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Xerox 8500DN Service Manual - Page 3

Color Printer, Service Manual

UPC - 095205022063

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Service Manual 701P27910 Phaser®8400/8500/8550/8560 Color Printer First Printing: January 2007 Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.

Section	Page
Phaser 8400/8500/8550/8560 Service	1
Symbols Marked on the Product	6
Power Safety Precautions	6
Electrostatic Discharge (ESD) Precautions	7
Service Safety Summary	8
Regulatory Specifications	10
Manual Organization	12
Contents	13
1 General Information	19
Printer Introduction and Overview	20
Printer Configurations	21
Control Panel Configuration	23
LED Indicators	23
Control Panel Feature Descriptions	23
Menu Maps	24
Control Panel Shortcuts	24
Parts of the Printer	25
Front View	25
Right Side View with Printer Interfaces	25
Rear View	26
Routine Maintenance Items and Consumables	27
Printer Specifications	28
Physical Dimensions and Clearances	28
Functional Specifications	30
Electrical Specifications	30
Environmental Specifications	30
Media and Tray Specifications	31
2 Theory of Operation	33
Main Printer Subsystems	34
Printer Subsystem Overview	34
Process Drive	36
Media Drive	37
Ink Loader	38
Printhead	39
Printhead Tilt	42
Drum Maintenance Kit	45
Purge System	46
Drum Assembly And Transfix System	48
Electronics Module	51
I/O Board	54
Sensors	54
Print Process	55
Printing	56
Paper Pick for Tray 1	57
Paper Pick for Trays 2 - 4	58
Transfixing and Exiting	59
Duplex Printing	62
Transfix and Print Speeds	63
Printer Self-Maintenance	65
Printhead Maintenance Cycle (Eliminate Light Stripes)	65
Paper Preheater Cleaning (Remove Print Smears)	66
Transfix Roller Oiling	66
Drum Cleaning - Chase Page	66
Configuration Card Personality Parameters	67
3 Error Messages and Codes	69
Introduction	70
Power-Up Error Messages and LED Codes	71
BIST Error Reporting	71
POST Error Reporting	72
PEST Error Reporting	74
Fault Code Error Message Troubleshooting	75
Fault Code Error Reporting	75
Interpreting Fault Codes	75
1,000.4x Errors - 525-Sheet Feeder Faults	76
1,0XX.6x Errors - 525-Sheet Feeder Program Faults	76
2,0XX.4x Errors - I/O Circuit Board Fault	77
2,0XX.6x Errors - I/O Board Program Faults	77
3,0XX.6x Errors - IPC Program Faults	78
4,0XX.4x Errors - Process Control System Fault	78
4,0XX.6x Errors - Process Control Software Fault	80
5,0XX.4x Errors - Y-Axis Sub-System Fault	81
5,0XX.6x Errors - Program Faults	81
6,0XX.4x Errors - X-Axis Fault	82
6,0XX.6x Errors - Program Faults	82
7,0XX.4x Errors - Process Motor Gearbox Faults	83
7,0XX.4x Errors- Printhead Tilt Faults	84
7,0XX.6x Errors - Program Faults	88
8,0XX.xx Errors - Wiper/Media Drive Faults	89
8,0XX.6x Errors - Program Faults	90
9,0XX.xx Errors - Ink Loader Faults	91
9,009.44 and 9,00X.6x Errors - Program Faults	92
11,0XX.xx Errors - Electronics Module Interface Fault	92
11,100.60 Errors - Temperature Error	94
12,000.60 Errors - Program Faults	94
13,0XX.xx Errors - Thermal Faults	94
13,000.6x Errors - Program Faults	99
19,0XX.xx Errors - Printhead Calibration faults.	100
19,0XX.6x Errors - Waveform Program Faults	101
21,000.69 Errors - Diagnostic Code Version Mismatch	101
22,0XX.6x Errors - Jam Codes	101
23,0XX.6x Errors - NVRAM Fault	101
26,0XX.6x Errors - Printing Faults	101
26,962.6x Errors - “Fall Out” Code	102
27,0XX.6x Errors - Profile Library	102
29,0XX.6x Errors - Jam Manager	102
31,0XX.4x Errors - Mechanical Initialization Jam	102
31,0XX.6x Errors - Program Faults	103
33,0XX.xx Errors - Tray Manager Device Faults	103
34,0XX.xx Errors - Printhead NVRAM Faults	103
36,000.40 Errors - Drum Maintenance Faults	104
36,001.67 Errors - Drum Maintenance Fault	104
36,002.44 Errors - Drum Maintenance Program Fault	104
37,0XX.xx Errors - PEST Faults	104
Jam Codes	116
Jam Code Definition Table	117
4 General Troubleshooting	131
Introduction	132
Hidden Service Menu	132
Service Diagnostics	134
Service Diagnostics Mode Menu	135
Service Diagnostics Menu Map	136
Check Menu Definition Tables	140
Check / Activators Menu	140
Check Shafts Menu	143
Check Paper Path Menu	146
Check Drive Menu	161
Check Drum Menu	167
Check Motors Menu	173
Check Misc Menu	176
Electronics Troubleshooting	181
Printer Power-Up Sequence	181
Miscellaneous Electrical Troubleshooting	186
Verifying Power Supply Operation	194
Measuring AC Power Supply Voltages	194
Measuring DC Power Supply Voltages	195
Ensuring Ground Integrity	195
Testing Motor and Solenoid Resistances	197
Paper Path and Media-Based Problems	198
Media-Based Problems	198
Pick Errors - Trays 2, 3, and 4	198
Paper-Pick Errors - Tray 1	199
Preheater and Transfix Jams	199
Checking the Process and Media Path Drive	199
Media Skews Passing Through the Paper Path	200
Operating System and Application Problems	201
Testing Communications Ports	201
Network Problems	203
Obtaining Serial Back Channel Trace	203
Obtaining a Back Channel Trace with USB to Serial Adapter	204
5 Print-Quality Troubleshooting	207
Print-Quality Problems Overview	208
Random Light Stripes	209
Predominate Light Stripes	210
Smudges or Smears	211
Print Too Light or Too Dark	213
Blank Prints	214
Color is Uneven or Wrong	215
Streaks or Lines Down the Print	217
Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Film	219
Ink on White Portion of Print	221
Fuzzy Text	223
Poor Primary Color Fills	224
Ghosting	226
Poor Small Text Resolution	228
Vertical Lines Appear Wavy	229
Oil Streaks on Print	230
Incomplete Image Transfer to Paper	232
Ink Smears on First Printed Side of Auto-Duplex Print	234
Repeating Defects on Print	235
White Stripes (Pinstripes)	236
Wrinkling	237
Image Is Offset or Cut-Off	239
Poor Ink Adhesion, Poor Image Durability	239
Analyzing Service Test Prints	240
Weak/Missing Jet	240
X-Axis Motion (8400 Only)	241
Color Bands, RGBK Dither	242
Reverse Text	243
Big Bands OHP	244
Gray Fill, Dot Size Uniformity	245
YMCKRGB Solid Fills	246
Primary Solid Fills 10x	246
Head-to-Drum Gap (8400 Only)	247
Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills	248
Manuf. Skew Margins	249
Cleaning Page	250
Other Test and Specialty Prints	250
6 Adjustments and Calibrations	251
Adjustments	252
Wiper Alignment Procedure	252
Printer Component Homing Positions and Indicators	254
Wiper Assembly Positions	254
Homing the Head Tilt Gear	255
Homing the Process Drive Train	258
Timing the Drum Maintenance Camshaft	259
Jet Substitution Mode	262
Enabling Jet Substitution Mode (8400)	262
Enabling Jet Substitution Mode (8500/8550/8560)	263
Disabling Jet Substitution Mode (8400)	263
Disabling Jet Substitution Mode (8500/8550/8560)	264
Resetting NVRAM	264
7 Cleaning and Maintenance	265
Service Cleaning Maintenance Procedure	266
Cleaning	266
Pick Roller Cleaning Method	267
Maintenance	268
Drum Maintenance Kit	268
Waste Tray	269
Lubrication	269
Inspection	269
8 Service Parts Disassembly	271
Overview	272
Standard Orientation of the Printer	272
General Notes on Disassembly	273
Covers	274
Front Door/Tray 1 Assembly (PL1.0.1)	274
Control Panel Cover (PL1.0.5)	275
Control Panel (PL1.0.6)	275
Right Side Cover (PL1.0.10)	275
Left Side Cover (PL1.0.9)	276
Exit Cover (PL1.0.7)	276
Ink Loader (PL1.0.8)	277
Imaging	278
Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor	278
Printhead, Right and Left Printhead Restraints	280
Head Tilt Solenoid (PL4.0.12)	285
X-Axis Bias Spring (PL2.0.19)	286
Wiper Assembly (PL2.0.17)	287
Stripper Carriage (PL2.0.12) and Transfix Roller (PL2.0.13)	289
Preheater (PL2.0.17)	290
Duplex Roller (PL3.0.8)	291
Transfix Load Module (PL2.0.15)	292
Transfix Camshaft (PL2.0.10)	295
Drum Maintenance Camshaft (PL2.0.11)	295
Drum Maintenance Pivot Plate (PL2.0.16)	296
Drum Assembly (PL2.0.3)	297
Purge Pump (PL2.0.7)	301
Paper Path	302
Exit Module (PL3.0.13)	302
Inner Simplex Guide (PL3.0.1)	303
Lower Inner Duplex Guide (PL3.0.2)	303
Lower Exit-Guide Assembly with Strip Flag (PL3.0.3)	303
Outer Duplex Guide With Safety Interlocks (PL3.0.4)	304
Upper Duplex Guide with Solenoid (PL3.0.5)	304
Take Away Roller (PL3.0.7)	306
Pick Assembly (PL3.0.10)	307
Tray Lift Motor and Gear (PL4.0.6)	309
Motors, Gears, Solenoids, Clutches, and Fans	310
Media Drive with Two Clutches and Solenoid (PL4.0.5)	310
Tray 1 Pick Solenoid (PL4.0.3)	311
Preheater Lift Solenoid (PL4.0.1)	312
Process Drive (PL4.0.14)	313
X-Axis Motor (PL4.0.12)	314
Head Tilt Gear (PL4.0.9)	315
Electronics	316
Electronics Module (PL5.0.5)	316
Wave Amplifier (PL5.0.4)	317
I/O Board (PL5.0.13)	318
Drum Heater Relay Board (PL5.0.17)	319
NVRAM (PL5.0.9)	320
DIMM Memory (PL5.0.8)	321
Hard Drive (PL5.0.7)	322
9 Parts Lists	323
Serial Number Format	324
Using the Parts List	325
PL 1.0 Covers	326
PL 2.0 Imaging	328
PL 3.0 Paper Path	330
PL 4.0 Motors, Gears, Solenoids, Clutches, and Fans	332
PL 5.0 Circuit Boards	334
PL 6.0 Sensors and Flags (Actuators)	336
Xerox Supplies	338
10 Wiring Diagrams	343
Main Wiring Diagram	344
Main Wiring Diagram (Continued)	345
Right-Side Wiring Diagram	346
Right-Side Wiring Diagram (Continued)	347
Left-Side Wiring Diagram	348
Left-Side Wiring Diagram (Continued)	349
Inside Front Wiring Diagram	350
Inside Top Wiring Diagram	351
Inside Top - Printhead Wiring Diagram	352
Reference	353
Menu Map (8400)	354
Menu Map (8500/8550/8560)	356
Media Margin Specification Table	358
Paper Weight Equivalence Table	359
On-site Printhead Troubleshooting Checklist (8400)	360
Ink Failure Checklist	364
On-site Printhead Troubleshooting Checklist (8500/8550/8560)	365