| 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 |
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