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 |