Tray 1 width value too low. 33,002.43 Tray 1 width value too high.
Initial Actions
• Check electrical connection to Tray 1 (P/J650).
• Check for obstructions or damage to the Media Guides.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 33,00x.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Tray 1/Front Door Assembly, PL 1.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
Table 2 Tray 1 Width Sensor Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the Tray 1 Harness connection to
the I/O Board (P/J610). Is the connection secure and the harness undamaged?
2 Test the Width Sensors.
Run the Service Diagnostics Tray 1 Width Sensor test. Does the sensor operate correctly?
Go to Step 2. Repair or replace the
Replace the I/O Board (REP 5.0.13).
harness.
Replace the Tray 1/ Front Door Assem­bly (REP 1.0.1).
Printhead NVRAM Faults
34,001.43 An error occurred while attempting read/write access to the Printhead calibra-
34,002.44 An error occurred while attempting read/write access to the Printhead ink data
34,003.45 An error occurred while attempting read/write access to the Printhead data par-
34,004.46 An error occurred while accessing the Printhead NVRAM hardware for pur-
tion partition in NVRAM. The Printhead cable may be unplugged.
partition in NVRAM.
tition in NVRAM.
poses of initialization. The Printhead cable may be unplugged.
Initial Actions
• Check data connection to the Printhead.
• Check for obstructions or damage to the Media Guides.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 34,00x.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Printhead, PL 2.0 Electronics Module, Figure 6 Printhead Interface Cable, PL 5.0 Electronics Module, Figure 6
Troubleshooting Procedure
Table 2 Printhead NVRAM Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the Printhead data cable connec-
tions (P/J3 and P/J180). Are the connections secure and the cable undamaged?
2 Replace the Printhead (REP 2.0.2).
Does the error persist?
Go to Step 2. Repair or replace the
cable.
Replace the Elec­tronics Module (REP
5.0.5).
Complete.
10/2006
2-37
Error Messages and Codes
33,00X.4x, 34,00X.4x
36,000.40 Drum Maintenance Faults
An error occurred while attempting to position the Drum Maintenance Kit. The following trou­bleshooting procedure applies to these errors:
36,001.67 Drum Maintenance Drive Faults
An error occurred while attempting to position the Drum Maintenance Kit. The following trou­bleshooting procedure applies to this error:
Printhead NVRAM Faults
36,000.40 An error occurred while attempting to position the Drum Maintenance Kit.
Initial Actions
• Check for ink spills or obstructions near the Drum Maintenance Kit.
• Check for obstructions or damage to the Pivot Plate and Cam Rollers.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 36,000.40 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Drum Maintenance Kit PL 1.0 Drum Maintenance Pivot Plate PL 2.0 I/O Board (2/2), Figure 10 Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8
Troubleshooting Procedure
Table 2 Drum Maintenance Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that system grounds are in place.
Are the grounds secure and undamaged?
2 Check the Drum Maintenance Pivot Plate
for cracks, and the Dram Maintenance Cam Rollers for damage or improper movement. Is there damage to the Pivot Plate or Cam Rollers?
3 Test Drum Maintenance operation.
Run the Service Diagnostics Drum Main­tenance/Transfix Home test. Does the system operate correctly?
4 Test the Drum Maintenance drive.
Run the Service Diagnostics Drum Main­tenance Drive test. Does the drive operate correctly?
Go to Step 2. Repair or replace the
Replace any dam­aged parts.
Go to Step 4. Replace the Pro-
Complete. Replace the Pro-
grounds. Go to Step 3.
cess Drive (REP
4.0.7).
cess Drive (REP
4.0.7)
Drum Maintenance Drive Faults
36,001.67 An error occurred while attempting to position the Drum Maintenance Kit.
Initial Actions
• Check for ink spills or obstructions near the Drum Maintenance Kit.
• Check for obstructions or damage to the Pivot Plate and Cam Rollers.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 36,001.67 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Drum Maintenance Kit PL 1.0 Drum Maintenance Pivot Plate PL 2.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
Table 2 Drum Maintenance Drive Faults 36,001.67 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that system grounds are in place.
Are the grounds secure and undamaged?
2 Test Drum Maintenance operation.
Run the Service Diagnostics Drum Main­tenance/Transfix Home test. Does the system operate correctly?
3 Test the Drum Maintenance drive.
Run the Service Diagnostics Drum Main­tenance Drive test. Does the drive operate correctly?
Go to Step 2. Repair or replace the
Go to Step 3. Replace the Pro-
Replace the Drum Maintenance Pivot Plate and Shaft (REP 2.0.16).
grounds.
cess Drive (REP
4.0.7).
Replace the Pro­cess Drive (REP
4.0.7)
Error Messages and Codes
36,000.40, 36,001.67
10/2006
2-38
Phaser 8510/8560MFP Multifunction Product
36,002.44 Drum Maintenance Kit Fault
An error occurred while attempting to position the Drum Maintenance Kit. The following trou­bleshooting procedure applies to this error:
Drum Maintenance Drive Faults
36,002.44 The system can not write to the Drum Maintenance Kit.
Initial Actions
• Check for ink spills or obstructions near the Drum Maintenance Kit.
• Check for obstructions or damage to the Pivot Plate and Cam Rollers.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 36,001.67 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Drum Maintenance Kit PL 1.0 Drum Maintenance Pivot Plate PL 2.0 I/O Board (2/2), Figure 10
Troubleshooting Procedure
Table 2 Drum Maintenance Drive Faults 36,001.67 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check that the Drum Maintenance Kit is
correctly installed. Is the installation correct?
2 Replace the Drum Maintenance Kit
Does the error persist?
Go to Step 2. Correct and retest.
Replace the Drum Maintenance Pivot Plate and Shaft (REP 2.0.16).
Complete.
37,0XX.xx PEST Heater Faults
An heating error has occurred. The following troubleshooting procedure applies to these errors:
PEST Heater Faults 37,001.46 An error occurred during PEST execution. 37,002.47 The Left Jetstack is drawing less power than expected. 37,003.48 The Right Jetstack is drawing less power than expected. 37,004.40 Ink Reservoir 0 is drawing less power than expected. 37,005.41 Ink Reservoir 1 is drawing less power than expected. 37,006.42 The Drum Heater is drawing less power than expected. 37,008.44 The Preheater is drawing less power than expected. 37,009.45 All Ink Melt Heaters are drawing less power than expected. 37,010.46 The Yellow (0) Ink Melt Heater is drawing less power than expected. 37,011.44 The Cyan (1) Ink Melt Heater is drawing less power than expected. 37,012.48 The Magenta (2) Ink Melt Heater is drawing less power than expected. 37,013.48 The Black (3) Ink Melt Heater is drawing less power than expected.
Initial Actions
• Check the Printhead, Preheater and Ink Loader power connections.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,0XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Ink Loader Assy, PL 2.0 Electronics Module, Figure 6 Printhead, PL 2.0 Electronics Module, Figure 6 Preheater, PL 2.0 Electronics Module Power, Figure 7
Troubleshooting Procedure
Table 2 PEST Heater Faults 37,0XX.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the affected component.
Run the Service Diagnostics test for the affected component. Does the affected component reach oper­ating temperature?
2 Check wiring to the affected component.
Is the wiring damaged?
10/2006
2-39
Go to Step 2. Replace the affected
Repair or replace the harness.
component.
Replace the affected component.
Error Messages and Codes
36,002.44, 37,0XX.xx
37,01X.41 PEST Fan Faults
An fan error has occurred. The following troubleshooting procedure applies to these errors:
PEST Heater Faults 37,014.41 The Electronics Module Fan is drawing less power than expected. 37,015.41 The Drum Fan is drawing less power than expected.
37,016.43 PEST 50 Volt Supply Fault
An error has occurred related to the Electronics Module 50 V Power Supply. The clutches oper­ate at 50 V. The Head Maintenance, Deskew, and Pick clutches are drawing too much power indicating a short in the supply or one of the components connected to it.
PEST 50 V Supply Fault
37,016.43 All three clutches failed.
Initial Actions
• Check the Electronics Module and Drum Cooling Fans.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,01X.41 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module Fan, PL 4.0 Left Side Harness (2/2), Figure 5 Drum Fan, PL 4.0 Right Side Harness / I/O Control, Figure 8
Troubleshooting Procedure
Table 2 PEST Fan Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the affected component.
Run the Service Diagnostics test for the affected fan. Does the affected fan operate correctly?
2 Check wiring to the affected component.
Is the wiring damaged?
Go to Step 2. Replace the fan.
Repair or replace the harness.
Replace the affected component.
Initial Actions
• Check the Electronics Module indicators.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,016.43 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 4.0 Left Side Harness (1/2), Figure 4 I/O Board, PL 5.0 I/O Board, Figure 9
Troubleshooting Procedure
CAUTION
Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge.
Table 2 PEST 50 V Supply Fault 37,016.43 Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check for a short in the Electronics Mod-
ule. Measure the 50 V power supply output. The test point is located on the power con­trol board below the main board RAM DIMMs. Is there 50 V across the TP and ground?
2 Shutdown the system and wait 30 sec-
onds for the capacitors to discharge. Unplug all connections to the Electronics Module. Turn the system On. Do the PE and PS indicators (near the Power Switch) flash momentarily?
Go to Step 2. Go to Step 2.
Go to Step 3. Replace the Elec-
tronics Module (REP
5.0.5).
Error Messages and Codes
37,01X.41, 37,016.43
10/2006
2-40
Phaser 8510/8560MFP Multifunction Product
Table 2 PEST 50 V Supply Fault 37,016.43 Troubleshooting Procedure
Step Questions or Actions Yes No
3 Shutdown the system and wait 30 sec-
onds for the capacitors to discharge. Connect I/O Board connector (P/J840). Turn the system On. Do the PE and PS indicators (near the Power Switch) flash momentarily?
4 Check the 50 V Supply LED.
If the 50V LED (Figure 2) illuminates, the short is on one of the external devices unplugged earlier. In this case, systemati­cally turn off the printer, plug a wiring har­ness back in, and turn the printer on until the 50V LED fails to illuminate. Was the defective part isolated?
5 Shutdown the system and wait 30 sec-
onds for the capacitors to discharge. Disconnect all connections to the I/O Board. Test the resistance of the I/O Board across pin 1 of J270 and ground. Pin 1 is on the left end of the jack. Is the resistance still less than 1K ohm?
6 Reconnect connections on the I/O Board
until you find one that creates a short at J270-1. Does a short appear at J270-1?
7 Reconnect the Wave Amplifier.
Turn the system On. Does the error persist?
8 Reconnect the Printhead.
Turn the system On. Does the error persist?
Go to Step 4. Go to Step 5.
Replace the defec­tive part.
Replace the I/O Board (REP 5.0.13).
Replace the affected component.
Go to Step 8. Leave power on to
Replace the Elec­tronics Module (REP
5.0.5).
Go to Step 5.
Go to Step 6.
Go to Step 7.
ensure the problem is fixed.
Leave power on to ensure the problem is fixed.
37,0XX.4x PEST Clutch/Solenoid Faults
An heating error has occurred. The following troubleshooting procedure applies to these errors:
PEST Heater Faults 37,017.44 The Head Maintenance Clutch is drawing less power than expected. 37,018.45 The Deskew Clutch is drawing less power than expected. 37,019.46 The Pick Clutch is drawing less power than expected. 37,020.48 The Tray 1 Pick Solenoid is drawing less power than expected. 37,021.42 The Strip Solenoid is drawing less power than expected. 37,022.4x The Preheater Lift Solenoid is drawing less power than expected. 37,023.4x The Head Tilt Solenoid is drawing less power than expected.
Initial Actions
• Check the indicated component for damage, wear, or obstructions.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,0XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Head Maintenance Clutch, PL 4.0 I/O Board (2/2), Figure 10 Deskew Clutch, PL 4.0 Left Side Harness (1/2), Figure 4 Pick Clutch, PL 4.0 Left Side Harness (1/2), Figure 4 Tray 1 Pick Solenoid, PL 4.0 Left Side Harness (1/2), Figure 4 Strip Solenoid, PL 3.0 I/O Board (1/2), Figure 9 Preheater Lift Solenoid, PL 4.0 Left Side Harness (2/2), Figure 5 Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 PEST Clutch/Solenoid Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the component indicated by the error.
Run the Service Diagnostics test for the affected component. Does the component operate correctly?
2 Check wiring to the affected component.
Is the wiring damaged?
10/2006
2-41
Go to Step 2. Replace the affected
Repair or replace the harness.
component.
Replace the affected component.
Error Messages and Codes
37,016.43, 37,0XX.4x
37,024.48 PEST Tray 2 Lift Motor Fault
An error has occurred related to the Tray 2 Lift Motor. The following troubleshooting procedure applies to this error:.
37,026.44 PEST Purge Pump Fault
An error has occurred related to the Purge Pump. The following troubleshooting procedure applies to this error:.
Tray 2 Lift Motor Fault
37,024.48 The Tray 2 Lift Motor is drawing less power than expected.
Initial Actions
• Check the Tray 2 Lift Plate for damage or obstructions.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,024.48 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Tray 2 Lift Motor, PL 4.0 Left Side Harness (1/2), Figure 4 Electronics Module, PL 4.0 Left Side Harness (1/2), Figure 4
Troubleshooting Procedure
Table 2 PEST Tray 2 Lift Motor Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Tray 2 Lift Motor.
Run the Service Diagnostics Tray 2 Lift Motor test. Does the motor operate correctly?
2 Check the motor connection to the Left
Side Harness. Is the connection secure and the harness undamaged?
Replace the Elec­tronics Module (REP
5.0.5).
Replace the motor (REP 4.0.10).
Go to Step 2.
Repair of replace the Left Side Harness.
Tray 2 Lift Motor Fault
37,026.44 The Purge Pump purge valve is drawing less power than expected.
Initial Actions
• Check the Purge Pump for damage or obstructions.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,026.44 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Purge Pump, PL 2.0 Left Side Harness (2/2), Figure 5 Electronics Module, PL 4.0 Left Side Harness (2/2), Figure 5
Troubleshooting Procedure
Table 2 PEST Purge Pump Fault Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Purge Pump.
Run the Service Diagnostics Purge Vent Solenoid test. Does the pump operate correctly?
2 Check the pump connection to the Left
Side Harness. Is the connection secure and the harness undamaged?
Go to Step 2. Replace the Purge
Replace the Purge Pump (REP 2.0.7).
Pump (REP 2.0.7).
Repair of replace the Left Side Harness.
Error Messages and Codes
37,024.48, 37,026.44
10/2006
2-42
Phaser 8510/8560MFP Multifunction Product
37,02X.4x PEST Relay Board Faults
An Relay Board error has occurred. The following troubleshooting procedure applies to these errors:
37,03X.4x PEST X-Axis Motor Faults
An X-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:
PEST Relay Board Faults 37,027.45 Both relay coils are drawing less power than expected. 37,028.46 The A coil is drawing less power than expected. 37,029.47 The B coil is drawing less power than expected.
Initial Actions
• Check the Relay Board’s power connection.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,02X.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Relay Board, PL 5.0 I/O Board (1/2), Figure 9 Electronics Module, PL 5.0 Electronics Module Power, Figure 7
Troubleshooting Procedure
Table 2 PEST Relay Board Faults 37,02X.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Relay Board.
Run the Service Diagnostics Drum Heater Relay test. Does the Relay Board operate correctly?
2 Check wiring to the affected component.
Is the wiring damaged?
Replace the Elec­tronics Module (REP
5.0.5).
Repair or replace the harness.
Go to Step 2.
Replace the Relay Board (REP 5.0.19).
PEST X-Axis Motor Faults 37,030.45 The X-Axis Motor is drawing less power than expected. 37,031.46 The X-Axis Motor first phase is drawing less power than expected. 37,032.47 The X-Axis Motor first phase is drawing too much power. 37,033.48 The X-Axis Motor second phase is drawing less power than expected. 37,034.40 The X-Axis Motor second phase is drawing too much power.
Initial Actions
• Check the X-Axis Motor connection.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,03X.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
X-Axis Motor, PL 4.0 Right Side Harness / I/O Control, Figure 8 Electronics Module, PL 5.0 Right Side Wire Routing, Figure 3
Troubleshooting Procedure
Table 2 PEST X-Axis Motor Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the X-Axis Motor.
Run the Service Diagnostics X-Axis Drive test. Does the motor operate correctly?
2 Check wiring to the motor.
Is the wiring damaged?
Replace the Elec­tronics Module (REP
5.0.5).
Repair or replace the harness.
Go to Step 2.
Replace the X-Axis Motor (REP 4.0.5).
10/2006
2-43
Error Messages and Codes
37,02X.4x, 37,03X.4x
37,035.44 and 37,036.45 PEST Y-Axis Motor Faults
A Y-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:
37,037.46 and 37,038.47 PEST Media Drive Faults
A Media Drive Assembly error has occurred. The following troubleshooting procedure applies to these errors:
PEST Y-Axis Motor Faults 37,035.44 The Y-Axis Motor is drawing less power than expected. 37,036.45 The Y-Axis Motor is drawing too much power.
Initial Actions
• Check for obstructions to Drum rotation.
• Check the condition of the Y-Axis Drive Belt.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,03X.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Y-Axis Motor, PL 4.0 Electronics Module Power, Figure 7 Drum Assembly, PL 2.0 Electronics Module, PL 5.0 Electronics Module Power, Figure 7
Troubleshooting Procedure
Table 2 PEST Y-Axis Motor Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check the Drum rotation.
Does the Drum rotate smoothly?
2 Check the Y-Axis Motor.
Remove the Y-Axis Belt (REP 2.0.4). Does the Y-Axis Motor shaft rotate freely?
3 Replace the Y-Axis Belt and test the Y-
Axis Motor. Run the Service Diagnostics Y-Axis Drive test. Does the motor operate correctly?
4 Check wiring to the motor.
Is the wiring damaged?
Go to Step 2. Replace the Drum
Go to Step 3. Replace the Y-Axis
Replace the Elec­tronics Module (REP
5.0.5).
Repair or replace the harness.
Assembly (REP
2.0.3).
Motor (REP 4.0.11).
Go to Step 4.
Replace the Y-Axis Motor (REP 4.0.11).
PEST Media Drive Faults 37,037.46 The Media Drive Motor is drawing less power than expected. 37,038.47 The Media Drive Motor is drawing too much power.
Initial Actions
• Check for obstructions to Media Drive rotation.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,037.46 and 37,038.47 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Media Drive, PL 4.0 Left Side Harness (2/2), Figure 5 Electronics Module, PL 5.0 Left Side Wire Routing (2/2), Figure 5
Troubleshooting Procedure
Table 2 PEST Media Drive Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Media Drive Motor.
Run the Service Diagnostics Media Path Motor test. Does the motor operate correctly?
2 Check wiring to the motor.
Is the wiring damaged?
Replace the Elec­tronics Module (REP
5.0.5).
Repair or replace the harness.
Go to Step 2.
Replace the Media Drive (REP 4.0.14).
Error Messages and Codes
37,035.44 and 37,036.45, 37,037.46 and 37,038.47
10/2006
2-44
Phaser 8510/8560MFP Multifunction Product
37,039.48 and 37,040.40 PEST Process Drive Faults
A Y-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:
37,0XX.4x PEST Power Supply Faults
An Power Supply error has occurred. The following troubleshooting procedure applies to these errors:
PEST Process Drive Faults 37,039.48 The Process Drive Motor is drawing less power than expected. 37,040.40 The Process Drive Motor is drawing too much power.
Initial Actions
• Check for obstructions to Process Drive rotation.
• Check the rotation of the Drum Maintenance and Transfix Roller shafts.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,039.48 and 37,040.40 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Process Drive, PL 4.0 Right Side Harness / I/O Control, Figure 8 Electronics Module, PL 5.0
Troubleshooting Procedure
Table 2 PEST Process Drive Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Check shaft rotation.
Do the Process Drive gears, Transfix Shaft, and Drum Maintenance shaft rotate freely?
2 Test the Process Drive Motor.
Run the Service Diagnostics Process Motor test. Does the motor operate correctly?
3 Check wiring to the motor.
Is the wiring damaged?
Go to Step 2. Repair or replace
Replace the Elec­tronics Module (REP
5.0.5).
Repair or replace the harness.
affected parts.
Go to Step 3.
Replace the Pro­cess Drive (REP
4.0.7).
PEST Power Supply Faults 37,041.41 The Power Supply failed to reset. 37,043.43 The Power Supply 2.5 V source over limit. 37,044.44 The Power Supply 2.5 V source under limit. 37,045.45 The Power Supply 3.3 V source over limit. 37,046.46 The Power Supply 3.3 V source under limit. 37,047.47 The Power Supply 12 V source over limit. 37,048.48 The Power Supply 12 V source under limit. 37,049.40 The Power Supply -12 V source over limit. 37,050.41 The Power Supply -12 V source under limit. 37,051.42 The Power Supply current over limit. 37,052.43 The Power Supply current under limit. 37,053.44 The Power Supply 50 V source over limit. 37,054.45 The Power Supply 50 V source under limit. 37,055.46 The Power Supply -50 V source over limit. 37,056.47 The Power Supply -50 V source under limit. 37,057.48 The Power Supply 15 V source over limit. 37,058.40 The Power Supply 15 V source under limit. 37,059.41 The Power Supply -15 V source over limit. 37,060.42 The Power Supply -15 V source under limit. 37,061.43 The Power Supply 5 V source over limit. 37,062.44 The Power Supply 5 V source under limit. 37,063.45 The Power Supply high switch not activated. Electrical short or missing reset line. 37,064.46 Vss too low. The Printhead power harness may be disconnected. 37,065.47 Vpp too low. The Printhead or Wave Amp may be disconnected. 37,066.48 The Wave Amplifier s drawing too much power. Possible short.
Initial Actions
• Check the component power connections and harness condition.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 37,0XX.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Electronics Module, PL 5.0
10/2006
2-45
37,039.48 and 37,040.40, 37,0XX.4x
Error Messages and Codes
Troubleshooting Procedure
Table 2 PEST Power Supply Faults 37,0XX.4x Troubleshooting Procedure
Step Questions or Actions Yes No
1 Test the Power Supply.
Run the Service Diagnostics Voltages test. Does the Power Supply operate correctly?
2 Check the Printhead Power connection.
Is the wiring disconnected or damaged?
Go to Step 2. Replace the Elec-
Repair or replace the harness.
tronics Module (REP
5.0.5).
Replace the Elec­tronics Module (REP
5.0.5).
39,002.40 and 39,003.41 Scanner Subsystem Test Faults
A Scanner DRAM or Optical self test error has occurred. The following troubleshooting proce­dure applies to these errors:
Scanner Subsystem Test Faults 39,002.40 The Scanner DRAM test failed. 39,003.41 The Scanner Optical Test failed.
Initial Actions
• Cycle system power and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 39,00X.4x Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Scanner Assembly, PL 1.0
Troubleshooting Procedure
Table 2 Scanner Subsystem Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Cycle system power and retest.
Does this correct the problem?
2 Replace the Scanner Assembly (REP
1.0.11).
Complete. Go to Step 2.
Complete.
Error Messages and Codes
37,0XX.4x, 39,002.40 and 39,003.41
10/2006
2-46
Phaser 8510/8560MFP Multifunction Product
39,004.42 Scanhead Locked or Shipping Restraint Faults
A Scanner self test determined the Scanhead was either locked, or the shipping restraint remained. The following troubleshooting procedure applies to these errors:
Scanhead Lock or Shipping Restraint Faults
39,004.42 The Scanhead did not reach Home position. Release Scanner Shipping Restraint
or Scanhead Locked appears on the Control Panel display.
Initial Actions
• Check the Scanhead lock.
• Check for packaging.
• If the problem persists, follow the procedure below.
39,005.43 Scanner Missing Fault
A Scanner was not detected. The following troubleshooting procedure applies to these errors:
Scanner Missing Fault
39,005.43 The system did not detect the Scanner Assembly.
Initial Actions
• Reseat the Scanner connection to the Electronics Module.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 39,004.42 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Scanner Assembly, PL 1.0
Troubleshooting Procedure
Table 2 Scanhead Locked Troubleshooting Procedure
Step Questions or Actions Yes No
1 Cycle system power and retest.
Does this correct the problem?
2 Replace the Scanner Assembly (REP
1.0.11).
Complete. Go to Step 2.
Complete.
Table 1 39,005.43 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Scanner Assembly, PL 1.0 Scanner Power Supply, PL 5.0 Exit Module Control Board, Figure 11 DADF, PL 1.0 Exit Module Control Board, PL 5.0 Exit Module Control Board, Figure 11 Exit Roller Motor, PL 4.0 Exit Module Control Board, Figure 11 Elevator Motor, PL 4.0 Exit Module Control Board, Figure 11
Troubleshooting Procedure
Table 2 Scanhead Missing Troubleshooting Procedure
Step Questions or Actions Yes No
1 Cycle system power and retest.
Does this correct the problem?
2 Check the Scanner Power Supply status
LED (see Figure 1). Is the Status LED blinking?
3 Remove the Output Tray and Side Covers.
Disconnect the Elevator (P/J303) and Exit Roller (P/J309) motors. Does the Status LED stop blinking and remain On?
4 With the Exit Module motors discon-
nected, disconnect the DADF from the Scanner. Does the Status LED stop blinking and remain On?
Complete. Go to Step 2.
Go to Step 3. Go to Step 5.
Replace the defec­tive motor or the Exit Module (REP 3.0.7)
Replace the DADF (REP 1.0.15).
Go to Step 4.
Go to Step 5.
10/2006
2-47
Error Messages and Codes
39,004.42 , 39,005.43
Table 2 Scanhead Missing Troubleshooting Procedure
Step Questions or Actions Yes No
5 Is the Status LED Off? Replace the Scanner
6 Disconnect the Scanner Assembly from
the Electronics Module. Does the Status LED light?
Power Supply (REP
5.0.2). If the error persists, replace the Electronics Module (REP 5.0.5).
Replace the Scanner Assembly (REP
1.0.11).
Go to Step 6.
Replace the Exit Module Control Board (REP 5.0.1). If the error persists, replace the Scanner Power Supply (REP
5.0.2). If the Status LED remains Off, replace the Electron­ics Module (REP
5.0.5).
39,010.8 Document Feeder Disconnected or Missing
The system could not detect the DADF. The following troubleshooting procedure applies to this error:
Document Feeder Disconnected or Missing Faults
39,010.8 The DADF was not detected. Document Feeder Disconnected or DADH Missing
Initial Actions
• Check the DADF connection to the Scanner Assembly.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Applicable Parts Wiring and Plug/Jack References
DADF, PL 1.0
Troubleshooting Procedure
Step Questions or Actions Yes No
1 Reseat the DADF connection to the Scan-
2 Cycle system power and retest.
appears on the Control Panel display.
Table 1 39,010.8 Troubleshooting Reference Table
Table 2 DADF Disconnected or Missing Troubleshooting Procedure
Go to Step 2. Complete. ner Assembly. Wait at least one minute. Does the problem persist?
Complete. Replace the DADF Does this correct the problem?
(REP 1.0.15).
Error Messages and Codes
39,005.43 , 39,010.8
10/2006
2-48
Phaser 8510/8560MFP Multifunction Product
39,011.40 and 39,012.40 DADF Subsystem Test Faults
The DADF DRAM or Optical self test error has occurred. The following troubleshooting proce­dure applies to these errors:
39,013.42 Document Feeder Jam
A media Jam is detected in the DADF. The following troubleshooting procedure applies to this error:
DADF Subsystem Faults 39,011.40 The DADF DRAM Test failed. 39,012.40 The DADF Optical Test failed.
Initial Actions
• Cycle system power and retest.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 39,011.40 and 39, 012.40 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
Document Feeder, PL 1.0
Troubleshooting Procedure
Table 2 DADF Subsystem Faults Troubleshooting Procedure
Step Questions or Actions Yes No
1 Cycle system power and retest.
Does this correct the problem?
2 Replace the DADF (REP 1.0.15). Complete.
Complete. Go to Step 2.
Document Feeder Disconnected or Missing Faults
39,013.42 Media Jam in the DADF was detected. Jam at Document Feeder appears on the
Control Panel display.
Initial Actions
• Check that the media is supported by the system.
• Check the pick rollers and separator pad.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 39,004.42 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
DADF Pick Roller and Pad, PL 1.0 DADF, PL 1.0
Troubleshooting Procedure
Table 2 Scanhead Locked Troubleshooting Procedure
Step Questions or Actions Yes No
1 Clean or replace the DADF Pick Rollers
and Separator Pad. Does the problem persist?
2 Remove all media, open and close the
DADF Front Cover, and retest. Does this correct the problem?
Go to Step 2. Complete.
Complete. Replace the DADF
(REP 1.0.15).
10/2006
2-49
Error Messages and Codes
39,011.40 and 39,012.40, 39,013.42
39,014.43 Document Feeder Calibration Fault
A calibration faults is detected in the DADF. The following troubleshooting procedure applies to this error:
Document Feeder Calibration Fault
39,014.43 DADF calibration fault.
Initial Actions
• Check that the media is supported by the system.
• Check the pick rollers and separator pad.
• If the problem persists, follow the procedure below.
Primary Causes
The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.
Table 1 39,004.42 Troubleshooting Reference Table
Applicable Parts Wiring and Plug/Jack References
DADF, PL 1.0
Troubleshooting Procedure
Table 2 Scanhead Locked Troubleshooting Procedure
Step Questions or Actions Yes No
1 Cycle system power and retest.
Does this correct the problem?
Complete. Replace the DADF
(REP 1.0.15).
Jam Codes
The printer stores the most recent 20 events in Jam History. To access this information for Phaser 8510/8560MFP systems, press and hold the Up Arrow button, then scroll to Jam His­tory and press OK to display the most recent jam list.
Table 1 Jam Code Key
Process Event Basis for Jam System State Media Supply
A Deskew Flag B Preheater Flag C Strip Flag D Exit Flag E Tray 1 Width F Front Door G Exit Door H Tray 2 Media J Tray 3 Media K Tray 4 Media M Media Drive N Y-Axis Motor P Process Drive V Tray 2 Event W Tray 3 Event X Tray 3 Pick Flag Y Tray 4 Event Z Tray 4 Pick Flag
2 Sensor Event 3 Timeout 4 Motor Stall 5 Motor Position 6 Length Short 7 Length Long
A Abnormal shutdown B Normal shutdown C Mechanical recovery D Warmup E Ready F Fault G Auto Drum Maintenance H Printhead Maintenance J Printhead purge K Oil Transfix Roller L Standby M Pick from Tray 2 N Pick from Tray 3 P Pick from Tray 4 Q Pick from Tray 1 R Pick from DUplex S Stage for transfix T Transfix V Drum Maintenance W Imaging X Exit Z Shutdown
1 Tray 1 2 Tray 2 3 Tray 3 4 Tray 4 5 Chase Page 6 Duplex
Error Messages and Codes
39,014.43 , Jam Codes
Not all jam code combinations are documented in this manual, only the codes that occur most commonly.
NOTE: The following table defines the first 3-digits. The 4th digit represents the tray number (1~4), 5 represents a chase page, and 6 represents duplex. Numbers following the 4th digit are the system page count:
Table 2 Jam Code Troubleshooting
Code Description / Procedure
A2C Deskew sensor in unexpected state during mechanical recovery.
1. Check the Drum Maintenance Kit NVRAM contacts during oiling for continuity.
2. Instruct customer to remove media from Tray 1 before opening the front door.
3. Replace the pivot arm.
A2E Deskew sensor in unexpected state at ready.
1. Check system grounding.
2. Replace Tray 1 Pick Solenoid.
10/2006
2-50
Phaser 8510/8560MFP Multifunction Product
Table 2 Jam Code Troubleshooting
Code Description / Procedure
A2F Deskew sensor in unexpected state.
1. Check system grounding.
2. Verify all doors and covers are fully closed and not moving during printing. A2J Deskew flag sensor event during head purge. A2K Deskew sensor in an unexpected state during a transfix roller oiling. A2M
The deskew flag tripped unexpectedly while picking paper from Tray 2.
A2N
The deskew flag tripped unexpectedly while picking paper from Tray 3.
A2P
The deskew flag tripped unexpectedly while picking paper from Tray 4.
A2S
Deskew sensor in unexpected state during media stage for transfix.
A2Q
The deskew flag tripped unexpectedly while the printer was picking paper from Tray 1.
1. Try using different, supported media
2. Ensure the paper guides are snug against the media in the tray
3. Push up on Tray {2 - 4} Nudger Roller until it is captured by actuator arm.
4. Run the following diagnostic tests, Deskew Flag, Tray {2-4} Pick Clutch and the
Tray {2-4} Solenoid.
5. Check system grounding.
6. Verify all doors and covers are fully closed and not moving during printing.
7. Replace the Tray {2 - 4} Pick Clutch.
8. Replace the Retard Roller (REP 3.0.18).
9. Replace the Preheater (REP 2.0.17). A3G
Deskew Sensor time-out event during an auto drum maintenance cycle.
A3M
The deskew flag timed out waiting for the paper picked from Tray 2.
A3N
The deskew flag timed out waiting for the paper picked from Tray 3.
A3P
The deskew flag timed out waiting for the paper picked from Tray 4.
A3Q
The deskew flag timed out waiting for the paper picked from Tray 1.
1. Verify media is appropriate for the tray.
2. Verify the tray is not overfilled and the guides are positioned correctly.
3. Check for obstructions in the paper path.
4. Test the appropriate Tray Solenoid.
5. Test the appropriate Tray Pick Clutch.
6. Ensure the take away rollers are in good condition.
7. Test the take away roller using the diagnostic Paper Path Drive test.
8. Replace the appropriate Separator Pad Assembly.
9. Replace the Pick Assembly (REP 3.0.18).
Table 2 Jam Code Troubleshooting
Code Description / Procedure
A3R Deskew sensor time-out during movement from exit roller to deskew roller when
duplexing print.
1. Ensure the media is appropriate for two-sided printing. Not too short, not too smooth.
2. Check the condition of the Exit Roller and the Duplex Roller.
3. Check the Front Door for obstructions or damage, replace the Front Door if nec­essary.
4. Test the operation of the exit roller and the duplex roller using diagnostic Duplex Paper Lead Edge Times test.
5. Test the deskew sensor using the diagnostic Sensors test.
B2C Preheat exit sensor unexpected state during mechanical recovery.
1. Clear jam and let printer finish mechanical recovery.
2. Check system grounds.
B2F
Preheater exit sensor in unexpected state during fault.
B2S
Preheater exit sensor in unexpected state during stage.
1. Check system grounds.
2. Check the Drum Maintenance Kit NVRAM contacts during oiling for continuity.
3. Check the waste tray.
4. Replace the Preheater (REP 2.0.17).
B2M
The preheat flag tripped unexpectedly while picking paper from Tray 2.
B2N
The preheat flag tripped unexpectedly while picking paper from Tray 3.
B2P
The preheat flag tripped unexpectedly while picking paper from Tray 4.
B2Q
The preheat flag tripped unexpectedly while picking paper from Tray 1.
1. Test the Preheater Sensor using Service Diagnostics.
2. Check system grounds.
B3M
The preheat flag timed out waiting for the paper picked from Tray 2.
B3N
The preheat flag timed out waiting for the paper picked from Tray 3.
B3P
The preheat flag timed out waiting for the paper picked from Tray 4.
B3Q
The preheat flag timed out waiting for the paper picked from Tray 1.
B3S
Preheater sensor timed out during stage.
B3T
Preheater Exit Sensor timed out during transfix.
1. Verify media is appropriate for the tray.
2. Check for paper path obstructions, ensure the Preheater plate moves freely.
3. Replace the Tray 1 Separator Pad Assembly.
4. Test the Preheater Exit Sensor using Service Diagnostics.
5. Check the condition of the Deskew Rollers.
6. Test the Deskew Clutch using Service Diagnostics.
7. Run the Paper Path Drive test from Service Diagnostics.
8. Replace the Preheater (REP 2.0.17), then retest.
10/2006
2-51
Error Messages and Codes
Jam Codes
Table 2 Jam Code Troubleshooting
Code Description / Procedure
C2C
Strip flag unexpected event during mechanical recovery.
C2D
Strip flag unexpected state during warm-up.
C2E
Strip flag unexpected event during system ready.
C2F
Strip flag unexpected event during fault.
C2K
Strip flag unexpected event during transfix roller oiling.
C2M
The strip flag actuated unexpectedly when paper was picked from Tray 2.
C2N
The strip flag actuated unexpectedly when paper was picked from Tray 3.
C2P
The strip flag actuated unexpectedly when paper was picked from Tray 4.
C2Q
The strip flag actuated unexpectedly when paper was picked from Tray 1.
C2R
Strip flag unexpected event during pick from the duplex path.
C2T
Strip flag unexpected event during transfix.
1. Check system grounds.
2. Check for paper tray overfill.
3. Test the Strip Sensor using Service Diagnostics.
4. Check the Stripper Blade for damage or debris.
5. Run the Paper Lead Edge Times test using Service Diagnostics.
6. Test the Deskew Clutch using Service Diagnostics.
7. Replace the Stripper Carriage Assembly (REP 2.0.12), then retest.
C2X Strip flag unexpected event during exit.
1. Check that the media is not too thick and is supported by the system.
2. Use a less glossy media.
3. Check that the guides in the tray are snug against the media.
4. If the Drum Maintenance Kit is near end of life, replace it.
5. Clean and inspect the exit rollers.
6. Test the Paper Path Drive using Service Diagnostics.
C3M
The strip flag timed out waiting for the paper picked from Tray 2.
C3N
The strip flag timed out waiting for the paper picked from Tray 3.
C3P
The strip flag timed out waiting for the paper picked from Tray 4.
C3Q
The strip flag timed out waiting for the paper picked from Tray 1.
C3T
Strip flag time-out during transfix.
1. Check that the media is the correct size and type for the tray. If envelope jam, try a different style.
2. Check the Drum Maintenance Kit for proper operation, replace if necessary.
3. Check that the Process Drive is correctly homed (ADJ 4.7.1).
4. Test the Stripper Carriage using the Stripper Contact test in Service Diagnostics.
5. Test the Transfix Drive using the Transfix Drive Slow and Transfix Drive Fast tests.
C3X Strip flag time-out during exit.
1. Open the Exit Door and ensure the springs for the idler rollers are present and installed correctly (they should be the same for all 5 rollers).
2. Verify the metal bar is installed on top of the Exit Guide.
Table 2 Jam Code Troubleshooting
Code Description / Procedure
C5X Print pulled back into transfix nip during exit.
1. Check that the media is not too thick and is supported by the system.
2. Use a less glossy media.
3. If the Drum Maintenance Kit is near end of life, replace it.
4. Clean and inspect the exit rollers.
5. Check that the Process Drive is correctly homed (ADJ 4.7.1).
6. Test the Paper Path Drive using Service Diagnostics.
7. Replace the Lower Exit Guide.
D2D
Exit flag unexpected event during warm-up.
D2M
The exit flag actuated unexpectedly when paper was picked from Tray 2.
D2N
The exit flag actuated unexpectedly when paper was picked from Tray 3.
D2P
The exit flag actuated unexpectedly when paper was picked from Tray 4.
D2Q
The exit flag actuated unexpectedly when paper was picked from Tray 1.
D2R
The exit flag actuated unexpectedly when duplexing
D2T
The exit flag actuated unexpectedly when transfixing
1. Check system grounds.
2. Test the Exit Sensor using Service Diagnostics.
3. Run the Paper Lead Edge Times test using Service Diagnostics.
4. Replace the problem component, then retest.
D2X The exit flag actuated unexpectedly exit.
1. Check that the media is not too thick and is supported by the system.
2. Use a less glossy media.
3. If the Drum Maintenance Kit is near end of life, replace it.
4. Clean and inspect the exit rollers.
5. Check that the Exit Sensor Flag for proper installation or damage. Replace if nec­essary.
6. Test the Paper Path Drive using Service Diagnostics.
7. Replace the problem component.
D3C
Exit flag time-out during mechanical recovery.
D3M
Exit flag timed out following Tray 2 Pick.
D3N
Exit flag timed out following Tray 3 Pick.
D3P
Exit flag timed out following Tray 4 Pick.
D3Q
Exit flag timed out following Tray 1 Pick.
D3R
Exit flag timed out during duplexing.
D3T
Exit flag time-out during transfix.
1. Check that the media is not too thick and is supported by the system.
2. Check that the exit path is free of obstructions.
3. If the Drum Maintenance Kit is near end of life, replace it.
4. Clean and inspect the Stripper Blade.
5. Clean and inspect the exit rollers. Check that the rollers rotate freely.
6. Check the Exit Sensor Flag for proper installation or damage. Replace if neces­sary.
7. Test the Paper Path Drive using Service Diagnostics.
8. Replace the problem component.
Error Messages and Codes
Jam Codes
10/2006
2-52
Phaser 8510/8560MFP Multifunction Product
Table 2 Jam Code Troubleshooting
Code Description / Procedure
E2D
Tray 1 width sensor during warm-up.
E2E
Tray 1 width sensor during operation.
E2Q
Tray 1 width sensor during Tray 1 pick
1. Check the Tray 1 width guides for proper operation. Verify the guides are not moving during printing.
2. Check the Front Door is closed and the wiring is properly connected and seated.
3. Test the Tray 1 Width Sensor using Service Diagnostics.
4. Check the Tray 1 wiring to the I/O board.
5. Replace the I/O Board (REP 5.0.13), then retest.
F2D
The Front Door Interlock tripped during warming up.
F2F
The Front Door Interlock tripped during fault state.
F2M
The Front Door Interlock tripped during a pick from Tray 2.
F2N
The Front Door Interlock tripped during a pick from Tray 3.
F2P
The Front Door Interlock tripped during a pick from Tray 4.
F2Q
The Front Door Interlock tripped during a pick from Tray 1.
F2R
The Front Door Interlock tripped during duplexing.
F2S
The Front Door Interlock tripped while the paper was staged for transfix.
F2T
The Front Door Interlock tripped during transfix.
F2V
The Front Door Interlock tripped during Drum oiling.
F2W
The Front Door Interlock tripped during imaging.
F2X
The Front Door Interlock tripped during exit.
1. Check the Front Door for damaged hinges, latch, or interlock actuator.
2. Check the covers for proper alignment and fit.
3. Test the Interlock Switch (Door Sensor test) using Service Diagnostics.
4. Check the Front Door Interlock Switch installation and wiring.
5. Replace the switch, then retest.
G2M Tray 2 removed during pick from Tray 2. H2N Tray 3 removed during pick from Tray 3. J2M Tray 4 removed during pick from Tray 4. J2P Tray 4 Media Present Sensor event pick from Tray 4.
Table 2 Jam Code Troubleshooting
Code Description / Procedure
M2C
Media Drive motor had an unexpected event during mechanical recovery.
M4A
Media Drive motor stalled during an abnormal printer shutdown.
M4B
Media Drive motor stalled during a normal printer shutdown.
M4C
Media Drive motor stalled during mechanical recovery.
M4D
Media Drive motor stalled during printer warm-up.
M4E
Media Drive motor stalled during ready state.
M4F
Media Drive motor stalled during a fault state.
M4G
Media Drive motor stalled during an auto drum maintenance cycle.
M4H
Media Drive motor stalled during printhead maintenance.
M4J
Media Drive motor stalled during printhead purge.
M4K
Media Drive motor stalled during an oil transfix roller cycle.
M4L
Media Drive motor stalled during standby mode.
M4M
Media Drive motor stalled during pick from Tray 2.
M4N
Media Drive motor stalled during pick from Tray 3.
M4P
Media Drive motor stalled during pick from Tray 4.
M4Q
Media Drive motor stalled during pick from Tray 1.
M4R
Media Drive motor stalled during duplex.
M4S
Media Drive motor stalled during transfix stage.
M4T
Media Drive motor stalled during transfix.
1. Check that the media is supported by the system.
2. Check that the exit path is free of obstructions.
3. Check system grounds.
4. Test the Media Drive motor using the Paper Path Drive test.
5. If necessary, retest using the Media Path Motor and Shafts tests.
6. Check the condition and movement of the rollers and gears.
7. Replace the Media Drive Assembly (REP 4.0.14).
N2T Y-Axis motor event during transfix (Tray 1 only - probably a multi-pick).
1. Check that the media is supported by the system.
2. Try a heavier media.
3. Send a snippet to turn off the multi-pick detection code.
4. Test the Y-Axis Motor using Service Diagnostics, replace if necessary (REP
4.0.11).
5. Run the Voltages test, replace the Electronics Module if necessary (REP 5.0.5).
N2W Y-Axis motor event during imaging. Probably a software fault. Check system grounds.
10/2006
2-53
Error Messages and Codes
Jam Codes
Table 2 Jam Code Troubleshooting
Code Description / Procedure
N4A
Y-Axis motor stalled on power-up following an abnormal shutdown.
N4B
Y-Axis motor stalled on power-up following a normal shutdown.
N4C
Y-Axis motor stalled during mechanical recovery
N4D
Y-Axis motor stalled during warm-up.
NFE
Y-Axis motor stalled during ready state.
N4F
Y-Axis motor stalled during a fault state.
N4G
Y-Axis motor stalled during an auto drum maintenance cycle.
N4H
Y-Axis motor stalled during printhead maintenance.
N4J
Y-Axis motor stalled during printhead purge.
N4K
Y-Axis motor stalled during an oil transfix roller cycle.
N4L
Y-Axis motor stalled during standby mode.
N4S
Y-Axis motor stalled during staging for transfix.
N4T
Y-Axis motor stalled during transfixing.
N4V
Y-Axis motor stalled during a print drum maintenance cycle.
N4W
Y-Axis motor stalled during drum imaging.
N4X
Y-Axis motor stalled during paper exit.
1. Check for supported media, generally label, trifold or envelopes cause this error.
2. Try running fewer sheets through the tray.
3. Check that the Process Drive is correctly homed (ADJ 4.7.1).
4. Test theY-Axis Motor using Service Diagnostics, replace if necessary (REP
4.0.11).
5. Test for Y-Axis Belt slippage using the Belt Slip test.
6. Replace the Tray 1 Separator Pad assembly.
7. Replace the Process Drive (REP 4.0.7).
N5T
Y-Axis motor out of position during transfixing.
N5W
Y-Axis motor out of position during drum imaging.
1. Check the Y-Axis drive belt.
2. Run the Check Drum Y-Axis Encoder test.
3. Run the Check Drum Y-Axis Drive test.
4. Test for Y-Axis Belt slippage using the Belt Slip test.
5. Replace the Y-Axis Motor (REP 4.0.11), or Drum Assembly (REP 2.0.3) if neces­sary.
N6T Y-Axis Motor media short during transfix. The media was shorter than expected. Legal
size paper from Tray 4 in standard print mode may buckle. Use slower print mode.
1. Check for supported media.
2. Check system grounds.
3. Run the Check Drum Y-Axis Encoder test.
4. Remove the Preheater (REP 2.0.17), and check the Preheater flag for ink or paper interference.
5. Replace the Preheater (REP 2.0.17).
Table 2 Jam Code Troubleshooting
Code Description / Procedure
N7T Y-Axis Motor media long during transfix. The media was longer than expected.
1. Check for supported media.
2. Try heavier media.
3. Try loading only a few sheets. Some photo media may require running one sheet at a time.
4. Run the diagnostic Check Drum Y-Axis Encoder test.
5. Replace the Pick Assembly and Retard Roller (REP 3.0.18).
6. Run the clean ink smears and check the Preheater exit flag for debris.
7. Remove the Preheater (REP 2.0.17), and check the Preheater flag for ink or paper interference.
8. Replace the Preheater (REP 2.0.17) if the error persists.
P4A
Process Drive stalled on power-up following an abnormal shutdown.
P4B
Process Drive stalled on power-up following a normal shutdown.
P4C
Process Drive stalled during mechanical recovery
P4D
Process Drive stalled during warm-up.
PFE
Process Drive stalled during ready state.
P4F
Process Drive stalled during a fault state.
P4G
Process Drive stalled during an auto drum maintenance cycle.
P4H
Process Drive stalled during printhead maintenance.
P4J
Process Drive stalled during printhead purge.
P4K
Process Drive stalled during an oil transfix roller cycle.
P4L
Process Drive stalled during standby mode.
P4S
Process Drive stalled during staging for transfix.
P4T
Process Drive stalled during transfixing.
P4V
Process Drive stalled during a print drum maintenance cycle.
P4W
Process Drive stalled during drum imaging.
P4X
Process Drive stalled during paper exit.
1. Check for supported media.
2. Check that the Process Drive is correctly homed (ADJ 4.7.1).
3. Test the Process Drive using Service Diagnostics.
4. Replace the Process Drive (REP 4.0.7) if necessary.
5. Run the Transfix Fast and Slow tests.
6. Replace the Transfix Camshaft (REP 2.0.10) and load arms if necessary.
7. Run the Tilt Drive test, replace if necessary.
8. Replace the Process Drive (REP 4.0.7).
Error Messages and Codes
Jam Codes
10/2006
2-54
Phaser 8510/8560MFP Multifunction Product
Table 2 Jam Code Troubleshooting
Code Description / Procedure
T2A
Exit Door Interlock tripped following an abnormal shutdown.
T2B
Exit Door Interlock tripped following a normal shutdown.
T2C
Exit Door Interlock tripped during mechanical recovery
T2D
Exit Door Interlock tripped during warm-up.
T2E
Exit Door Interlock tripped during ready state.
T2F
Exit Door Interlock tripped during a fault state.
T2G
Exit Door Interlock tripped during an auto drum maintenance cycle.
T2H
Exit Door Interlock tripped during Printhead maintenance.
T2J
Exit Door Interlock tripped during Printhead purge.
T2K
Exit Door Interlock tripped during an oil transfix roller cycle.
T2L
Exit Door Interlock tripped during standby mode.
T2M
Exit Door Interlock tripped during pick from Tray 2.
T2N
Exit Door Interlock tripped during pick from Tray 3.
T2P
Exit Door Interlock tripped during pick from Tray 4.
T2Q
Exit Door Interlock tripped during pick from Tray 1.
T2R
Exit Door Interlock tripped during duplexing.
T2S
Exit Door Interlock tripped during transfix staging.
T2T
Exit Door Interlock tripped during transfixing.
T2X
Exit Door Interlock tripped during paper exit.
T2Z
Exit Door Interlock tripped during shutdown.
1. Check for supported media.
2. Check system grounds.
3. Run the Monitor Sensors test using Service Diagnostics.
4. Check the Exit Door Interlock Switch. Replace if necessary (REP 6.0.2).
5. Check the Drum Maintenance Kit is functioning properly and the blade is not cov­ered with ink debris. Replace if necessary
6. Replace the Transfix Roller (REP 2.0.12).
V2D
Tray 2 Paper Size Switch activated during warm-up.
V2E
Tray 2 Paper Size Switch activated during ready state.
V2F
Tray 2 Paper Size Switch activated during a fault state.
V2K
Tray 2 Paper Size Switch activated during an oil transfix roller cycle.
V2L
Tray 2 Paper Size Switch activated during standby mode.
V2M
Tray 2 Paper Size Switch activated during pick from Tray 2.
V2N
Tray 2 Paper Size Switch activated during pick from Tray 3.
V2P
Tray 2 Paper Size Switch activated during pick from Tray 4.
V2Q
Tray 2 Paper Size Switch activated during pick from Tray 1.
V2R
Tray 2 Paper Size Switch activated during duplexing.
V2S
Tray 2 Paper Size Switch activated during transfix staging.
V2T
Tray 2 Paper Size Switch activated during transfixing.
V2X
Tray 2 Paper Size Switch activated during paper exit.
1. Check system grounds.
2. Check that the Tray 2 media guides are set correctly.
3. Run the Monitor Sensors test using Service Diagnostics.
4. Check the Paper Size Switch. Replace if necessary (REP 6.0.7).
5. Replace the Pivot Arm.
Table 2 Jam Code Troubleshooting
Code Description / Procedure
W2D
Tray 3 Paper Size Switch activated during warm-up.
W2E
Tray 3 Paper Size Switch activated during ready state.
W2F
Tray 3 Paper Size Switch activated during a fault state.
W2L
Tray 3 Paper Size Switch activated during standby mode.
W2M
Tray 3 Paper Size Switch activated during pick from Tray 2.
W2N
Tray 3 Paper Size Switch activated during pick from Tray 3.
W2P
Tray 3 Paper Size Switch activated during pick from Tray 4.
W2Q
Tray 3 Paper Size Switch activated during pick from Tray 1.
W2R
Tray 3 Paper Size Switch activated during duplexing.
W2V
Tray 3 Paper Size Switch activated during an auto drum maintenance cycle.
W2S
Tray 3 Paper Size Switch activated during transfix staging.
W2T
Tray 3 Paper Size Switch activated during transfixing.
W2X
Tray 3 Paper Size Switch activated during paper exit.
1. Check system grounds.
2. Check that the Tray 3 media guides are set correctly.
3. Run the Monitor Sensors test using Service Diagnostics.
4. Replace the 525-Sheet Feeder.
W4N
Tray 3 Paper Size Switch activated during pick from Tray 3.
W4P
Tray 3 Paper Size Switch activated during pick from Tray 4.
W2S
Tray 3 Paper Size Switch activated during pick from Tray 1.
1. Check system grounds.
2. Check that the Tray 3 media guides are set correctly.
3. Run the Monitor Sensors test using Service Diagnostics.
4. Replace the 525-Sheet Feeder.
X2A
Tray 3 pick flag actuated during an abnormal shutdown.
X2B
Tray 3 pick flag actuated during a normal shutdown.
X2C
Tray 3 pick flag actuated during mechanical recovery
X2D
Tray 3 pick flag actuated during warm-up.
X2E
Tray 3 pick flag actuated during ready state.
X2F
Tray 3 pick flag actuated during a fault state.
X2L
Tray 3 pick flag actuated during standby mode.
X2M
Tray 3 pick flag actuated during pick from Tray 2.
X2N
Tray 3 pick flag actuated during pick from Tray 3.
X2P
Tray 3 pick flag actuated during pick from Tray 4.
X2Q
Tray 3 pick flag actuated during pick from Tray 1.
X2R
Tray 3 pick flag actuated during duplexing.
X2S
Tray 3 pick flag actuated during transfix staging.
X2V
Tray 3 pick flag actuated during an auto drum maintenance cycle.
X2W
Tray 3 pick flag actuated during drum imaging.
X2X
Tray 3 pick flag actuated during paper exit.
1. Check system grounds.
2. Check that the Tray 2 media guides are set correctly
3. Run the Monitor Sensors test using Service Diagnostics.
4. Replace the 525-Sheet Feeder.
5. Replace the Pivot Arm.
10/2006
2-55
Error Messages and Codes
Jam Codes
Table 2 Jam Code Troubleshooting
Code Description / Procedure
X3D
Tray 3 pick flag timed-out during warm-up.
X3E
Tray 3 pick flag timed-out during ready state.
X3F
Tray 3 pick flag timed-out during a fault state.
X3K
Tray 3 pick flag timed-out during an oil transfix roller cycle.
X3L
Tray 3 pick flag timed-out during standby mode.
X3M
Tray 3 pick flag timed-out during pick from Tray 2.
X3N
Tray 3 pick flag timed-out during pick from Tray 3.
X3P
Tray 3 pick flag timed-out during pick from Tray 4.
X3Q
Tray 3 pick flag timed-out during pick from Tray 1.
X3R
Tray 3 pick flag timed-out during duplexing.
X3S
Tray 3 pick flag timed-out during transfix staging.
X3T
Tray 3 pick flag timed-out during transfixing.
X3V
Tray 3 pick flag timed-out during a drum maintenance cycle.
X3W
Tray 3 pick flag timed-out during drum imaging.
X3X
Tray 3 pick flag timed-out during paper exit.
1. Check for supported media.
2. Reduce the amount of media loaded in the tray and reposition the guides to fit snugly against the media.
3. Check the rollers for damage, debris or excessive wear. Clean or replace as nec­essary.
4. Run the Tray 3 Pick Shaft test using Service Diagnostics.
5. Check system grounds.
6. Push up on the Nudger Roller until it is captured by the Actuator Arm.
7. Run the Pick Clutch test using Service Diagnostics. Replace if necessary.
8. Run the Media Path Drive test using Service Diagnostics.
9. Replace the Pick Roller Assembly (REP 3.0.18).
10. Replace the 525-Sheet Feeder.
Y2D
Tray 4 Paper Size Switch activated during warm-up.
Y2E
Tray 4 Paper Size Switch activated during ready state.
Y2F
Tray 4 Paper Size Switch activated during a fault state.
Y2L
Tray 4 Paper Size Switch activated during standby mode.
Y2M
Tray 4 Paper Size Switch activated during pick from Tray 2.
Y2N
Tray 4 Paper Size Switch activated during pick from Tray 3.
Y2P
Tray 4 Paper Size Switch activated during pick from Tray 4.
Y2Q
Tray 4 Paper Size Switch activated during pick from Tray 1.
Y2R
Tray 4 Paper Size Switch activated during duplexing.
Y2S
Tray 4 Paper Size Switch activated during transfix staging.
Y2T
Tray 4 Paper Size Switch activated during transfixing.
Y2V
Tray 4 Paper Size Switch activated during a drum maintenance cycle.
Y2W
Tray 4 Paper Size Switch activated during Drum imaging.
Y2X
Tray 4 Paper Size Switch activated during paper exit.
1. Check system grounds.
2. Check that the media guides are adjusted correctly.
3. Run the Monitor Sensors test to test the Tray 4 Paper Size Switch.
4. Replace the Tray 4 525-Sheet Feeder.
5. Replace the pivot arm.
Table 2 Jam Code Troubleshooting
Code Description / Procedure
Z2A
Tray 4 pick flag actuated during an abnormal shutdown.
Z2B
Tray 4 pick flag actuated during a normal shutdown.
Z2C
Tray 4 pick flag actuated during mechanical recovery
Z2D
Tray 4 pick flag actuated during warm-up.
Z2E
Tray 4 pick flag actuated during ready state.
Z2F
Tray 4 pick flag actuated during a fault state.
Z2L
Tray 4 pick flag actuated during standby mode.
Z2M
Tray 4 pick flag actuated during pick from Tray 2.
Z2N
Tray 4 pick flag actuated during pick from Tray 3.
Z2P
Tray 4 pick flag actuated during pick from Tray 4.
Z2Q
Tray 4 pick flag actuated during pick from Tray 1.
Z2R
Tray 4 pick flag actuated during duplexing.
Z2S
Tray 4 pick flag actuated during transfix staging.
Z2T
Tray 4 pick flag actuated during transfix.
Z2V
Tray 4 pick flag actuated during an auto drum maintenance cycle.
Z2W
Tray 4 pick flag actuated during drum imaging.
Z2Z
Tray 4 pick flag actuated during paper exit.
1. Check system grounds.
2. Run the Monitor Sensors test using Service Diagnostics.
3. Replace the 525-Sheet Feeder.
4. Replace the Pivot Arm.
Z3B
Tray 4 pick sensor timed-out during a normal shutdown.
Z3D
Tray 4 pick sensor timed-out during warm-up.
Z3E
Tray 4 pick sensor timed-out during ready state.
Z3F
Tray 4 pick sensor timed-out during a fault state.
Z3L
Tray 4 pick sensor timed-out during standby mode.
Z3M
Tray 4 pick sensor timed-out during a pick from Tray 2.
Z3N
Tray 4 pick sensor timed-out during a pick from Tray 3.
Z3P
Tray 4 pick sensor timed-out during a pick from Tray 4.
Z3Q
Tray 4 pick sensor timed-out during a pick from Tray 1.
Z3R
Tray 4 pick sensor timed-out during duplexing.
Z3S
Tray 4 pick sensor timed-out during transfix staging.
Z3T
Tray 4 pick sensor timed-out during transfix.
Z3V
Tray 4 pick sensor timed-out during an auto drum maintenance cycle.
Z3W
Tray 4 pick sensor timed-out during drum imaging.
Z3Z
Tray 4 pick sensor timed out while exiting print
1. Check the paper loaded in Tray 4 is the correct size and type.
2. Check the rollers for damage, debris or excessive wear. Clean or replace as nec­essary.
3. Run the Tray 4 Pick Shaft test.
4. Replace the Tray 4 525-Sheet Feeder.
Error Messages and Codes
Jam Codes
10/2006
2-56
Phaser 8510/8560MFP Multifunction Product
IQ1 IOT Image Quality Entry RAP .................................................................................. 3-3
IQ2 Dark Streaks on Copied Image................................................................................ 3-4
IQ3 Voids in the Copied Image ....................................................................................... 3-4
IQ4 Skewed Copy Image ................................................................................................ 3-5
IQ6 Fuzzy Text or Image................................................................................................. 3-5
IQ5 Copy Image is Lighter or Darker than the Original ................................................... 3-6
IQ7 Copied Image Colors Do Not Match the Original ..................................................... 3-6
IQ8 Dark Streaks on Copied Image................................................................................ 3-7
IQ9 Copy Image is Skewed............................................................................................. 3-7
IQ10 Copy Image is Lighter or Darker than the Original................................................. 3-8
IQ11 Copied Image Colors Do Not Match the Original ................................................... 3-8
IQ12 Fuzzy Text or Image............................................................................................... 3-9
IQ13 Random Light Stripes............................................................................................. 3-9
IQ14 Predominate Light Stripes...................................................................................... 3-10
IQ15 Smudges or Smears............................................................................................... 3-11
IQ16 Printed Image is Too Light or Too Dark ................................................................. 3-11
IQ17 No Image is Printed................................................................................................ 3-12
IQ18 Color is Uneven or Color is Wrong......................................................................... 3-12
IQ19 Streaks or Lines Down the Print............................................................................. 3-13
IQ20 Scratches or Marks Parallel to the Long Axis of Printing ....................................... 3-14
IQ21 Ink on the White Portion of the Printed Page......................................................... 3-15
IQ22 Fuzzy Text.............................................................................................................. 3-16
IQ23 Poor Primary Color Fill ........................................................................................... 3-17
IQ24 Ghosting................................................................................................................. 3-18
IQ25 Poor Small Text Resolution.................................................................................... 3-19
IQ26 Vertical Lines Appear Wavy ................................................................................... 3-20
IQ27 Oil Streaks on Print ................................................................................................ 3-20
IQ28 Incomplete Image Transfer .................................................................................... 3-21
IQ29 Ink Smears on First Side of Duplex Print ............................................................... 3-22
IQ30 Repeating Print Defects ......................................................................................... 3-23
IQ31 White Stripes (Pinstripes)....................................................................................... 3-23
IQ32 Wrinkling................................................................................................................. 3-24
IQ33 Image is Offset or Cut-Off ...................................................................................... 3-24
IQ34 Poor Ink Adhesion, Poor Image Durability ............................................................. 3-25
Analyzing Service Test Prints ......................................................................................... 3-25
Jet Substitution Mode...................................................................................................... 3-31
3 Image Quality
10/2006
3-1
Image Quality
IQ1 IOT Image Quality Entry RAP
The purpose of this RAP is to establish the source of the imaging defect. After following the Ini­tial Actions, select the RAP that best describes the observed defect.
Table 2 Scanner Image Quality Problems
Symptom RAP
Fuzzy Text or Image IQ12
Initial Actions
Computer applications, hardware malfunctions, or communication between the IIT and IOT can cause scan/copy print-quality issues. Hardware failures that result in image quality problems can occur in the DADF, Scanner Assembly or Print Engine. Use the following steps to deter­mine which part of the system is at fault.
1. Ensure the DADF and Scanner connectors are securely connected.
2. Cycle power to the system.
3. Print the 2-sided demo page from the Control Panel. If the image defect appears on the printed page, the problem is within the Print Engine. When analyzing a print-quality defect from a Print Engine malfunction, determine if the defect occurs:
• in all colors
• in only one color
• as a repeating or random defect
4. Copy a page directly from the platen.
5. Copy a page from the DADF, selecting 2-sided copy to see if the defect is on the 1st, 2nd or both sides of the page.
6. If the image defect appears on the 1st side, the problem is within the Scanner Assembly.
7. If the image defect appears on the 2nd side of the page, the problem is the DADF.
NOTE: To aid in troubleshooting image quality issues, print the Paper Tips page. The paper should be from an unopened ream that has been acclimated to room temperature.
Procedure
After determining the source of the image quality problem, examine the image and select the relevant corrective procedure from one of the following tables.
Table 1 DADF Image Quality Problems
Symptom RAP
Dark Streaks on the Copied Image IQ2 Voids in the Copied Image IQ3 Skewed Copy Image IQ4 Copied Image is Lighter or Darker than the Original IQ5 Fuzzy Text or Image IQ6 Copy Image Colors Do Not Match Original IQ7
Table 2 Scanner Image Quality Problems
Symptom RAP
Dark Streaks on the Scanned Image IQ8 Skewed Scan Image IQ9 Scanned Image is Lighter or Darker than the Original IQ10 Scan Image Colors Do Not Match Original IQ11
Table 3 Print Engine Image Quality Problems
Symptom RAP
Random Light Stripes IQ13 Predominate Light Stripes IQ14 Smudges or Smears IQ15 The printed Image is too Light or Dark IQ16 No Image is Printed IQ17 Color is Uneven or Wrong IQ18 Streaks or Lines Down the Print IQ19 Scratches or Marks Parallel to the Long Printing Axis IQ20 Ink on the White Portion of the Page IQ21 Fuzzy Text IQ22 Poor Primary Color Fills IQ23 Ghosting IQ24 Poor Small Text Resolution IQ25 Vertical Lines Appear Wavy IQ26 Oil Streaks on Print IQ27 Incomplete Image Transfer IQ28 Ink Smears on First Printed Side of Duplex Print IQ29 Repeating Defects IQ30 White Stripes IQ31 Wrinkling IQ32 Image if Offset or Cutoff IQ33 Poor Ink Adhesion, Poor Image Durability IQ34
If a print quality problem is not resolved using the image quality troubleshooting procedures, see Analyzing Service Test Prints.
NOTE: The Troubleshooting Print Quality page includes instructions for printing the Eliminate Light Stripes test print. The Eliminate Light Stripes test print indicates individual weak or miss­ing jets or an obstruction in the imaging path that produces a vertical band down the entire page. You may also see color variations from jet to jet on the Eliminate Light Stripes test print. Some variation is normal and usually self corrects within a few printed pages.
10/2006
3-3
Image Quality
IQ1
IQ2 Dark Streaks on Copied Image
This RAP addresses image quality problems associated with the DADF.
IQ3 Voids in the Copied Image
This RAP addresses image quality problems associated with the DADF.
Initial Actions
1. Check that supported media is being used.
2. Check for Ink build-up or debris. Clean if necessary.
3. Copy another page. If the problem persists, perform the following corrective actions.
4. Reseat all DADF connections.
Procedure
Table 1 IQ2 Dark Streaks on Copied Image
Step Questions and Actions Yes No
1 Check the DADF for ink build up.
Open the DADF Front Cover. Clean the inside of the DADF Front Cover, including the ribs, rollers and separator pad. Does the problem persist?
2 Check the CVT Window for ink build up.
Clean the CVT Window. Does the problem persist?
3 Check DADF calibration.
Perform the DADF to Scanner Calibration adjustment procedure (ADJ 1.15.1). Does the problem persist?
4 Replace the DADF (REP 1.0.15).
Does the problem persist?
Go to Step 2. Complete.
Go to Step 3. Complete. Advise
the customer that periodic cleaning of the CVT win­dow may be nec­essary.
Go to Step 4. Complete.
Replace the Scanner Assem­bly (REP 1.0.11).
Complete.
Initial Actions
1. Check that supported media is being used.
2. Reseat all DADF connections.
Procedure
Table 1 IQ3 Voids in the Copied Image
Step Questions and Actions Yes No
1 Does the void run the entire length of one
side of the image.
2 Open the DADF and check that the Calibra-
tion Strip extends fully. The Lamp should be completely covered by the strip. Block the DADF Cover Sensor, select 2-sided copy, and then feed media through the DADF. Does the strip extend and retract properly?
3 Remove any debris obstructing the Lamp.
Does the problem persist?
Go to Step 2. Go to Step 3.
Go to Step 3. Replace the DADF.
Replace the DADF. Complete.
Image Quality
IQ2, IQ3
10/2006
3-4
Figure 1 DADF Calibration Strip
Phaser 8510/8560MFP Multifunction Product
IQ4 Skewed Copy Image
This RAP addresses image quality problems associated with the DADF. See the Skew and Margins test print discussion.
Initial Actions
1. Reset the Media Guides on the DADF Input Tray.
2. Check that supported media is being used.
3. Check that image skew exceeds specifications.
4. Reseat all DADF connections.
IQ6 Fuzzy Text or Image
This RAP addresses image quality problems associated with the DADF.
Initial Actions
1. Check that supported media is being used.
2. Reseat all DADF connections.
3. Cycle power to the system.
Procedure
Procedure
Table 1 IQ4 Skewed Copy Image
Step Questions and Actions Yes No
1 Check that the original is printed on sup-
ported media and is undamaged. Is the original supported?
2 Check that the paper guides are correctly
adjusted, and clean the Pick Roller and Sepa­rator Pad. Does the problem persist?
3 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
Go to Step 2. Use the Platen.
Go to Step 3. Complete.
Replace the DADF (REP 1.0.15).
Complete.
Table 1 IQ6 Fuzzy Text or Image
Step Questions and Actions Yes No
1 Print the Graphics Demo page for fuzzy
image or the Configuration page for fuzzy text. Does the text appear fuzzy?
2 Make a copy of the page printed in Step 1.
Does the image still appear fuzzy?
3 Check and/or adjust the Control Panel copy
settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Use Text or Mixed print mode to evaluate text. Graphics lose image quality in these two modes. If the system is set to Photo or Graphics mode, text quality decreases. Does the problem persist after making the adjustments?
4 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
5 Scan a copy of the page printed in Step 2.
Does the problem persist?
The problem is with the Print Engine. See IQ22.
Go to Step 3. Go to Step 4.
Go to Step 4. Complete.
Go to Step 5. Complete.
Replace the Scan­ner Assembly (REP 1.0.11).
Go to Step 2.
Replace the DADF (REP 1.0.15).
10/2006
3-5
Image Quality
IQ4, IQ6
IQ5 Copy Image is Lighter or Darker than the Original
This RAP addresses image quality problems associated with the DADF.
IQ7 Copied Image Colors Do Not Match the Original
This RAP addresses image quality problems associated with the DADF.
Initial Actions
1. Check that supported media is being used.
2. Reseat all DADF connections.
Procedure
NOTE: The Control Panel settings for Color Mode, Document Type, Output Quality, and Lighten/Darken influence the output in different ways. Finding a satisfactory combination of these settings for a particular original might require several attempts. In some cases, these controls may not completely compensate for artifacts introduced in the scanning process.
Table 1 IQ5 Copy Image is Lighter or Darker than the Original
Step Questions and Actions Yes No
1 Check and/or adjust the Control Panel copy
settings.
1. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section.
2. Use the Lighten/Darken Output Quality adjustment to attempt to correct the problem.
3. Check that the print mode is not set to Draft or Standard.
Does the problem persist after making the adjustments?
2 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
Go to Step 2. Complete.
Replace the DADF. Complete.
Initial Actions
1. Check that supported media is being used.
2. Test output using Laser Original Mode.
3. Reseat all DADF connections.
4. Cycle power to the system.
NOTE: There can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.e., ink jet copy, laser toner copy, etc.). A Laser Original Mode is also available to adjust the imaging system to more accurately produce copies of laser originals. Color matching varies because the reflective characteristics of the original vary.
The Control Panel settings for Color Mode, Document Type, Output Quality, and Lighten/ Darken influence the output in different ways. Finding a satisfactory combination of these set­tings for a particular original might require several attempts. In some cases, these controls may not completely compensate for artifacts introduced in the scanning process.
Procedure
Table 1 IQ7 Copied Image Colors Do Not Match the Original
Step Questions and Actions Yes No
1 Print the Graphics Demo page.
Make a copy of the Graphics Demo page. Do the colors vary between the two?
2 Check and/or adjust the Control Panel copy
settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Does the problem persist after making the adjustments?
3 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
4 Replace the DADF.
Does the problem persist?
5 Check the cabling between the Scanner and
Print Engine. Is the cabling damaged?
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Complete.
Go to Step 5. Complete.
Replace the Scan­ner Assembly (REP 1.0.11).
Replace the Elec­tronics Module. If the problem per­sists, replace the Scanner Assem­bly (REP 1.0.11).
Image Quality
IQ5, IQ7
10/2006
3-6
Phaser 8510/8560MFP Multifunction Product
IQ8 Dark Streaks on Copied Image
This RAP addresses image quality problems associated with the Scanner Assembly.
IQ9 Copy Image is Skewed
This RAP addresses image quality problems associated with the Scanner Assembly.
Initial Actions
1. Check that supported media is being used.
2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.
3. Check for Ink build-up or debris. Clean if necessary.
4. Copy another page. If the problem persists, perform the following corrective actions.
Procedure
Table 1 IQ8 Dark Streaks on Copied Image
Step Questions and Actions Yes No
1 Check the CVT Window for ink build up.
Clean the CVT Window. Scan another page. Does the problem persist?
2 Check DADF calibration.
Perform the DADF to Scanner Calibration adjustment procedure (ADJ 1.15.1). Does the problem persist?
Go to Step 2. Complete.
Replace the Scanner Assem­bly (REP 1.0.11).
Complete.
Initial Actions
1. Check that supported media is being used.
2. Adjust the guides on the DADF Input Tray.
3. Check that image skew exceeds specifications.
4. Reseat all DADF connections.
Procedure
Table 1 IQ9 Copy Image is Skewed
Step Questions and Actions Yes No
1 Check that the original is printed on sup-
ported media and is undamaged. Print the Paper Tips page for a listing of sup­ported media. Is the original supported?
2 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
Go to Step 2. Use the Platen.
Replace the Scan­ner Assembly (REP 1.0.11).
Complete.
10/2006
3-7
Image Quality
IQ8, IQ9
IQ10 Copy Image is Lighter or Darker than the Original
This RAP addresses image quality problems associated with the DADF.
IQ11 Copied Image Colors Do Not Match the Original
This RAP addresses image quality problems associated with the DADF.
Initial Actions
1. Check that supported media is being used.
2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.
Procedure
Table 1 IQ10 Copy Image is Lighter or Darker than the Original
Step Questions and Actions Yes No
1 Check and/or adjust the Control Panel copy
settings.
1. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section.
2. Use the Lighten/Darken Output Quality adjustment to attempt to correct the problem.
3. Check that the print mode is not set to Draft or Standard.
Does the problem persist after making the adjustments?
2 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
Go to Step 2. Complete.
Replace the Scan­ner Assembly (REP 1.0.11).
Complete.
Initial Actions
1. Check that supported media is being used.
2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.
3. Cycle power to the system.
NOTE: There can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.e., ink jet copy, laser toner copy, etc.). Reds may never match the original. A Laser Original Mode is also available to adjust the imaging system to more accurately produce copies of laser originals. Color matching varies because the reflec­tive characteristics of the original vary.
Procedure
Table 1 IQ11 Copied Image Colors Do Not Match the Original
Step Questions and Actions Yes No
1 Print the Graphics Demo page.
Make a copy of the Graphics Demo page. Do the colors vary between the two?
2 Check and/or adjust the Control Panel copy
settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Does the problem persist after making the adjustments?
3 Adjust the Original Type and Output Quality
modes and monitor how the copy changes with different combinations of settings. Does the problem persist?
4 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
5 Replace the DADF (REP 1.0.15).
Does the problem persist?
6 Check the cabling between the Scanner and
Print Engine. Is the cabling damaged?
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Complete.
Go to Step 5. Complete.
Go to Step 6. Complete.
Replace the Scan­ner Assembly (REP 1.0.11).
Replace the Elec­tronics Module (REP 5.0.5). If the problem persists, replace the Scan­ner Assembly.
Image Quality
IQ10, IQ11
10/2006
3-8
Phaser 8510/8560MFP Multifunction Product
IQ12 Fuzzy Text or Image
This RAP addresses image quality problems associated with the DADF.
Initial Actions
1. Check that supported media is being used.
2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.
3. Cycle power to the system.
Procedure
Table 1 IQ12 Fuzzy Text or Image
Step Questions and Actions Yes No
1 Print the Graphics Demo page for fuzzy
image or the Configuration page for fuzzy text. Does the text appear fuzzy?
2 Make a copy of the page printed in Step 1.
Does the image still appear fuzzy?
3 Check and/or adjust the Control Panel copy
settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Use Text or Mixed print mode to evaluate text. Graphics lose image quality in these two modes. If the system is set to Photo or Graphics mode, text quality decreases. Does the problem persist after making the adjustments?
4 Perform the DADF to Scanner Calibration
adjustment procedure (ADJ 1.15.1). Does the problem persist?
5 Scan a copy of the page printed in Step 2.
Does the problem persist?
The problem is with the Print Engine. See IQ22.
Go to Step 3. Go to Step 4.
Go to Step 4. Complete.
Go to Step 5. Complete.
Replace the Scan­ner Assembly (REP 1.0.11).
Go to Step 2.
Replace the DADF (REP 1.0.15).
IQ13 Random Light Stripes
This RAP addresses image quality problems associated with the Print Engine. Random light stripes typically result from an obstructed Printhead jet. Indications of a random light stripe condition are one or more color bars missing on the test page, or output that appears as fol­lows:
Figure 1 Random Light Stripes
NOTE: If there are discolored jets, as shown in Figure 2, print several solid fill test prints in the affected color. In the following example, the center yellow stripe has discolored jets, therefore you would print the yellow solid fill.
10/2006
3-9
Figure 2 Discolored Jets on the Light Stripes Page
Image Quality
IQ12, IQ13
Initial Actions
1. Check that supported media is being used.
2. Run the Eliminate Light Stripes routine from the Control Panel.
Procedure
NOTE: If the Eliminate Light Stripes page indicates that the missing jets are arranged as 3 side by side or 2 at the end of a row, jet substitution as described in Step 4 will not correct the prob­lem.
Table 1 IQ13 Random Light Stripes
Step Questions and Actions Yes No
1 Run the Eliminate Light Stripes routine from
the Control Panel. Multiple attempts are sometimes needed to clear obstructed jets. Does the problem persist?
2 Clean the Print Engine exit path, and wipe the
Stripper Blade with a lint-free cloth. Does the problem persist?
3 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
4 Select the Jet Substitution Mode.
1. On the Control Panel, select Trouble­shooting, and then press the OK button.
2. Select Print Quality Problems, and then press the OK button.
3. Select Eliminate Light Stripes, and then press the OK button.
4. Select Jet Substitution Mode, and then press the OK button.
5. Follow the Control Panel prompts to select the color and malfunctioning jet number indicated on the Light Stripes Test page.
Does the problem persist?
5 Turn off the system for at least 4 hours.
Run the Eliminate Light Stripes routine. Does the problem persist?
Go to Step 2. Complete.
Go to Step 3. Complete.
Replace the Main­tenance Kit. If the problem persists, go to Step 4.
Go to Step 5. Complete.
Follow Printhead Troubleshooting Checklist.
Complete.
Complete.
IQ14 Predominate Light Stripes
This RAP addresses image quality problems associated with the Print Engine. Predominate light stripes typically result from something scraping the image off the Drum before Transfixing. Indications of a random light stripe condition are all four color bars missing on the test page, or output that appears as follows:
Figure 1 Example of Predominate Light Stripe Output
NOTE: If there are a series of regularly spaced white lines approximately 6 mm (.25 in.) apart, see IQ31.
Initial Actions
1. Check that supported media is being used.
2. Run the Eliminate Light Stripes routine from the Control Panel.
Procedure
Table 1 IQ14 Predominate Light Stripes
Step Questions and Actions Yes No
1 Clean the Print Engine exit path, and wipe the
Stripper Blade with a lint-free cloth. Does the problem persist?
2 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
Go to Step 2. Complete.
Replace the Drum Maintenance Kit. If the problem per­sists, use IQ13.
Complete.
Image Quality
IQ13, IQ14
10/2006
3-10
Phaser 8510/8560MFP Multifunction Product
IQ15 Smudges or Smears
This RAP addresses image quality problems associated with the Print Engine. Smudges or smears typically result from ink residue in the paper path. Residue can collect on the rollers, paper guide ribs, or inside the Preheater. Smudges or smears can appear as follows:
Figure 1 Example of Smudged or Smeared Output
Initial Actions
1. Check that supported media is being used.
2. Run the Remove Print Smears routine from the Control Panel.
Procedure
Table 1 IQ15 Smudges or Smears
Step Questions and Actions Yes No
1 Clean the Print Engine exit path, and wipe the
Stripper Blade with a lint-free cloth. Does the problem persist?
2 Run the Remove Print Smears routine.
Does the problem persist?
3 Repeat Step 2 up to 3 times if necessary.
Load fresh media and reprint the test page. Does the problem persist?
4 Remove the Drum Maintenance Kit and wipe
the clear plastic blade with a lint-free cloth. Does the problem persist?
5 Clean the rollers and Stripper Blade.
Does the problem persist?
6 Check the Drum Maintenance Pivot Plate and
Cam Rollers for damage or debris. Replace any defective parts. Does the problem persist?
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Complete.
Replace the Drum Maintenance Kit. If the problem per­sists, go to Step 5.
Go to Step 6. Complete.
Replace the Pre­heater (REP
2.0.17).
Complete.
Complete
IQ16 Printed Image is Too Light or Too Dark
This RAP addresses image quality problems associated with the Print Engine.
Initial Actions
1. Check that supported media is being used.
2. Verify the settings for media type match the media loaded in the tray.
Procedure
Table 1 IQ16 Printed Image is Too Light or Too Dark
Step Questions and Actions Yes No
1 Verify that paper type matches the type
selected in the driver and by the application. Does the problem persist after making the adjustments?
2 Check and/or adjust the Control Panel print
mode settings.
1. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section.
2. Use the Lighten/Darken Output Quality adjustment to attempt to correct the problem.
3. Check that the print mode is not set to Draft or Standard.
Does the problem persist?
3 Insert new ink and print solid fill test prints
until the affected color returns to normal. This could require several ink sticks of the affected color. Does the problem persist?
4 Purge the ink from the affected color up to 10
times, checking output every 3 purges until the discoloration clears. Does the problem persist?
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Complete.
Replace the Print­head (REP 2.0.2).
Complete.
10/2006
3-11
Image Quality
IQ15, IQ16
IQ17 No Image is Printed
This RAP addresses image quality problems associated with the Print Engine. The printer pro­cesses a sheet of paper, but no image appears on the output.
NOTE: Blank sheets accompanying multi-picks or chase pages following a jam are a part of normal operation.
Initial Actions
1. Check that supported media is being used.
2. Check for media or debris around the Printhead and Drum.
Procedure
Table 1 IQ17 No Image is Printed
Step Questions and Actions Yes No
1 Follow the instructions on the Printhead Trou-
bleshooting Checklist. Does the problem persist?
2 Inspect and reseat the Wave Amp and data
cables connected to the Printhead. Replace any defective cables. Does the problem persist?
Go to Step 2. Complete.
Replace the Elec­tronics Module (REP 5.0.5). If the problem persists, replace the Print­head (REP 2.0.2).
Complete.
IQ18 Color is Uneven or Color is Wrong
This RAP addresses image quality problems associated with the Print Engine. Uneven or incorrect colors typically result from incorrect colors in the Ink Loader, old ink in the Printhead, color mixing at the faceplate, or Drum thermal problems. Indications of uneven or incorrect color appears as follows:
Figure 1 Example of Uneven or Incorrect Color Output
NOTE: Using non-Xerox ink may cause unpredictable color results.
Initial Actions
1. Check that supported media is being used.
2. Run the Eliminate Light Stripes routine from the Control Panel.
Image Quality
IQ17, IQ18
Procedure
Table 1 IQ18 Color is Uneven or Color is Wrong
Step Questions and Actions Yes No
1 Clear discolored jets in the Printhead.
Print a Solid Fill test print for the affected color. Purge the Printhead up to 3 times. If some improvement is seen, the ink could be discol­ored due to exposure. Replace the affected ink and print another test. Does the problem persist?
2 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
10/2006
3-12
Go to Step 2. Complete.
Replace the Main­tenance Kit. If the problem persists, go to Step 3.
Phaser 8510/8560MFP Multifunction Product
Complete.
Table 1 IQ18 Color is Uneven or Color is Wrong
Step Questions and Actions Yes No
3 Check thermal regulation of the Drum.
Run the Service Diagnostics Drum Thermal test. Are the reported values within range?
4 Check the Drum Fan.
Does the fan operate correctly?
5 Check that the Drum Temperature Sensor
contacts the Drum. Clean or replace the Drum Temperature Sen­sor (REP 6.0.4). Does the problem persist?
Go to Step 5. Go to Step 4.
Go to Step 5. Replace the Drum
Replace the Drum Heater Relay Board (REP
5.0.19). If the prob­lem persists, replace the Drum Assembly (REP
2.0.3), followed by the Electronics Module (REP
5.0.5).
Fan (REP 4.0.6). Complete.
IQ19 Streaks or Lines Down the Print
This RAP addresses image quality problems associated with the Print Engine. Streaking or lines typically result from parts in contact with the Drum, dirty Wiper Blade, or debris in the paper path. Indications of streaks or lines can appear as follows:
Figure 1 Example of Streaks and Lines on Output
Initial Actions
1. Check that supported media is being used.
2. Check for any dirt, debris or jammed media in the exit path.
3. Run the Remove Print Smears routine from the Control Panel.
Procedure
Table 1 IQ19 Streaks or Lines Down the Print
Step Questions and Actions Yes No
1 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
2 Check the exit area, exit frame, Preheater,
Drum Maintenance Kit, Printhead and the Stripper Blade to see that nothing is in con­tact with the Drum. Clean the Stripper Blade. Does the problem persist?
10/2006
3-13
Replace the Main­tenance Kit. If the problem persists, go to Step 2.
Go to Step 3. Complete.
Complete.
Image Quality
IQ18, IQ19
Table 1 IQ19 Streaks or Lines Down the Print
Step Questions and Actions Yes No
4 If streaking or lines occur on only one side of
a 2-sided print, the Preheater may be scrap­ing ink off the print. Look for ink shavings along the streaks on the print. Clean the Preheater using the Remove Print Smears routine. Does the problem persist?
5 Check for a possible weak or missing jet.
Print the Weak or Missing Jet test print. Does the problem persist?
6 Check for a discoloration in a jet.
Print the Solid Fill test page for the affected color. Does the problem persist?
7 Check the X-Axis Drive.
If the X-Axis Drive does not move the Print­head smoothly, vertical lines appear on the output. Verify that the drive functions normally and that the cabling is properly dressed. Does the X-Axis Drive function correctly?
8 Check the Preheater temperature.
Run the Service Diagnostics Duplex Path test. Is the operating temperature of the Preheater within normal range.
Go to Step 5. Complete.
Go to Step 6. Complete.
Go to Step 7. Complete.
Go to Step 8. Repair or replace
Replace the Pre­heater (REP
2.0.17).
(REP 4.0.5) the drive as necessary.
Replace the Elec­tronics Module (REP 5.0.5).
IQ20 Scratches or Marks Parallel to the Long Axis of Printing
This RAP addresses image quality problems associated with the Print Engine. Scratches or marks typically result from debris in the paper path. Indications of scratches can appear as fol­lows:
Figure 1 Example of Scratches on Output
Initial Actions
1. Check that supported media is being used.
2. Check for a missing jet(s) using the Light Stripes page.
3. Check for any dirt, debris or jammed media in the exit path.
4. Run the Remove Print Smears routine from the Control Panel.
Image Quality
IQ19, IQ20
Procedure
Table 1 IQ20 Scratches or Marks Parallel to the Long Axis of Printing
Step Questions and Actions Yes No
1 Check the exit area, exit frame, Preheater,
Drum Maintenance Kit, Printhead and the Stripper Blade to see that nothing is in con­tact with the Drum. Clean the Stripper Blade. Does the problem persist?
2 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
3 Using transparency media, print from Tray 1.
Does the problem persist?
10/2006
3-14
Go to Step 2. Complete.
Replace the Drum Maintenance Kit. If the problem per­sists, go to Step 3.
Go to Step 4. Go to Step 5.
Phaser 8510/8560MFP Multifunction Product
Complete.
Table 1 IQ20 Scratches or Marks Parallel to the Long Axis of Printing
Step Questions and Actions Yes No
4 The scratch occurred during the pick or trans-
port process from Trays 2, 3, or 4. Inspect the Pick Guides, Front Door, and Maintenance Kit. Replace or clean parts as needed. Does the problem persist?
5 Check for debris on the Preheater.
Run the Service Diagnostics Remove Print Smears routine. Does the problem persist?
6 Force a sheet of thick (65 to 85 lb.) paper
through the Preheater. Using care not to damage the sensor actua­tors, gently buff the heating surface by mov­ing the sheet back and forth through the Preheater. Does the problem persist?
7 Check the paper guides for nicks, cuts, or
debris. Are the guides damaged?
Go to Step 5. Complete.
Go to Step 6. Complete.
Go to Step 7. Complete.
Replace damaged parts.
Clean all parts in the paper path.
IQ21 Ink on the White Portion of the Printed Page
This RAP addresses image quality problems associated with the Print Engine. Color appearing on blank areas of the output is called latent image. Latent images typically result from insuffi­cient oiling of the Drum. Insufficient oiling is often the result of a dirty, defective, or expended Drum Maintenance Kit. Printing on pre-punched media can also contribute to latent images. debris in the paper path. Indications of latent images can appear as follows:
Figure 1 Example of Latent Image on Output
Initial Actions
1. Check that supported media is being used.
2. Check for any dirt, debris or jammed media in the exit path.
3. Run the Remove Print Smears routine from the Control Panel.
Procedure
Table 1 IQ21 Ink on the White Portion of the Printed Page
Step Questions and Actions Yes No
1 Try printing using a smoother, higher quality
paper, some recycled papers are too coarse. Watermarked or punched paper could also cause latent images. Does the problem persist?
2 Remove the Drum Maintenance Kit and wipe
the clear plastic Wiper Blade with a lint-free cloth. Does the problem persist?
3 Clean the Stripper Blade.
Run the Service Diagnostics Remove Print Smears routine. Does the problem persist?
10/2006
3-15
Go to Step 2. Complete.
Replace the Drum Maintenance Kit. If the problem per­sists, go to Step 3.
Go to Step 4. Complete.
Complete.
Image Quality
IQ20, IQ21
Table 1 IQ21 Ink on the White Portion of the Printed Page
Step Questions and Actions Yes No
4 Check the thermal regulation of the Drum.
Run the Service Diagnostics temperature tests. Replace the Drum Temperature Sensor (REP
6.0.4), if necessary. Does the problem persist?
5 Check for dust or debris on the Feed Rollers.
Run the Service Diagnostics Remove Print Smears routine. Replace the rollers (REP 3.0.18), if neces­sary. Does the problem persist?
Go to Step 5. Complete.
Follow Printhead Troubleshooting Checklist.
Complete.
IQ22 Fuzzy Text
This RAP addresses image quality problems associated with the Print Engine. Fuzzy text typi­cally results from one of the three causes illustrated. An error in Y-Axis Drum rotation results in text appearing as shown at the upper left. Fuzzy text may also occur following a Printhead replacement. The text at the lower left is the result of Drum thermal problems. X-Axis errors cause text to appear as shown at the lower right.
Image Quality
IQ21, IQ22
Figure 1 Examples of Fuzzy Text on Output
Initial Actions
1. Check that supported media is being used.
2. Check for any dirt, debris or jammed media in the exit path.
3. Run the Remove Print Smears routine from the Control Panel.
Procedure
Table 1 IQ22 Fuzzy Text
Step Questions and Actions Yes No
1 Try printing using a smoother, higher quality
paper, some recycled papers are too coarse. Watermarked or punched paper could also cause latent images. Does the problem persist?
10/2006
3-16
Go to Step 2. Complete.
Phaser 8510/8560MFP Multifunction Product
Table 1 IQ22 Fuzzy Text
Step Questions and Actions Yes No
2 Use a higher quality print mode.
Does the problem persist?
3 Check that the dot on the Printhead Roll
Block is aligned with the label of the left side of the frame. See Figure 7. Adjust the position of the dot if necessary. Does the problem persist?
4 Check the thermal regulation of the Drum.
Run the Service Diagnostics temperature tests. Replace the Drum Temperature Sensor (REP
6.0.4), if necessary. Does the problem persist?
5 Check Y-Axis motion.
Run the Service Diagnostics Y-Axis Encoder test. Does the problem persist?
6 Check X-Axis motion.
Follow the White Stripes (Pinstripes) proce­dure to correct an X-Axis problem. Does the problem persist?
7 Check that the Printhead is tilted forward
against the Drum in proper print position. Realign the Printhead if necessary. Does the problem persist?
Go to Step 3. Complete.
Go to Step 4. Complete.
Go to Step 5. Complete.
Go to Step 6. Complete.
Go to Step 7. Complete.
Follow Printhead Troubleshooting Checklist.
Complete.
IQ23 Poor Primary Color Fill
This RAP addresses image quality problems associated with the Print Engine. Poor primary color fills typically result from obstructed jets. X-Axis errors may also cause banding. Indica­tions of poor primary color fill can appear as follows:
Figure 1 Example of Poor Primary Color Fill on Output
Initial Actions
1. Check that supported media is being used.
2. Check for any dirt, debris or jammed media in the exit path.
3. Run several solid fill test prints in the affected color.
Procedure
Table 1 IQ23 Poor Primary Color Fill
Step Questions and Actions Yes No
1 Banded or inconsistent primary fills may indi-
cate a missing, weak, or discolored jet. Print the Weak/Missing Jet test print. If there are discolored jets, print the Solid Fill test print for the affected color. Does the problem persist?
2 Test the Y-Axis Encoder.
Run the Service Diagnostics Encoder test. Does the problem persist?
10/2006
3-17
Go to Step 2. Complete.
Replace the Drum Assembly (REP
2.0.3). If the prob­lem persists, go to Step 3.
Complete.
Image Quality
IQ22, IQ23
Table 1 IQ23 Poor Primary Color Fill
Step Questions and Actions Yes No
3 If banding is uniform, or in a corduroy pattern,
check the X-Axis motion. Run the Service Diagnostics X-Axis Motor tests. Is X-Axis motion impeded? If so, use the White Stripes (Pinstripes) procedure to trou­bleshoot the problem. Does the problem persist?
4 Try the procedure listed under the Solid Fill
test prints. Does the problem persist?
Replace the X-Axis Motor (REP 4.0.5). If the problem per­sists, replace the Electronics Mod­ule (REP 5.0.5).
Follow Printhead Troubleshooting Checklist.
Complete.
Complete.
IQ24 Ghosting
This RAP addresses image quality problems associated with the Print Engine. Ghosting typi­cally results from stacked prints, faulty or expended Drum Maintenance Kit, or Drum thermal regulation. Ghosting is indicated by images from a previous print appearing on subsequent prints as follows:
Figure 1 Example of Ghosting on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
Image Quality
IQ23, IQ24
Procedure
Table 1 IQ24 Ghosting
Step Questions and Actions Yes No
1 This problem can occur when prints are
stacked in the Output Tray. The resulting pressure, and system heat causes “blocking” which has the appearance of ghosting. Print the Weak/Missing Jet test print. If there are discolored jets, print the Solid Fill test print for the affected color. Does the problem persist?
2 Run multiple, 2-sided prints. Some amount of
Transfix Roller ghosting is inherent to the sys­tem. This type of ghosting is most pro­nounced on the first 2-sided print. Ghosting should fade on subsequent prints. Does the problem persist?
10/2006
3-18
Go to Step 2. Complete.
Go to Step 3. Complete.
Phaser 8510/8560MFP Multifunction Product
Table 1 IQ24 Ghosting
Step Questions and Actions Yes No
3 Check and clean the Drum Maintenance Kit
Wiper Blade. Replace the kit if necessary. Run the Service Diagnostics X-Axis tests. Does the problem persist?
4 Test the Drum Maintenance system.
Run the Service Diagnostics maintenance system tests. Does the problem persist?
5 Check these Drum maintenance system parts
for damage or defects: Drum Maintenance Pivot Plate Drum Maintenance Cam Shaft Is there any damage?
6 Test the Drum temperature regulation.
Run the Service Diagnostics Drum tempera­ture tests. Check the Drum Temperature Sensor. Does the problem persist?
Go to Step 4. Complete.
Go to Step 5. Complete.
Replace any dam­aged parts. If the problem persists, go to Step 6.
Replace the Drum Temperature Sen­sor (REP 6.0.4).
Go to Step 6.
Complete.
IQ25 Poor Small Text Resolution
This RAP addresses image quality problems associated with the Print Engine. Poor text resolu­tion typically results from Drum thermal regulation, or X-Axis drive problems. Poor text resolu­tion is indicated by characters appearing heavy or plugged up as follows:
Figure 1 Example of Poor Text Resolution on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
Procedure
Table 1 IQ25 Poor Small Text Resolution
Step Questions and Actions Yes No
1 Try using a higher quality print mode.
Does the problem persist?
2 Test the Drum temperature regulation.
Run the Service Diagnostics Drum tempera­ture tests. Check the Drum Temperature Sensor. Does the problem persist?
3 Check the X-Axis Drive installation and lubri-
cation? Does the problem persist?
10/2006
3-19
Go to Step 2. Complete.
Replace the Drum Temperature Sen­sor (REP 6.0.4). If the problem per­sists, got to Step 3.
Replace the X-Axis Motor (REP 4.0.5).
Complete.
Complete.
Image Quality
IQ24, IQ25
IQ26 Vertical Lines Appear Wavy
This RAP addresses image quality problems associated with the Print Engine. Wavy or ill­formed vertical lines typically result from excessive Drum oiling. An error in X-Axis or Y-Axis motion could also cause this problem. Wavy vertical lines can appear as follows:
IQ27 Oil Streaks on Print
This RAP addresses image quality problems associated with the Print Engine. Oil streaking typically results from excessive Drum oiling. An problem with the Drum Maintenance Kit is the likely cause. Oil streaks can appear as follows:
Figure 1 Example of Wavy Vertical Lines on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
Procedure
Table 1 IQ26 Vertical Lines Appear Wavy
Step Questions and Actions Yes No
1 Check and clean the Drum Maintenance Kit
Wiper Blade. Does the problem persist?
2 Check X-Axis motion.
Verify that there is nothing interfering with X­Axis motion. Replace any defective parts found. Does the problem persist?
3 Check Y-Axis motion.
Run the Service Diagnostics Y-Axis Encoder test. Does the problem persist?
4 Check the Drum maintenance Cam Roller
and Pivot Plate are functioning correctly. Run the Service Diagnostics Drum Mainte­nance tests. Does the problem persist?
Replace the Drum Maintenance Kit. If the problem per­sists, go to Step 2.
Go to Step 3. Complete.
Go to Step 4. Complete.
Replace any defective parts found.
Complete.
Complete.
Figure 1 Example of Oil Streaks on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
3. Run the Remove Print Smears routine.
Procedure
Table 1 IQ27 Oil Streaks on Print
Step Questions and Actions Yes No
1 Check and clean the Drum Maintenance Kit
Wiper Blade. Does the problem persist?
2 Check the Drum Maintenance Kit ground con-
nection. Verify that the ground connection is secure between the Drum Maintenance Shaft and Drum Fan. Does the problem persist?
3 Run the Remove Print Smears routine.
Does the problem persist?
4 Clean the Stripper Blade and Exit Guides.
Does the problem persist?
Replace the Drum Maintenance Kit. If the problem per­sists, go to Step 2.
Go to Step 3. Complete.
Go to Step 4. Complete.
Go to Step 5. Complete.
Complete.
Image Quality
IQ26, IQ27
10/2006
3-20
Phaser 8510/8560MFP Multifunction Product
Table 1 IQ27 Oil Streaks on Print
Step Questions and Actions Yes No
5 Check that the Drum Maintenance Cam
Roller and Pivot Plate are functioning cor­rectly. Run the Service Diagnostics Drum Mainte­nance tests. Does the problem persist?
Replace any defective parts found.
Complete.
IQ28 Incomplete Image Transfer
This RAP addresses image quality problems associated with the Print Engine. Incomplete image transfer typically results from coarse, underweight, or watermarked media. Incomplete image transfer limited to one side of the page may be the result of improper Drum oiling. Incomplete image transfer can appear as follows:
Figure 1 Example of Incomplete Image Transfer on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
3. Run the Remove Print Smears routine.
Procedure
Table 1 IQ28 Incomplete Image Transfer
Step Questions and Actions Yes No
1 Tray using a higher quality print mode.
Does the problem persist?
2 Check that the Drum maintenance Cam
Roller and Pivot Plate are functioning cor­rectly. Run the Service Diagnostics Drum Mainte­nance tests. Does the problem persist?
3 Clean the Stripper Blade and Exit Guides.
Does the problem persist?
4 Test the Drum temperature regulation.
Run the Service Diagnostics Drum tempera­ture tests. Check the Drum Temperature Sensor. Does the problem persist?
10/2006
3-21
Go to Step 2. Complete.
Replace any defective parts found. If the prob­lem persists, go to Step 3.
Go to Step 4. Complete.
Replace the Drum Temperature Sen­sor (REP 6.0.4). If the problem per­sists, go to Step 3.
Complete.
Complete.
Image Quality
IQ27, IQ28
Table 1 IQ28 Incomplete Image Transfer
Step Questions and Actions Yes No
5 Is the image incomplete of only the sides of
the print? This indicates incomplete Transfix Cam rotation. Check for a damaged Transfix Cam Roller or a malfunction of the Process Drive. Replace any damaged parts found. Does the problem persist?
6 Check the Preheater temperature.
Run the Service Diagnostics Preheater tests. Does the problem persist?
Go to Step 6. Complete.
Replace the Trans­fix Load Module (REP 2.0.15) and Transfix Load Arms.
Complete.
IQ29 Ink Smears on First Side of Duplex Print
This RAP addresses image quality problems associated with the Print Engine. Ink smearing typically results from dirt or debris in the paper path, or the Preheater operating at too high a temperature. Ink smearing can appear as follows:
Figure 1 Example of Ink Smears on Output
Initial Actions
1. Check that supported media is being used.
2. Check the Drum Maintenance Kit.
3. Run the Remove Print Smears routine.
Image Quality
IQ28, IQ29
Procedure
Table 1 IQ29 Ink Smears on First Side of Duplex Print
Step Questions and Actions Yes No
1 Clean the Stripper Blade and Exit Guides.
Does the problem persist?
2 Check the duplex paper path for damage,
obstructions, or contamination. Clean or replace parts as necessary. Does the problem persist?
3 Run the Remove Print Smears routine.
Does the problem persist?
4 Check the Preheater temperature.
Run the Service Diagnostics Preheater tests. Does the problem persist?
10/2006
3-22
Go to Step 2. Complete.
Go to Step 3. Complete.
Go to Step 4. Complete.
Replace the Pre­heater (REP
2.0.17). If the prob­lem persists, replace the Elec­tronics Module (REP 5.0.5).
Phaser 8510/8560MFP Multifunction Product
Complete.
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use