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Xerox 8400N - Phaser Color Solid Ink Printer Service Manual

Manual is about: Xerox Printer User Manual

Summary of 8400N - Phaser Color Solid Ink Printer

  • Page 1

    Service manual phaser ® 8400/8500/8550/8560 701p27910 color printer.

  • Page 3: Service Manual

    Service manual 701p27910 phaser ® 8400/8500/8550/8560 color printer 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 t...

  • Page 4

    Ii phaser 8400/8500/8550/8560 color printer service manual prepared by: xerox corporation xog worldwide product training and information 26600 sw parkway wilsonville, or 97070 copyright © 2007 xerox corporation. All rights reserved. Unpublished rights reserved under the copyright laws of the united ...

  • Page 5: Service Terms

    Phaser 8400/8500/8550/8560 color printer service manual iii service terms manual terms various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when...

  • Page 6: Power Safety Precautions

    Iv phaser 8400/8500/8550/8560 color printer service manual symbols marked on the product 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...

  • Page 7

    Phaser 8400/8500/8550/8560 color printer service manual v electrostatic discharge (esd) precautions some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by electrostatic discharge (esd). These components include integrated circuits (ics), large...

  • Page 8: Service Safety Summary

    Vi phaser 8400/8500/8550/8560 color printer service manual service safety summary 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 ...

  • Page 9

    Phaser 8400/8500/8550/8560 color printer service manual vii servicing mechanical components when servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning do not try to manually rotate or manually stop the drive assemblies while any printer mot...

  • Page 10: Regulatory Specifications

    Viii phaser 8400/8500/8550/8560 color printer service manual 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 st...

  • Page 11

    Phaser 8400/8500/8550/8560 color printer service manual ix european union the ce mark applied to this product symbolizes xerox’s declaration of conformity with the following applicable directives of the european union as of the dates indicated: ■ january 1, 1995: low voltage directive 73/23/eec as a...

  • Page 12: Manual Organization

    X phaser 8400/8500/8550/8560 color printer service manual manual organization the phaser 8400/8500/8550/8560 color printer service manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operation...

  • Page 13: Contents

    Phaser 8400/8500/8550/8560 color printer service manual xi contents contents service terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iii symbols marked on the product . . . . . . . ....

  • Page 14: 3 Error Messages And Codes

    Xii phaser 8400/8500/8550/8560 color printer service manual contents printer self-maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 printhead maintenance cycle (eliminate light stripes) . . . ....

  • Page 15: 4 General Troubleshooting

    Phaser 8400/8500/8550/8560 color printer service manual xiii contents jam codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 jam code definition table . . . . . . . . . . . . . ....

  • Page 16

    Xiv phaser 8400/8500/8550/8560 color printer service manual contents 5 print-quality troubleshooting print-quality problems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 random light stripes . . . . . . ...

  • Page 17: 8 Service Parts Disassembly

    Phaser 8400/8500/8550/8560 color printer service manual xv contents 7 cleaning and maintenance service cleaning maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 cleaning . . . . . . . . . . . . . . . . . . ....

  • Page 18: 9 Parts Lists

    Xvi phaser 8400/8500/8550/8560 color printer service manual contents electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 electronics module (pl5.0.5) . . . . . . . . . . . ....

  • Page 19: In This Chapter...

    1 chapter general information in this chapter... ■ printer introduction and overview ■ printer configurations ■ control panel configuration ■ parts of the printer ■ routine maintenance items and consumables ■ printer specifications.

  • Page 20

    1-2 phaser 8400/8500/8550/8560 color printer service manual general information printer introduction and overview the phaser 8400/8500/8550/8560 color printer service manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure understanding of this prod...

  • Page 21: Printer Configurations

    Phaser 8400/8500/8550/8560 color printer service manual 1-3 general information printer configurations the configuration card holds configuration information that enables or disables built-in features as described in the following tables. Phaser 8400 printer configurations features 8400b 8400bd 8400...

  • Page 22

    1-4 phaser 8400/8500/8550/8560 color printer service manual general information phaser 8500/8550 printer configurations phaser features 8500n 8500dn 8550dp 8550dt 8550dx maximum print speed 24ppm 24ppm 30ppm 30ppm 30ppm memory 128 mb 128 mb 256 mb 256 mb 512 mb hard drive optional* optional* optiona...

  • Page 23: Control Panel Configuration

    Phaser 8400/8500/8550/8560 color printer service manual 1-5 general information control panel configuration the control panel consists of one tricolor led, a display window, and six functional buttons. These buttons navigate the menu system, perform functions, and select modes of operation for the p...

  • Page 24: Menu Maps

    1-6 phaser 8400/8500/8550/8560 color printer service manual general information menu maps the customer menu map helps you navigate the control panel menus. The menu map’s are provided in the reference section of this manual, see page a-2. To print the menu map: 1. On the control panel, select inform...

  • Page 25: Parts of The Printer

    Phaser 8400/8500/8550/8560 color printer service manual 1-7 general information parts of the printer this section shows the main external components of the printer, including interfaces, the electronics module, and the internal sensors. Front view right side view with printer interfaces 1. Optional ...

  • Page 26

    1-8 phaser 8400/8500/8550/8560 color printer service manual general information rear view the rear view consists of the printer’s main electronics and power supply, which are enclosed in a metal case called the electronics module. The rear panel allows access to the electronics module, ram, and nvra...

  • Page 27

    Phaser 8400/8500/8550/8560 color printer service manual 1-9 general information routine maintenance items and consumables drum maintenance kit life expectancy depends on the kit capacity. For example, the standard-capacity kits produce 10,000 prints regardless of the colors used. Extended-capacity d...

  • Page 28: Printer Specifications

    1-10 phaser 8400/8500/8550/8560 color printer service manual general information printer specifications physical dimensions and clearances print engine only value width: 422 mm (16.6 in.) depth: 514 mm (20.24 in.) height: 368 mm (14.48 in.) weight: 26.8 kg (59 lb.) optional 525-sheet feeder value wi...

  • Page 29

    Phaser 8400/8500/8550/8560 color printer service manual 1-11 general information note check that the printer is on a stable, non-vibrating suface. Advise the customer to use care not to shake the printer excessively when loading media or closing the front door. During operation, the ink is in liquid...

  • Page 30

    1-12 phaser 8400/8500/8550/8560 color printer service manual general information functional specifications electrical specifications environmental specifications characteristic specification printing process solid-ink color medium yellow, cyan, magenta, and black ink sticks, each shape- coded. The p...

  • Page 31

    Phaser 8400/8500/8550/8560 color printer service manual 1-13 general information media and tray specifications an y t ray tr ay 1 on ly 2 -s id ed (dup le x) s in g le -s id e d o n ly paper size paper type paper weight/media type letter (8.5 x 11 in.) or a4 (210 x 297 mm) plain paper or letterhead ...

  • Page 32

    1-14 phaser 8400/8500/8550/8560 color printer service manual general information custom note print custom size media from tray 1 only. Maximum: 216 mm wide x 355 mm long (8.5 in. Wide x 14 in. Long) l l l minimum: 75 mm wide x 127 mm long (3 in. Wide x 5 in. Long) l l minimum: 139.7 mm wide x 210 mm...

  • Page 33: In This Chapter...

    2 chapter theory of operation in this chapter... ■ main printer subsystems ■ print process ■ printer self-maintenance ■ configuration card personality parameters.

  • Page 34: Main Printer Subsystems

    2-2 phaser 8400/8500/8550/8560 color printer service manual theory of operation main printer subsystems printer subsystem overview the printer is made up of eight major subsystems, which are described in this section: ■ process drive ■ media drive ■ ink loader ■ printhead ■ drum maintenance kit ■ pu...

  • Page 35

    Phaser 8400/8500/8550/8560 color printer service manual 2-3 theory of operation the ink loader: stores and melts the ink. The melted ink drops into the printhead ink reservoirs underneath the ink loader. The printhead: delivers ink onto the drum surface to create an image. The printhead includes 123...

  • Page 36

    2-4 phaser 8400/8500/8550/8560 color printer service manual theory of operation process drive a small dc servomotor powers the process drive gearbox to rotate the gears to specific positions during the printing process. The process drive is able to actuate each camshaft system independently through ...

  • Page 37

    Phaser 8400/8500/8550/8560 color printer service manual 2-5 theory of operation media drive the media drive assembly drives each roller in the media transport path. A gear train located behind the motor connects it to the exit rollers, which are built into the exit module. Gear trains located within...

  • Page 38

    2-6 phaser 8400/8500/8550/8560 color printer service manual theory of operation ink loader the ink loader consists of four parallel channels with an ink melting element at the end of each channel. Coil springs exert pressure on four ink sticks to load one unique color in each channel. When the print...

  • Page 39

    Phaser 8400/8500/8550/8560 color printer service manual 2-7 theory of operation printhead the printhead is the heart of the printer, spanning nearly the length of the drum. Using its 1236 jet nozzles (309 jets for each primary color), with a horizontal motion of slightly less than 5 mm (0.2 inches),...

  • Page 40

    2-8 phaser 8400/8500/8550/8560 color printer service manual theory of operation the printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array. Channels formed by the stacked plates route ink past the 1236 individual, piezo-elec...

  • Page 41

    Phaser 8400/8500/8550/8560 color printer service manual 2-9 theory of operation x-axis or lateral movement of the printhead is accomplished using a stepper motor driving a fine-thread screw system. The printhead, mounted to the x- axis shaft, moves laterally across the surface of the drum. To find t...

  • Page 42

    2-10 phaser 8400/8500/8550/8560 color printer service manual theory of operation printhead tilt the printhead is able to rotate into four basic positions: 1. Printhead lock / ship position (19.5 degrees): the printhead restraint pins are resting against the right and left locks. In this position, th...

  • Page 43

    Phaser 8400/8500/8550/8560 color printer service manual 2-11 theory of operation in the print position (0 degrees), the printhead is forward and rests against the right and left head-to-drum buttons. The head-to-drum buttons define the space between the jet stack and the drum. When the process drive...

  • Page 44

    2-12 phaser 8400/8500/8550/8560 color printer service manual theory of operation as viewed from the left side of the printer, when the arrows are not aligned, the tilt gear is engaged. To accommodate printhead maintenance, the printhead is tilted back away from the drum. This creates room for the wi...

  • Page 45

    Phaser 8400/8500/8550/8560 color printer service manual 2-13 theory of operation drum maintenance kit the drum maintenance kit creates a thin layer of silicone oil on the surface of the drum prior to printing. The oil keeps the ink from sticking to the drum’s surface and facilitates image transfer t...

  • Page 46

    2-14 phaser 8400/8500/8550/8560 color printer service manual theory of operation purge system proper printhead operation is dependant on the correct operation of the purge system. The purge system uses air pressure and a wiper blade to purge any debris or air bubbles that may be obstructing the prin...

  • Page 47

    Phaser 8400/8500/8550/8560 color printer service manual 2-15 theory of operation warning when servicing the printer be careful of the purge system as it passes the printhead. If a damaged wiper blade catches on the printhead, it could propel hot liquid ink upward into your face. S8500-018 purge pump...

  • Page 48

    2-16 phaser 8400/8500/8550/8560 color printer service manual theory of operation drum assembly and transfix system the drum assembly and transfix module form the key portion of the printer where imaging takes place. The drum assembly and transfix module are separate, yet interrelated. This section d...

  • Page 49

    Phaser 8400/8500/8550/8560 color printer service manual 2-17 theory of operation warning always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system, which is inherently dangerous. Since the motor speeds up if it senses the drum drive system slowing down, finge...

  • Page 50

    2-18 phaser 8400/8500/8550/8560 color printer service manual theory of operation transfix system the transfix roller applies pressure to the back side of the media as it moves between the transfix roller and drum. This pressure transfers the image from the drum to the paper. A set of springs in the ...

  • Page 51

    Phaser 8400/8500/8550/8560 color printer service manual 2-19 theory of operation electronics module the electronics module includes the main board, the power control board, and the power supply. The electronics module is a field replaceable unit (fru). Main board the main board performs the image pr...

  • Page 52

    2-20 phaser 8400/8500/8550/8560 color printer service manual theory of operation information stored on the configuration card includes the feature value, ethernet address, and personality parameters. The card reads a combination of feature values and the printer hardware capabilities; this will dete...

  • Page 53

    Phaser 8400/8500/8550/8560 color printer service manual 2-21 theory of operation the dc power supply generates + 3.3 v, +/- 15 v, and +/- 50 v. These voltages provide direct or regulated voltage values to various circuits in the printer. The power control board regulates +/- 15 v to +/- 12 and other...

  • Page 54

    2-22 phaser 8400/8500/8550/8560 color printer service manual theory of operation i/o board all sensor and switch readings are input into the i/o board. The i/o board translates these states into encoded information that it sends over a serial data bus (i/o board data cable) to the electronics module...

  • Page 55: Print Process

    Phaser 8400/8500/8550/8560 color printer service manual 2-23 theory of operation print process once the printer processes an image and creates a printing bitmap, the print cycle begins. Sensors maintain correct operating temperatures for the printhead and drum. Sensors also monitor ink levels in the...

  • Page 56

    2-24 phaser 8400/8500/8550/8560 color printer service manual theory of operation printing to print, the drum rotates at a speed dependent upon print resolution. As the drum reaches the correct speed, the jets begin to fire to deposit the image on the oiled portion of the drum. As the jets fire, the ...

  • Page 57

    Phaser 8400/8500/8550/8560 color printer service manual 2-25 theory of operation paper pick for tray 1 to pick a sheet of paper, the tray 1 solenoid actuates, and the drive gear rotates slightly to engage with the drive train. A bias force from the lift plate against a rotating cam causes the roller...

  • Page 58

    2-26 phaser 8400/8500/8550/8560 color printer service manual theory of operation paper pick for trays 2 - 4 note trays 3 and 4 are 525-sheet feeders. For trays 2 through 4, the paper pick process is different than the pick process used by tray 1. To pick a sheet of paper, the media path drive starts...

  • Page 59

    Phaser 8400/8500/8550/8560 color printer service manual 2-27 theory of operation transfixing and exiting transfixing and exiting consists of four major functions: 1. Staging the paper for rendezvous with the image on the drum and transfix roller nip. 2. Loading the transfix roller and engaging the d...

  • Page 60

    2-28 phaser 8400/8500/8550/8560 color printer service manual theory of operation s8500-026 drum transfix cam transfix load arm transfix load module transfer roller transfix load spring transfix cam process drive transfix roller gear swing arm gear.

  • Page 61

    Phaser 8400/8500/8550/8560 color printer service manual 2-29 theory of operation exit sensor preheat sensor transfix roller paper preheater strip sensor release blade strip solenoid s8500-027.

  • Page 62

    2-30 phaser 8400/8500/8550/8560 color printer service manual theory of operation duplex printing when duplex printing, the exit rollers pull the media to a predetermined location, such that the trailing edge is adjacent to the exit rollers. Then, the exit rollers pull the media back into the duplex ...

  • Page 63

    Phaser 8400/8500/8550/8560 color printer service manual 2-31 theory of operation transfix and print speeds transfix speeds characteristic setpoint, paper media fast color standard enhanced high res/ photo peak transfix speed, simplex tray feed 20 ips (8400) 25 ips (8500/ 8550/8560) 17 ips (8400) 25 ...

  • Page 64

    2-32 phaser 8400/8500/8550/8560 color printer service manual theory of operation approximate print speeds (8500/8550/8560) tray (source) / resolution simplex, a4 paper auto duplex, a4 paper tray 1 fast color (225 x 400 dpi) 12 pages per minute (ppm) 8.5 sides per minute (spm) standard (300 x 450 dpi...

  • Page 65: Printer Self-Maintenance

    Phaser 8400/8500/8550/8560 color printer service manual 2-33 theory of operation printer self-maintenance the printer has several automatic or semi-automatic maintenance functions. These functions may be started automatically after a certain number of prints or during printer startup, or they may be...

  • Page 66

    2-34 phaser 8400/8500/8550/8560 color printer service manual theory of operation paper preheater cleaning (remove print smears) this customer-initiated cleaning procedure is selected by choosing remove print smears on the control panel’s print quality problems menu. This procedure cleans ink out of ...

  • Page 67

    Phaser 8400/8500/8550/8560 color printer service manual 2-35 theory of operation configuration card personality parameters configuration card “shadowed” personality parameters attribute parameter size (bytes) n/a “version” not parameter version (of the layout of personality parameters) 4 nest base p...

  • Page 68

    2-36 phaser 8400/8500/8550/8560 color printer service manual theory of operation notes: 1. “parallel” and “usb”, “on” and “enabled” parameters have not been identified as personality parameters. They are not tied to networking. Http keyuser_username 11 http admin_hostaccesslist 256 http keyuser_host...

  • Page 69: In This Chapter...

    3 chapter error messages and codes in this chapter... ■ introduction ■ power-up error messages and led codes ■ bist error reporting ■ post error reporting ■ pest error reporting ■ fault code error message troubleshooting ■ jam codes.

  • Page 70: Introduction

    3-2 phaser 8400/8500/8550/8560 color printer service manual error messages and codes introduction this section covers troubleshooting procedures utilizing control panel error messages and codes. Some procedures require running service diagnostics test functions to verify that a specific printer comp...

  • Page 71

    Phaser 8400/8500/8550/8560 color printer service manual 3-3 error messages and codes power-up error messages and led codes the printer 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 ...

  • Page 72

    3-4 phaser 8400/8500/8550/8560 color printer service manual error messages and codes post error reporting post checks the communication paths within the electronics module and to other various printer components. Post testing initializes the control panel, and in most cases if an error occurs, a tex...

  • Page 73

    Phaser 8400/8500/8550/8560 color printer service manual 3-5 error messages and codes 6.08 n/a soft ide drive general failure. Reseat ide cable and power cable. If problem persists, replace the ide drive. The printer will work without the ide drive. 6.808 07.01 flutter only soft control panel link is...

  • Page 74

    3-6 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 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 printer components. Error codes for pest tests are displ...

  • Page 75

    Phaser 8400/8500/8550/8560 color printer service manual 3-7 error messages and codes fault code error message troubleshooting fault code error reporting fault codes are saved to nvram and can be retrieved from the printer’s fault history. All procedures that ask for a test to be run are referencing ...

  • Page 76

    3-8 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 1,000.4x errors - 525-sheet feeder faults 1,001.46: the upper 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted. 1,002.47: the lower 525-sheet feeder had an overcurrent condition...

  • Page 77

    Phaser 8400/8500/8550/8560 color printer service manual 3-9 error messages and codes 2,0xx.4x errors - i/o circuit board fault 2,001.47: the print engine cannot detect the presence of the i/o board. 2,0xx.6x errors - i/o board program faults 2,001.69: the electronics module failed to initialize. 2,0...

  • Page 78

    3-10 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 3,0xx.6x errors - ipc program faults there is a communication problem between the engine and postscript regions. A. Reset nvram, and then retest. B. Replace the eeprom chip. 4,0xx.4x errors - process control system...

  • Page 79

    Phaser 8400/8500/8550/8560 color printer service manual 3-11 error messages and codes 4,024.42: this fault code indicates a problem with the wiper. The wiper is not aligned properly and engaged the headtilt while in the waste lock position. 4,025.46: this fault code indicates a problem with the proc...

  • Page 80

    3-12 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 4,0xx.6x errors - process control software fault 1. Reset nvram and then retest. 2. Ensure ground integrity (see “ensuring ground integrity” on page 4-65). 3. Replace the eeprom chip. 4. Reboot the printer. 3 remov...

  • Page 81

    Phaser 8400/8500/8550/8560 color printer service manual 3-13 error messages and codes 5,0xx.4x errors - y-axis sub-system fault 5,001.41: the drum turned one full revolution without seeing the drum home sensor activate. 5,002.42: the y-axis encoder is not working properly or the drum has stalled. 5,...

  • Page 82

    3-14 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 6,0xx.4x errors - x-axis fault 6,000.41: an x-axis motor current error occurred. 6,0xx.6x errors - program faults 6,001.64: the x-axis task received an unexpected message. 6,002.65: attempt to home the x-axis from ...

  • Page 83

    Phaser 8400/8500/8550/8560 color printer service manual 3-15 error messages and codes 7,0xx.4x errors - process motor gearbox faults 7,002.44: there is a problem with the process motor sub-system. The process motor stalled during operation. 7,006.Xx: the head tilt solenoid is not activating the head...

  • Page 84

    3-16 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 7,0xx.4x errors- printhead tilt faults the 7,007.49, 7,008.41, 7009.42, and 7,010.43 errors indicate that the printhead was unable to tilt normally on its axis. Possible causes include: ■ the printer was powered of...

  • Page 85

    Phaser 8400/8500/8550/8560 color printer service manual 3-17 error messages and codes 7,007.49: the process motor stalled while tilting the head. 7,008.41: the head tilt is not engaged, or the printhead is stuck in the tilt position by the tilt arms. Troubleshooting procedure for 7,007 error code st...

  • Page 86

    3-18 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 7,009.42: the printhead is tilted back but not properly restrained in the park arms. 8 perform the wiper alignment procedure (see “wiper alignment procedure” on page 6-2). Did this correct the problem? Complete. Go...

  • Page 87

    Phaser 8400/8500/8550/8560 color printer service manual 3-19 error messages and codes 7,010.43: the printhead is stuck in the tilted position, or is not able to tilt forward to the print position, due to problems. 7,011.44: this is a soft fault and will not halt the printer. 7,012.45: the drum trans...

  • Page 88

    3-20 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 7,0xx.6x errors - program faults 1. Reset nvram and retest. 2. Ensure ground integrity for the printer (see “ensuring ground integrity” on page 4-65). 8 use service diagnostics to run the head maintenance wiper clu...

  • Page 89

    Phaser 8400/8500/8550/8560 color printer service manual 3-21 error messages and codes 8,0xx.Xx errors - wiper/media drive faults 8,005.48: the media drive stalled while moving the wiper to home position. 8,006.49: the wiper cannot verify the home position. 8,007.41: the wiper stalled finding home. 8...

  • Page 90

    3-22 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 8,0xx.6x errors - program faults 1. Reset nvram, and then retest. 2. Ensure ground integrity for the printer (see “ensuring ground integrity” on page 4-65). 6 run the wiper alignment test (see “wiper alignment proc...

  • Page 91

    Phaser 8400/8500/8550/8560 color printer service manual 3-23 error messages and codes 9,0xx.Xx errors - ink loader faults 9,000.44: ink loader device fault 9,005.49: the cyan ink melt heater is on, but ink is not dripping. 9,006.41: the magenta ink melt heater is on, but ink is not dripping. 9,007.4...

  • Page 92

    3-24 phaser 8400/8500/8550/8560 color printer service manual error messages and codes note xerox is not financially responsible for the incorrect operation of its products caused by the use of non- xerox ink. 9,009.44 and 9,00x.6x errors - program faults 9,009.44: this fault indicates a device failu...

  • Page 93

    Phaser 8400/8500/8550/8560 color printer service manual 3-25 error messages and codes 11,006.43: printhead broken serial link detected. 11,006.45: 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 fai...

  • Page 94

    3-26 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 11,100.60 errors - temperature error the root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Check that the room temperature does not exceed specifications and the fa...

  • Page 95

    Phaser 8400/8500/8550/8560 color printer service manual 3-27 error messages and codes troubleshooting procedure for 13,008 to 13,010 error code (drum heater) step questions and actions yes no 1 check that the ambient room temperature is within specifications (see “environmental specifications” on pa...

  • Page 96

    3-28 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 13,067.43: the drum temperature sensor circuit is open. 13,069.45: the drum temperature sensor circuit is shorted. 13,071.47: the drum temperature sensor returned a bad reading, or the reading was corrupted by esd ...

  • Page 97

    Phaser 8400/8500/8550/8560 color printer service manual 3-29 error messages and codes 13,200.41: the printhead right jetstack heater is too hot. 13,202.43: the printhead right jetstack heater took too long to reach its setpoint. 13,259.46: the printhead right jetstack thermistor circuit is open. 13,...

  • Page 98

    3-30 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 13,327.42: the printhead reservoir thermistor returned a bad reading, or the reading was corrupted by esd. 13,328.43: the ink loader cyan heater is too hot. 13,330.45: the ink loader cyan heater took too long to re...

  • Page 99

    Phaser 8400/8500/8550/8560 color printer service manual 3-31 error messages and codes 13,000.6x errors - program faults 13,001.62: thermals failed to read from printer nvram. 13,002.63: value is not in valid range. 13,003.64: thermal control task received an unexpected message. 13,004.65: thermal co...

  • Page 100

    3-32 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 19,0xx.Xx errors - printhead calibration faults. 19,001.46: hfd server failed due to nvram operation. This fault only occurs when the printer is set in manufacturing mode. Program fault. 19,002.47: attempted to per...

  • Page 101

    Phaser 8400/8500/8550/8560 color printer service manual 3-33 error messages and codes 19,005.63: wave amplifier overcurrent. This error can occur in too-low humidity environments. Printer self-resets. 19,0xx.6x errors - waveform program faults 19,001.68 thru 19,039.61: waveform printhead calibration...

  • Page 102

    3-34 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 26,962.6x errors - “fall out” code check the previous error in the fault history and troubleshoot that code. 27,0xx.6x errors - profile library ensure the ground integrity of the printer (see “ensuring ground integ...

  • Page 103

    Phaser 8400/8500/8550/8560 color printer service manual 3-35 error messages and codes 31,0xx.6x errors - program faults 1. Reset nvram, and then retest. 2. Ensure ground integrity for the printer (see “ensuring ground integrity” on page 4-65). 33,0xx.Xx errors - tray manager device faults 33,001.42:...

  • Page 104

    3-36 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 36,000.40 errors - drum maintenance faults 36,001.67 errors - drum maintenance fault 1. Replace the drum maintenance pivot plate. 2. Replace the drum maintenance kit. 36,002.44 errors - drum maintenance program fau...

  • Page 105

    Phaser 8400/8500/8550/8560 color printer service manual 3-37 error messages and codes ■ reservoir heater, 37,004.40 or 37,005.41 ■ drum heater error 37,006.42 ■ preheater error 37,008.44 ■ ink melters errors 37,009.45 thru 37,013.40 the printer includes several heaters powered by ac. The printer its...

  • Page 106

    3-38 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 37,012.48: inkmelt 3 (black) disconnect. The inkmelt heater is not drawing the expected power from the supply. Inkmelt 2 (magenta) disconnect. The inkmelt heater is not drawing the expected power from the supply. 3...

  • Page 107

    Phaser 8400/8500/8550/8560 color printer service manual 3-39 error messages and codes 37,014.41: drum fan disconnect. The drum fan is not drawing the expected power. Electronics module fan disconnect. The electronics module fan is not drawing the expected power. 37,015.42: drum fan disconnect. The d...

  • Page 108

    3-40 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 50v power supply fault troubleshooting procedure step questions and actions yes no 1 check for a short in the electronics module. Note damage to circuits within the electronics module may occur if the power supply ...

  • Page 109

    Phaser 8400/8500/8550/8560 color printer service manual 3-41 error messages and codes 5 to isolate the problem to the i/o board or its related cabling, unplug these i/o board connectors. ■ umbilical right j1 ■ waste tray sense j110 ■ stripper solenoid j250 ■ paper tray sense j610 ■ ink load signal j...

  • Page 110

    3-42 phaser 8400/8500/8550/8560 color printer service manual error messages and codes 37,022.40: preheat solenoid disconnect. The preheat solenoid is not drawing the expected power from the supply. 37,023.41: head tilt solenoid disconnect. The head tilt solenoid is not drawing the expected power fro...

  • Page 111

    Phaser 8400/8500/8550/8560 color printer service manual 3-43 error messages and codes 8400 8500/8550/ 8560 8400 pest description 37,022.40: 37,025.43: pressure pump motor disconnect. The purge pump is not drawing the expected power. Troubleshooting procedure for purge pump step questions and actions...

  • Page 112

    3-44 phaser 8400/8500/8550/8560 color printer service manual error messages and codes troubleshooting procedures for drum heater relay board step questions and actions yes no 1 run the drum heater relay test. Did the test pass? Replace the electronics module. Go to step 2. 2 check the wiring for dam...

  • Page 113

    Phaser 8400/8500/8550/8560 color printer service manual 3-45 error messages and codes troubleshooting procedure for y-axis motor step questions and actions yes no 1 1. Remove any obstructions interfering with drum rotation. 2. Inspect the drum and ensure the drum rotates smoothly, if not replace the...

  • Page 114

    3-46 phaser 8400/8500/8550/8560 color printer service manual error messages and codes troubleshooting procedure for process drive step questions and actions yes no 1 do the process drive gears, transfix camshaft, and drum maintenance camshaft rotate freely? Go to step 2. Look for drag in the rollers...

  • Page 115

    Phaser 8400/8500/8550/8560 color printer service manual 3-47 error messages and codes 37,056.47: power supply -50 volt under limit. Power supply -50 volt under limit. 37,057.48: power supply +15 volt over limit. Power supply +15 volt over limit. 37,058.40: power supply +15 volt under limit. Power su...

  • Page 116: Jam Codes

    3-48 phaser 8400/8500/8550/8560 color printer service manual error messages and codes jam codes the printer stores the most recent 20 events in jam history. To access this information for 8400 models (in customer mode), press and hold the red cancel button, followed by pressing the ok button when th...

  • Page 117

    Phaser 8400/8500/8550/8560 color printer service manual 3-49 error messages and codes . Jam code definition table not all jam code combinations are documented in this manual, only the codes that occur most commonly. Note the following table only shows the 3-digit jam code. For phaser 8500/ 8550/8560...

  • Page 118

    3-50 phaser 8400/8500/8550/8560 color printer service manual error messages and codes a2e deskew sensor in unexpected state at ready. 1. Ensure ground integrity, see page 4-65. 2. Replace tray 1 pick solenoid. A2f deskew sensor in unexpected state. 1. Ensure ground integrity of the printer, see page...

  • Page 119

    Phaser 8400/8500/8550/8560 color printer service manual 3-51 error messages and codes 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. Check printer specificat...

  • Page 120

    3-52 phaser 8400/8500/8550/8560 color printer service manual error messages and codes c2f strip flag unexpected event during fault. C2k strip flag unexpected event during transfix roller oiling. C2m the strip flag actuated unexpectedly when paper picked from tray 2. C2n the strip flag actuated unexp...

  • Page 121

    Phaser 8400/8500/8550/8560 color printer service manual 3-53 error messages and codes c5x print pulled back into transfix nip during exit. 1. Ensure the media is not too thick and that it is supported by the printer. 2. Use a less glossy media. 3. If the drum maintenance unit is near the end of its ...

  • Page 122

    3-54 phaser 8400/8500/8550/8560 color printer service manual error messages and codes e2q tray 1 width sensor during tray 1 pick. 1. Examine the tray 1 width guides for proper movement and ensure the side guides are not being adjusted while printing. 2. Ensure the front door is closed and the wiring...

  • Page 123

    Phaser 8400/8500/8550/8560 color printer service manual 3-55 error messages and codes m4l media drive stalled while the printer was in standby mode. M4m media drive stalled while the printer picked from tray 2. M4n media drive stalled while the printer picked from tray 3. M4p media drive stalled whi...

  • Page 124

    3-56 phaser 8400/8500/8550/8560 color printer service manual error messages and codes n4x y-axis motor stalled while the print exited the printer. 1. Check the media, generally label, trifold or envelopes cause this error. 2. Try running fewer sheets through the tray. 3. Ensure the process drive is ...

  • Page 125

    Phaser 8400/8500/8550/8560 color printer service manual 3-57 error messages and codes p4g process motor stalled while the printer performed an auto drum maintenance cycle. P4h process motor stalled while the printer performed printhead maintenance. P4j process motor stalled while the printer perform...

  • Page 126

    3-58 phaser 8400/8500/8550/8560 color printer service manual error messages and codes t2m the exit cover open flag unexpectedly tripped when the printer picked from tray 2. T2n the exit cover open flag unexpectedly tripped when the printer picked from tray 3. T2p the exit cover open flag unexpectedl...

  • Page 127

    Phaser 8400/8500/8550/8560 color printer service manual 3-59 error messages and codes v2x tray 2 media size sensor unexpectedly activated while exiting print. 1. Ensure ground integrity of the printer, see page 4-65. 2. Ensure the tray 2 paper guides are correctly set. 3. Run the monitor sensors tes...

  • Page 128

    3-60 phaser 8400/8500/8550/8560 color printer service manual error messages and codes x2f tray 3 pick flag triggered unexpectedly while printer was in a fault state. X2l tray 3 pick flag triggered unexpectedly while printer in standby. X2m tray 3 pick flag triggered unexpectedly while picking from t...

  • Page 129

    Phaser 8400/8500/8550/8560 color printer service manual 3-61 error messages and codes x3x tray 3 pick flag sensor timed out while exiting print. 1. Verify the paper loaded in tray 3 is supported media. 2. Reduce the amount of media in the tray and reposition the guides to fit firmly against the medi...

  • Page 130

    3-62 phaser 8400/8500/8550/8560 color printer service manual error messages and codes z2m tray 4 pick flag triggered unexpectedly while pick from tray 2. Z2n tray 4 pick flag triggered unexpectedly while pick from tray 4. Z2p tray 4 pick flag triggered unexpectedly while pick from tray 4. Z2q tray 4...

  • Page 131: In This Chapter...

    4 chapter general troubleshooting in this chapter... ■ service diagnostics ■ service diagnostics mode menu ■ check menu definition tables ■ electronics troubleshooting ■ ensuring ground integrity ■ paper path and media-based problems ■ operating system and application problems.

  • Page 132: Introduction

    4-2 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting introduction this chapter covers the general start-up, power on self test (post), and power supply operations of the printer to aid in troubleshooting problems not associated with a control panel error message or err...

  • Page 133

    Phaser 8400/8500/8550/8560 color printer service manual 4-3 general troubleshooting reset nvram provides access to reset the printer back to its factory-default settings and erase all network settings. If possible, print the configuration page before resetting nvram. Power saver timeout selects the ...

  • Page 134: Service Diagnostics

    4-4 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting service diagnostics the printer has built-in diagnostics to aid in troubleshooting. Service diagnostics provides tests for sensors, motors, switches, clutches, fans and solenoids. Service diagnostics also contains fu...

  • Page 135

    Phaser 8400/8500/8550/8560 color printer service manual 4-5 general troubleshooting service diagnostic control panel button descriptions service diagnostics mode menu this mode can be entered from the hidden service menu. All diagnostics are available in this mode. The printer reboots after entering...

  • Page 136

    4-6 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting service diagnostics menu map service diagnostics menu map menu description main menu displays general help text describing the general operation of the control panel/menu system. Development menu a temporary submenu ...

  • Page 137

    Phaser 8400/8500/8550/8560 color printer service manual 4-7 general troubleshooting exercise menu functions for causing mechanical actions which may then be observed. Press a control panel button to stop the test activators menu pulses the activator to cause it to generate some sound or motion. Exer...

  • Page 138

    4-8 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting drum maintenance cam shaft cycles the motor/shaft repeatedly. Deskew shaft wiper shaft tray 1 pick shaft tray 2 pick shaft tray 2 lift motor tray 3 pick shaft cycles the motor/shaft repeatedly. If not installed gener...

  • Page 139

    Phaser 8400/8500/8550/8560 color printer service manual 4-9 general troubleshooting function menu functions for commanding more complex actions by portions of the printer mechanism. Initialize mechanism performs a power up mechanical initialization sequence. Print dmu blot raises the dm unit up agai...

  • Page 140

    4-10 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting check menu definition tables a submenu containing a set of extensive tests that return measured mechanism parameters for comparison against stated limits. Refer to the table associated with each test for their norma...

  • Page 141

    Phaser 8400/8500/8550/8560 color printer service manual 4-11 general troubleshooting the deskew clutch test gathers data on the performance of the deskew clutch coil. Gathers data on the performance of the tray 1 pick solenoid coil and flapper. Gathers data on the performance of the pick clutch coil...

  • Page 142

    4-12 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting gathers data on the performance of the stripper solenoid coil and plunger. Gathers data on the performance of the purge vent solenoid coil. Gathers data on the performance of the drum heater dual relay assembly by e...

  • Page 143

    Phaser 8400/8500/8550/8560 color printer service manual 4-13 general troubleshooting check shafts menu runs the media path drive train and engages the deskew clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive ...

  • Page 144

    4-14 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting 3 ccw on average fe. 250 to 600 1.0 to 2.5 reports the average effort required to rotate the deskew shaft in the ccw direction at a constant velocity. An unusual value could indicate a difference in the composition ...

  • Page 145

    Phaser 8400/8500/8550/8560 color printer service manual 4-15 general troubleshooting 8 cw on fe settling time (sec). 0.010 to 0.20 0 to .2 reports the time it takes the mp motor servo system to "settle down" after the sudden addition of the deskew shaft load. A longer time could indicate a looseness...

  • Page 146

    4-16 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting check paper path menu runs the media path drive train and engages the head maintenance clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, stead...

  • Page 147

    Phaser 8400/8500/8550/8560 color printer service manual 4-17 general troubleshooting 4 ccw on fe ripple. 25 to 100 .08 to .31 reports the variation of effort needed to rotate the wiper shaft in the ccw direction at a constant velocity. A larger value could indicate particles in the gears or non unif...

  • Page 148

    4-18 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting runs the media path drive train and engages the tray 1 pick saolenoid on the fly. The pick shaft goes through two full revolutions while drive requirements are determined. 9 cw on average fe. -50 to 15 .02 to .2 rep...

  • Page 149

    Phaser 8400/8500/8550/8560 color printer service manual 4-19 general troubleshooting 1 on response time. (sec). -1.5 to 0.95 reports the time between pick solenoid activation and a detectable response from the mp drive system indicating that pick shaft engagement. A higher value of r1 could indicate...

  • Page 150

    4-20 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting test is the same for each pick shaft although for tray 2 the media path drive motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used. Test determines if the shaft can be driven by...

  • Page 151

    Phaser 8400/8500/8550/8560 color printer service manual 4-21 general troubleshooting 2 on fe settling time (sec). Reports the time it takes the mp motor servo system to "settle down" after the sudden addition of the tray 2 pick shaft load. A longer time could indicate looseness in the tray 2 pick sh...

  • Page 152

    4-22 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting test picks paper from selected tray (test currently supports picking from tray 2 only) and moves it through either the simplex or duplex paper path to determine paper path power requirements. Paper is picked and mov...

  • Page 153

    Phaser 8400/8500/8550/8560 color printer service manual 4-23 general troubleshooting tray 4 pick 2 tray 4 pick interval (us) reports the interval from the time the engine software is commanded to start the tray 4 pick process until the tray 4 pick sensor activates. 3 tray 4 transport interval (us) r...

  • Page 154

    4-24 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on t...

  • Page 155

    Phaser 8400/8500/8550/8560 color printer service manual 4-25 general troubleshooting tray 4 pick 2 tray 4 pick trailing edge interval (us) reports the interval from the time the engine software is commanded to start the tray 4 pick process until the tray 4 pick sensor deactivates. Tray 3 pick 3 tray...

  • Page 156

    4-26 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting paper is picked and moved through either the simplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick...

  • Page 157

    Phaser 8400/8500/8550/8560 color printer service manual 4-27 general troubleshooting test picks paper from selected tray (test currently supports picking from tray 2 only) and moves it through either the simplex or duplex paper path to determine paper path power requirements. 5 preheat bounce interv...

  • Page 158

    4-28 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting paper is picked and moved through either simplex or duplex paper path to determine leading edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray an...

  • Page 159

    Phaser 8400/8500/8550/8560 color printer service manual 4-29 general troubleshooting paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on t...

  • Page 160

    4-30 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting paper is picked and moved through either the duplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick ...

  • Page 161

    Phaser 8400/8500/8550/8560 color printer service manual 4-31 general troubleshooting check drive menu this test moves the wiper drive mechanism through the complete range of its motion in each direction and does an “on the fly” reversal to verify operability. Wiper drive r# definition typical value ...

  • Page 162

    4-32 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test moves the gear train in one direction while capturing data, does a reversal to capture reversal transient data, then operates in the other direction. 11 bottom encounter distance (uin) -2500 to -1800 -4250...

  • Page 163

    Phaser 8400/8500/8550/8560 color printer service manual 4-33 general troubleshooting this test drives the x-axis motor in each direction until the printhead stalls into the stops. Next, the test moves the printhead into the clear and performs an on the fly reversal. X-axis drive r# definition typica...

  • Page 164

    4-34 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting with the drum turning at a constant velocity, the transfix roller is loaded against the drum, held for one revolution, then raised. The velocity with which the transfix roller is moved differs for the two tests. Wit...

  • Page 165

    Phaser 8400/8500/8550/8560 color printer service manual 4-35 general troubleshooting this test drives the printhead tilt mechanism through one cycle to determine if it is controllable and operating as expected. 4 roller average period (sec) 50 to 1600 -.05 to .05 reports the average period of the y-...

  • Page 166

    4-36 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test raises the lift plate to verify motion and sensor operation. If the test is requested for a tray not installed, an “option not detected” message appears. 2 pre standby peak magnitude (pm ticks) -5100 to -5...

  • Page 167

    Phaser 8400/8500/8550/8560 color printer service manual 4-37 general troubleshooting check drum menu uses the sine and cosine sum data to determine the characteristics of the encoder disk and encoder sensors. Y-axis encoder r# definition typical value (8400) typical value (8500/ 8550/8560) actions 0...

  • Page 168

    4-38 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting rotates the drum at a constant velocity and samples the y-axis position. Uses the data to determine y-axis motor and drum vibration and the most significant other vibrational frequencies. Y-axis geometry r# definiti...

  • Page 169

    Phaser 8400/8500/8550/8560 color printer service manual 4-39 general troubleshooting this procedure performs a “4 corner” test using the minimum and maximum velocity and acceleration used during printing and minimum and maximum load for a total of eight test cycles. Measures servo response parameter...

  • Page 170

    4-40 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test does a chase using a special sheet of preprinted media and records the y-axis following error. This test modifies the y-axis servo loop so that it is unstable and oscillates. The oscillation frequency is r...

  • Page 171

    Phaser 8400/8500/8550/8560 color printer service manual 4-41 general troubleshooting this test holds the drum stationary while the stripper solenoid is activated and released. The drum servo error signal illustrates activation/deactivation timing and how strongly the drum was contacted by the blade....

  • Page 172

    4-42 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test uses the drum servo error signal to indicate when the drum is contacted by the roller blade. 4 release displacement (mpts) -0.75 to 2.2 -4.5 to 4.5 reports the static difference between the average ya_fe b...

  • Page 173

    Phaser 8400/8500/8550/8560 color printer service manual 4-43 general troubleshooting check motors menu this test turns on the y-axis motor and runs it very slowly for one revolution. This test turns on the x-axis motor and runs it very slowly for one revolution. Y-axis motor r# definition typical va...

  • Page 174

    4-44 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test turns on the process motor and runs it very slowly for one revolution. This test turns on the media path motor and runs it very slowly for one revolution. Process motor r# definition typical value (8400) t...

  • Page 175

    Phaser 8400/8500/8550/8560 color printer service manual 4-45 general troubleshooting this test turns on the specified motor and runs it at constant velocity for approximately 20 revolutions while recording drive data. The test is the same for each motor. Requesting a test for tray not installed gene...

  • Page 176

    4-46 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting check misc menu this test looks at the paper path sensors to identify if anything would prevent a page from printing. The control panel will display messages indicating if anything unexpected is found for: r0 = uppe...

  • Page 177

    Phaser 8400/8500/8550/8560 color printer service manual 4-47 general troubleshooting this test scans the thermocouples and reports data on the current temperature with the goal of providing a picture of the current temperature state of the printer. All degrees are reported in celsius. This test dete...

  • Page 178

    4-48 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting 2 initial pumping power (watts) reports minimum pumping power after start up peak (r1). This is the first value to reflect the system pressure. If the volume is normal (hose/ printhead), then the drop is large and t...

  • Page 179

    Phaser 8400/8500/8550/8560 color printer service manual 4-49 general troubleshooting this test determines averaged readings for key system voltages. This test drives the process drive to move the wiper blade a short distance in each direction to verify the home position. Voltages r# definition typic...

  • Page 180

    4-50 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting this test drives the process motor a short distance in each direction to verify that the dmfix drive unit was in its home position. Drum maint/transfix home r# definition typical value (8400) typical value (8500/ 85...

  • Page 181: Electronics Troubleshooting

    Phaser 8400/8500/8550/8560 color printer service manual 4-51 general troubleshooting electronics troubleshooting printer power-up sequence the following lists the chain of events that occur when you turn on a printer. You can follow this list as one means of determining if the printer is operating c...

  • Page 182

    4-52 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting mechanical initialization 8400 (1/2) start the thermals 13,xxx unbind media path motor and home the mpt 31,000 home the y-axis 5001, 5004 wait for the head to read ok_to_wipe temperatures 13.Xxx home xa 6000 move xa...

  • Page 183

    Phaser 8400/8500/8550/8560 color printer service manual 4-53 general troubleshooting mechanical initialization 8400 (2/2) _head parked on? Last power down? Move cap/wiper to the park arms- and restrain head again. 8035,7009 home dmfix 7002 jog the x axis in order to release the head tilt arms. Move ...

  • Page 184

    4-54 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting mechanical initialization (8500/8550/8560) home xa and move xa to the headtilt position 6000 use the headtilt solenoid and tilt the head to standby 7007, 7006, 7008, 8005, 8055, 8007, 8008, 8009 is the head tilt cam...

  • Page 185

    Phaser 8400/8500/8550/8560 color printer service manual 4-55 general troubleshooting unplanned shutdown if the printer was not shutdown by the power switch the last time it was turned off or it was shutdown with ink on the drum: as soon as the printer has warmed up, the media path motor moves the wi...

  • Page 186

    4-56 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting miscellaneous electrical troubleshooting the electronics module contains the power supply, image processor board and the power control board. If a component of the electronics module fails, and service is necessary,...

  • Page 187

    Phaser 8400/8500/8550/8560 color printer service manual 4-57 general troubleshooting c. Unplug power cord and remove printer's covers. Caution use caution around motors, pulleys and live ac connections when working with the printer covers off. A. Unplug the following electronics module connections. ...

  • Page 188

    4-58 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting ■ inkload signal j910 ■ dmu sense j860 ■ drum thermistor j870 ■ exit module j680 ■ heater relay control j950 c. Retest the resistance of the i/o board. If the resistance is still less than 1k ohm, replace the i/o bo...

  • Page 189

    Phaser 8400/8500/8550/8560 color printer service manual 4-59 general troubleshooting f. If the pe and ps indicators do not flash momentarily, the short is on the printhead. Replace the printhead and retest the printer. Skip the rest of this section if the pe and ps indicators flash because the probl...

  • Page 190

    4-60 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting display functions, but sent jobs do not print 1. Computer driver incorrect or improperly installed a. Verify printer hardware is functional by sending a test print via the printer control panel. B. If a test print i...

  • Page 191

    Phaser 8400/8500/8550/8560 color printer service manual 4-61 general troubleshooting f. Plug in all cables removed during service. G. Trace through all service steps performed to reattach any cables that were unplugged during debugging. H. Attach printer covers. I. Perform full test of printer. Prin...

  • Page 192

    4-62 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting a. Turn off printer and wait 30 seconds for power supply capacitors to discharge. B. Replace 525-sheet feeder. C. Perform full test of printer. Printer does not print, leds are on and the display is frozen with no e...

  • Page 193

    Phaser 8400/8500/8550/8560 color printer service manual 4-63 general troubleshooting n. If the electronics module, i/o board and control panel are working, the error code 34,001.43 should appear on the display to indicate the printhead is disconnected. If the correct error code is displayed, continu...

  • Page 194

    4-64 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting verifying power supply operation the power supply is divided into two sections: the ac section used for heaters and the dc section for control logic, printhead drivers, and motors. Verifying the power supply involve...

  • Page 195

    Phaser 8400/8500/8550/8560 color printer service manual 4-65 general troubleshooting detecting condition of fuse f2 and f3 1. The drum and preheater connect to f3. 2. The printhead and ink loader connect to f2. 3. Turn the power switch off and wait for the printer to shut down. 4. Unplug the power c...

  • Page 196

    4-66 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting key ground connections the following illustration shows the grounding points in the printer. S8500-032 transfix roller ground springs i/o board ground dm ground clip x-axis motor x-axis return spring ground y-axis m...

  • Page 197

    Phaser 8400/8500/8550/8560 color printer service manual 4-67 general troubleshooting testing motor and solenoid resistances 1. Turn off the printer and disconnect the power cord. 2. With a dmm set for measuring resistance, test each motor's windings for correct resistance (disconnected from the prin...

  • Page 198

    4-68 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting paper path and media-based problems for paper path and media-based problems, first check the displayed error codes using the error code definition table beginning on page 3-7 to help determine where the error is occ...

  • Page 199

    Phaser 8400/8500/8550/8560 color printer service manual 4-69 general troubleshooting paper-pick errors - tray 1 1. Verify the media being used is the correct size and weight. 2. Clean the tray 1 pick roller and separator pad, refer to the cleaning procedure. 3. Ensure the printer is operating under ...

  • Page 200

    4-70 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting 9. Inspect the gears and mating cam gears for stripped or damaged gear teeth. 10. Replace the process drive gearbox. 11. Replace the media path drive gearbox. Media skews passing through the paper path 1. Ensure the...

  • Page 201

    Phaser 8400/8500/8550/8560 color printer service manual 4-71 general troubleshooting operating system and application problems print an internal test print from the printer’s control panel to ensure the problem is not printer related. There is additional help available at www.Xerox.Com/office/ suppo...

  • Page 202

    4-72 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting ethernet port verification for default assigned ip address 169.254.Xxx.Xxx an alternate method is required to test the ethernet port when the pc’s ip address falls within the range 169.254.Xxx.Xxx. Pcs that have not...

  • Page 203: Network Problems

    Phaser 8400/8500/8550/8560 color printer service manual 4-73 general troubleshooting network problems the printer maintains 6 logs in memory detailing network functions. The logs contain tcp/ip, netware and appletalk initialization events. The logs can also be accessed remotely via centreware. The l...

  • Page 204

    4-74 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting to obtain a trace: 1. Connect the serial cable to your pc. Serial port settings are 19.2 kbaud, 8 bits, no parity, 1 stop bit, and software control. 2. Turn off the printer. 3. Remove the rear panel to access the ma...

  • Page 205

    Phaser 8400/8500/8550/8560 color printer service manual 4-75 general troubleshooting 6. Name the new connection with the model number of the printer. Configure the new connection using the com port configured in step 3, then click ok. Set “bits per second” to 19200, and set “flow control” to hardwar...

  • Page 206

    4-76 phaser 8400/8500/8550/8560 color printer service manual general troubleshooting.

  • Page 207: In This Chapter...

    5 chapter print-quality troubleshooting in this chapter... ■ print-quality problems overview ■ analyzing service test prints.

  • Page 208

    5-2 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting print-quality problems overview print-quality defects can be attributed to printer components, consumables, media, internal software, external software applications, and environmental conditions. To successfull...

  • Page 209

    Phaser 8400/8500/8550/8560 color printer service manual 5-3 print-quality troubleshooting random light stripes one or more color bars are missing on the test page. This is likely caused by a weak or clogged printhead jet. Initial actions ■ run the eliminate light stripes routine from the control pan...

  • Page 210

    5-4 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting predominate light stripes all four color bars are missing on the test page. A thin stripe with no colon is likely due to foreign debris scratching ink off the drum or the print. If there are a series of regular...

  • Page 211

    Phaser 8400/8500/8550/8560 color printer service manual 5-5 print-quality troubleshooting smudges or smears smudges or smears appear on the page. The likely cause is ink residue in the media path. Check for residue on the rollers, stripper blade, guide ribs, or inside the preheater. High coverage im...

  • Page 212

    5-6 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting smudges or smears troubleshooting procedure step questions and actions yes no 1 clean the exit path, including the stripper blade with a lint-free cloth. Did this correct the problem? Complete. Go to step 2. 2 ...

  • Page 213

    Phaser 8400/8500/8550/8560 color printer service manual 5-7 print-quality troubleshooting print too light or too dark the overall image density is too light or dark. Initial actions ■ check the media used is supported by this printer. ■ check the media settings are correct at the control panel. Trou...

  • Page 214

    5-8 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting blank prints the printer processes a sheet of paper, but no image is printed on it. Note blank sheets accompanying multi-picks or chase pages following a jam are a part of normal operation. Initial actions ■ ch...

  • Page 215

    Phaser 8400/8500/8550/8560 color printer service manual 5-9 print-quality troubleshooting color is uneven or wrong this may be due to incorrect colors in the ink loader, old ink in the printhead, color mixing at the faceplate, or drum thermal problems. Using non-xerox ink may cause unpredictable col...

  • Page 216

    5-10 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting 3 check thermal regulation of the drum. Run the service diagnostics drum thermal check test, see “temperature status” on page 4-47. Are the drum thermal values out of the appropriate range? Go to step 4. Go to...

  • Page 217

    Phaser 8400/8500/8550/8560 color printer service manual 5-11 print-quality troubleshooting streaks or lines down the print there are several possible causes of streaks running the length of a print. Initial actions ■ check the media used is supported by this printer. ■ check that the exit path is cl...

  • Page 218

    5-12 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting 4 if there are streaks on the front side only of a 2-sided print, the preheater may be scraping ink off the print. 1. Look for ink shavings along the streaks on the printed paper. 2. Clean the preheater using ...

  • Page 219

    Phaser 8400/8500/8550/8560 color printer service manual 5-13 print-quality troubleshooting scratches or marks parallel to the long axis of printing, particularly with film scratches or marks are usually caused by debris in the paper path. The scratch or mark may extend into non-printed areas or be m...

  • Page 220

    5-14 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting 2 1. Check the drum maintenance kit. If the defect is a thin line that is glossier than the surrounding area, it may be due to a defect on the maintenance kit wiper blade. 2. Clean the wiper blade or replace t...

  • Page 221

    Phaser 8400/8500/8550/8560 color printer service manual 5-15 print-quality troubleshooting ink on white portion of print color on the print where no color should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. ...

  • Page 222

    5-16 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting 3 1. Clean the stripper blade, it may be contaminated with ink. 2. Run remove print smears . Did this correct the problem? Complete. Go to step 4. 4 1. Check for ink on the transfix roller. 2. Run remove print...

  • Page 223

    Phaser 8400/8500/8550/8560 color printer service manual 5-17 print-quality troubleshooting fuzzy text text appears indistinct and difficult to read. There are three typical reasons for fuzzy text, as called out in this illustration. 1. Top left image displays a y-axis drum rotation problem. 2. Lower...

  • Page 224

    5-18 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting poor primary color fills primary fills appear banded and inconsistent. Initial actions ■ check the media used is supported by this printer. ■ check that the paper path is clean and clear of debris. 4 1. Test t...

  • Page 225

    Phaser 8400/8500/8550/8560 color printer service manual 5-19 print-quality troubleshooting poor primary fills troubleshooting procedure step questions and actions yes no 1 banded and inconsistent primary fills may indicate a missing, weak, or discolored jet. 1. Print the weak/missing jet test print....

  • Page 226

    5-20 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting ghosting the image from a previous print is on the current print. This problem can occur from prints being stacked in the output tray, causing the pressure of the stack and the heat of the printer to cause “bl...

  • Page 227

    Phaser 8400/8500/8550/8560 color printer service manual 5-21 print-quality troubleshooting 3 inspect and clean the drum maintenance kit wiper blade. If necessary, replace the kit. Did this correct the problem? Complete. Go to step 4. 4 test drum maintenance operation. 1. Run service diagnostics to v...

  • Page 228

    5-22 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting poor small text resolution small characters appear heavy and “plug up.” initial actions ■ check the media used is supported by this printer. ■ check that the paper path is clean and clear of debris. Troublesho...

  • Page 229

    Phaser 8400/8500/8550/8560 color printer service manual 5-23 print-quality troubleshooting vertical lines appear wavy straight vertical lines appear to be wavy and ill-formed. This problem is likely caused by too much oil on the drum. Initial actions ■ check the media used is supported by this print...

  • Page 230

    5-24 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting oil streaks on print oil stains the edge of the print. This problem is likely caused by too much oil on the drum or poor drum maintenance kit grounding. Initial actions ■ check the media used is supported by t...

  • Page 231

    Phaser 8400/8500/8550/8560 color printer service manual 5-25 print-quality troubleshooting 2 check the drum maintenance kit ground. Inspect the back of the drum maintenance kit to drum maintenance camshaft to drum fan ground clip. Did this correct the problem? Complete. Go to step 3. 3 run remove pr...

  • Page 232

    5-26 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting incomplete image transfer to paper all of the image does not transfer to the paper. Media that is not smooth enough or too light can cause this problem. This problem can also occur on watermarked paper or when...

  • Page 233

    Phaser 8400/8500/8550/8560 color printer service manual 5-27 print-quality troubleshooting 4 check and clean the drum maintenance kit wiper blade. Replace the kit if necessary. Did this correct the problem? Complete. Go to step 5. 5 1. Test the drum temperature sensor with service diagnostics. 2. Ch...

  • Page 234

    5-28 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting ink smears on first printed side of auto-duplex print preheater temperature is too high. Initial actions note for 8500/8550/8560 models only. If the customer is manually duplexing, check that the customer is s...

  • Page 235

    Phaser 8400/8500/8550/8560 color printer service manual 5-29 print-quality troubleshooting repeating defects on print the distance between each artifact of a repeating image defect reveals which imaging component is causing the defect. Transfix roller defects show up as light spots in solid fill are...

  • Page 236

    5-30 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting white stripes (pinstripes) this print-quality problem has a series of regularly spaced white stripes approximately 6 mm (.25 in.) apart. If the x-axis motor does not move the printhead smoothly and evenly duri...

  • Page 237

    Phaser 8400/8500/8550/8560 color printer service manual 5-31 print-quality troubleshooting wrinkling damage is usually in a corner with solid fills. This problem is more often seen on short-grain media. Some wrinkling on envelope flaps is normal. Wrinkling may occur on the second side of a 2-sided p...

  • Page 238

    5-32 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting initial actions ■ check the media used is supported by this printer. ■ check that the paper path is clean and clear of debris. Troubleshooting reference applicable parts example print ■ preheater ■ drum mainte...

  • Page 239

    Phaser 8400/8500/8550/8560 color printer service manual 5-33 print-quality troubleshooting image is offset or cut-off 1. Print an information page (internal page embedded in the printer). 2. Verify that the tray guides are adjusted correctly. 3. Ensure that the paper size settings for the driver and...

  • Page 240

    5-34 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting analyzing service test prints this section shows how to select and analyze all test prints stored in the printer. A variety of test prints are available in the hidden service menu to aid in determining the qua...

  • Page 241

    Phaser 8400/8500/8550/8560 color printer service manual 5-35 print-quality troubleshooting x-axis motion (8400 only) note for x-axis motion problems, see “analyzing service test prints” on page 5-34 (solid fill prints). This print is used by engineering and manufacturing. The print must be printed o...

  • Page 242

    5-36 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting color bands, rgbk dither the large, secondary colored areas in this print reveal banding and weak jets. Look for: vertical “bars” or bands of much lighter color or a different hue running in-line in one or mor...

  • Page 243

    Phaser 8400/8500/8550/8560 color printer service manual 5-37 print-quality troubleshooting reverse text the print indicates if the printhead is producing properly-sized drops of ink and that the drum temperature is not too high. Note this print should be made with the printer covers closed and in pl...

  • Page 244

    5-38 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting big bands ohp this print allows you to evaluate transparency printing. It prints two transparencies from tray 1, one with primary color fills and one with secondary color fills and a band of 50% blue, as this ...

  • Page 245

    Phaser 8400/8500/8550/8560 color printer service manual 5-39 print-quality troubleshooting gray fill, dot size uniformity this print consists of a 66% black fill. It reveals thermal variations, transfix roller pressure variations, or drum oiling variations. Look for: large area of differences in the...

  • Page 246

    5-40 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting ymckrgb solid fills these seven prints show uniformity of fill. If colors are uneven or wrong, see “color is uneven or wrong” on page 5-9. Look for: even, uniform fills throughout each print. Wrinkles or defor...

  • Page 247

    Phaser 8400/8500/8550/8560 color printer service manual 5-41 print-quality troubleshooting head-to-drum gap (8400 only) these prints indicate if the gap between the printhead and the drum is correct. Lines: the horizontal lines of the print are made up of long and short dashes. Inspect the first and...

  • Page 248

    5-42 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting black, red, green, blue, cyan, magenta, and yellow solid fills these prints show uniformity of fill. Check for the following: 1. Even, uniform fills throughout the print. 2. There should be no wrinkling or def...

  • Page 249

    Phaser 8400/8500/8550/8560 color printer service manual 5-43 print-quality troubleshooting manuf. Skew margins this print consists of an image used by manufacturing to gauge skew and margin on 2 sided prints. To measure skew, measure between the edge of the paper and the magenta frame should be with...

  • Page 250

    5-44 phaser 8400/8500/8550/8560 color printer service manual print-quality troubleshooting if you have skew on duplex prints, check for a worn duplex roller an verify that the front door is completely closed and latched on both the left and right sides.If the lead-edge margins are outside of toleran...

  • Page 251: In This Chapter...

    6 chapter adjustments and calibrations in this chapter... ■ printer component homing positions and indicators ■ jet substitution mode ■ jet substitution mode.

  • Page 252: Adjustments

    6-2 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations adjustments wiper alignment procedure 1. Remove the printer covers using the procedures that begin on page 8-4. 2. Remove the left head maintenance drive gear by removing the e-clip from the drive shaft. Left i...

  • Page 253

    Phaser 84000/8500/8550/8560 color printer service manual 6-3 adjustments and calibrations 3. Rotate the left and right idler gears until the wiper is all the way to the bottom and the gears cannot be rotated further. Rotating the left and right gears together ensures that the wiper stays parallel an...

  • Page 254

    6-4 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations printer component homing positions and indicators after servicing the printer, manually set the following assemblies to their home position before powering on the printer. If the assemblies are not home, gears ...

  • Page 255

    Phaser 84000/8500/8550/8560 color printer service manual 6-5 adjustments and calibrations homing the head tilt gear the printhead is not in the printer if the printhead is removed, manually rotate the head tilt gear, located on the inside of the left frame, to its disengaged position. S8500-061 drum...

  • Page 256

    6-6 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations the printhead is in the printer 1. Remove the drum maintenance kit. Caution center the printhead on its x axis before continuing with step 2. Check that the printhead is clear of the frame to prevent the printh...

  • Page 257

    Phaser 84000/8500/8550/8560 color printer service manual 6-7 adjustments and calibrations note when the tilt gear is disengaged, the two arrows on the left side of the printer are pointing at each other. S8500-063 tilt gear engaged tilt gear disengaged.

  • Page 258

    6-8 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations homing the process drive train examine the process drive gears for the following: ■ the holes is the process drive frame must align with the holes in the gear. ■ the hole in the drum maintenance camshaft gear m...

  • Page 259

    Phaser 84000/8500/8550/8560 color printer service manual 6-9 adjustments and calibrations timing the drum maintenance camshaft caution use either the pins that come with replacement process drives, or a paper clip, bent into a u shape to hold the gears in their proper position during removal and rep...

  • Page 260

    6-10 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations 4. Apply pressure in the direction indicated by the arrow to the drum maintenance kit and drum maintenance pivot plate to force these components against the drum maintenance camshaft. This forces the cam to ho...

  • Page 261

    Phaser 84000/8500/8550/8560 color printer service manual 6-11 adjustments and calibrations 7. Check that the hole in camshaft gear is aligned with the arrow embossed on the ground plane. The hole in the upper mating gear should align with the adjacent hole in the frame. 8. Remove the pins holding th...

  • Page 262: Jet Substitution Mode

    6-12 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations jet substitution mode on 8400 models, the jet substitution mode provides a temporary solution for print-quality problems when weak or missing jets cannot be recovered. When jet substitution mode is active, adj...

  • Page 263

    Phaser 84000/8500/8550/8560 color printer service manual 6-13 adjustments and calibrations to correct print-quality problems, refer to the eliminate light stripes test page to determine which jets are weak or missing. 1. Select jet substitution mode , and then press the ok button. 2. Select jet sele...

  • Page 264: Resetting Nvram

    6-14 phaser 84000/8500/8550/8560 color printer service manual adjustments and calibrations disabling jet substitution mode (8500/8550/8560) after the printhead is replaced, disable jet substitution mode to restore normal operation. To deselect jet substitution mode: 1. On the control panel, scroll t...

  • Page 265: In This Chapter...

    7 chapter cleaning and maintenance in this chapter... ■ maintenance ■ inspection ■ cleaning.

  • Page 266: Cleaning

    7-2 phaser 8400/8500/8550/8560 color printer service manual cleaning and maintenance service cleaning maintenance procedure cleaning is indicated if the printer is having print-quality or paper-feeding problems. Some cleaning procedures, such as purging the jet nozzles are done automatically when ne...

  • Page 267

    Phaser 8400/8500/8550/8560 color printer service manual 7-3 cleaning and maintenance pick roller cleaning method tray 1 tray 1 pick roller can be cleaned with an alcohol moistened swab. 1. Open the front door. 2. Rotate the roller and clean it with an alcohol-moistened swab. 3. Rotate the roller so ...

  • Page 268: Maintenance

    7-4 phaser 8400/8500/8550/8560 color printer service manual cleaning and maintenance trays 2~4 use off-the-shelf clear packaging tape and follow the procedures listed below to clean the pick roller and pick pad for trays 2~4. This cleaning method has been found to be extremely effective for removing...

  • Page 269: Lubrication

    Phaser 8400/8500/8550/8560 color printer service manual 7-5 cleaning and maintenance a control panel message indicates when the maintenance kit is low. Printing is still possible when the drum maintenance kit is low. When the message indicates the drum maintenance kit is “empty,” replace the kit to ...

  • Page 270

    7-6 phaser 8400/8500/8550/8560 color printer service manual cleaning and maintenance belts: there are 3 rubber belts in the printer. Inspect the belts for wear. Look for these problems: ■ loose rubber particles below the belts indicate a worn belt. ■ missing teeth in the belts ■ cracking or moderate...

  • Page 271: In This Chapter...

    8 chapter service parts disassembly in this chapter... ■ overview ■ general notes on disassembly ■ covers ■ imaging ■ paper path ■ motors, gears, solenoids, clutches, and fans ■ electronics.

  • Page 272: Overview

    8-2 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly overview this section contains the removal procedures for selected printer parts listed in the field replaceable units (service parts) parts list. In general, replacement procedures are not given because re-install...

  • Page 273

    Phaser 8400/8500/8550/8560 color printer service manual 8-3 service parts disassembly general notes on disassembly caution follow the steps of all disassembly procedures in the order given to avoid damaging printer components. 1. Before servicing the printer, switch off the printer power, wait until...

  • Page 274: Covers

    8-4 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly covers front door/tray 1 assembly (pl1.0.1) 1. Open the front door by pulling out on the handle to the right side of the door. 2. Remove the right and left stay retainers from the front door. 3. Open the plug cover...

  • Page 275

    Phaser 8400/8500/8550/8560 color printer service manual 8-5 service parts disassembly control panel cover (pl1.0.5) 1. Open the exit cover. 2. Using either your fingers or a small flathead screwdriver, loosen the control panel cover on the left side, and then slide it forward while lifting up to rem...

  • Page 276

    8-6 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly left side cover (pl1.0.9) 1. Remove the control panel cover (page 8-5). 2. Open the exit cover and front door. 3. Remove the rear screw. 4. Release the latching tabs and remove the left side cover. Exit cover (pl1....

  • Page 277

    Phaser 8400/8500/8550/8560 color printer service manual 8-7 service parts disassembly ink loader (pl1.0.8) 1. Remove the right side cover (page 8-5). 2. Remove the left side cover (page 8-6). 3. Remove the exit cover (page 8-6). 4. Lift the ink loader clear of the chassis and hold it in position aga...

  • Page 278: Imaging

    8-8 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly imaging y-axis belt, y-axis tension spring, and y-axis motor (pl 2.0.4) (pl 2.0.14) (pl 4.0.4) warning the use of safety glasses is recommended for this procedure. 1. Remove the left side cover (page 8-6). 2. Relie...

  • Page 279

    Phaser 8400/8500/8550/8560 color printer service manual 8-9 service parts disassembly 7. Remove 3 screws (3 coarse thread and 1 fine thread) from the spring arm. The 3 screws securing the arm to the motor remain in place. 8. If replacing the motor, remove 3 motor screws to separate the motor from th...

  • Page 280

    8-10 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly printhead, right and left printhead restraints (pl 2.0.4) (pl 2.0.5 and 2.0.6) warning allow components adaquate time to cool before servicing the printer. Caution perform the steps in the order given to prevent d...

  • Page 281

    Phaser 8400/8500/8550/8560 color printer service manual 8-11 service parts disassembly 5. On the left side, pull the x-axis bias spring hook out slightly and shift to the side (rotate down). Allow the hook to rest against the detents in the frame. 6. Disconnect the air hose from the purge pump. S850...

  • Page 282

    8-12 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly 7. Remove left and right printhead restraints. First remove the screw, then pull inward towards the printhead, then lift up and slightly toward the rear to remove. Note adjust printhead position as required to rem...

  • Page 283

    Phaser 8400/8500/8550/8560 color printer service manual 8-13 service parts disassembly 9. Disconnect the heater harness and free the harness from its restraint. 10. Lift the printhead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame. 11. D...

  • Page 284

    8-14 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly 12. Disconnect the flex cable from the printhead (phaser 8400 printers have two cables). Caution do not pinch or tear the air hose while removing the printhead as this will damage the printer. 13. Lift the printhe...

  • Page 285

    Phaser 8400/8500/8550/8560 color printer service manual 8-15 service parts disassembly 10. After completing the installation, print the light stripes page and check for jets in service mode. If necessary, use the control panel to reset the jet substitution mode. Head tilt solenoid (pl4.0.12) note be...

  • Page 286

    8-16 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly x-axis bias spring (pl2.0.19) caution the spring is in close proximity to the drum. Use care not to damage the drum with the removal tools or the spring. 1. Remove the printhead (page 8-10). 2. Using your hands, a...

  • Page 287

    Phaser 8400/8500/8550/8560 color printer service manual 8-17 service parts disassembly wiper assembly (pl2.0.17) caution place several sheets of paper between the printhead and the drum to protect the drum from damage. 1. Remove the printhead (page 8-10). 2. Using the gears, position the wiper blade...

  • Page 288

    8-18 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly replacement 1. Position the wiper so both ends are all the way down following reassembly (see “wiper alignment procedure” on page 6-2). 2. When reinstalling the belt into the wiper clip in 8500/8550/8560 models, p...

  • Page 289

    Phaser 8400/8500/8550/8560 color printer service manual 8-19 service parts disassembly stripper carriage (pl2.0.12) and transfix roller (pl2.0.13) caution hold the transfix roller and stripper carriage with one hand during removal of the transfix roller shaft to prevent the transfix roller from fall...

  • Page 290

    8-20 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly preheater (pl2.0.17) 1. Open the front door. 2. Remove the lower inner duplex guide (page 8-33). 3. Remove the inner simplex guide (page 8-33). 4. Unplug the ac and sensor flag connectors from the bottom of the pr...

  • Page 291

    Phaser 8400/8500/8550/8560 color printer service manual 8-21 service parts disassembly 6. Slide the preheater off the shelves and out of the printer. Replacement note the fingers on the inner simplex guide, go over the segmented roller. First snap the left retainer into place, then the right. Duplex...

  • Page 292

    8-22 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly transfix load module (pl2.0.15) 1. Remove the front door (page 8-4). 2. Remove the ink loader (page 8-7). 3. Remove the preheater (page 8-20). 4. Remove the media drive (page 8-40). 5. Remove 4 screws, disconnect ...

  • Page 293

    Phaser 8400/8500/8550/8560 color printer service manual 8-23 service parts disassembly 9. Remove the clevis pins securing the transfix load arms to the chassis, and remove the transfix load arms and transfix roller. 10. Remove the transfix camshaft (page 8-25) 11. Remove the grounding springs from t...

  • Page 294

    8-24 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly 12. Remove two screws securing each end of the transfix load module to the chassis. 13. Remove the transfix load module by rotating the bottom in and pulling it forward. Note the transfix load module is a very tig...

  • Page 295

    Phaser 8400/8500/8550/8560 color printer service manual 8-25 service parts disassembly transfix camshaft (pl2.0.10) 1. Perform steps 1 through 7 (remove transfix load arms) of the transfix load module removal procedure (page 8-22). 2. Remove the process drive (page 8-43). 3. Slide the shaft to the r...

  • Page 296

    8-26 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly drum maintenance pivot plate (pl2.0.16) 1. Remove the drum maintenance kit. 2. Remove the right side cover (page 8-5). 3. Remove the left side cover (page 8-5). 4. Remove the grounding clip on the right end of the...

  • Page 297

    Phaser 8400/8500/8550/8560 color printer service manual 8-27 service parts disassembly drum assembly (pl2.0.3) 1. Remove the front door (page 8-4). 2. Remove the right side cover (page 8-5). 3. Remove the left side cover (page 8-5). 4. Remove the exit cover (page 8-6). 5. Remove the ink loader (page...

  • Page 298

    8-28 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly 15. Remove the exit module (page 8-32). Caution the drum temperature sensor harness is routed through the exit module. Use care during removal to avoid damaging the sensor. 16. Remove the clevis pins securing the ...

  • Page 299

    Phaser 8400/8500/8550/8560 color printer service manual 8-29 service parts disassembly 19. Remove the drum assembly from the chassis by lifting it straight up as shown in the following figure. Note you will need to temporarily remove 3 screws of the media drive motor (pl 4.8) and pull the motor out ...

  • Page 300

    8-30 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly 8. Align the clevis on the transfix load arms with the holes in the mounting ears on the drum. The transfix load arms point in the opposite direction from the drum thermistor. Ensure that the cam followers on the ...

  • Page 301

    Phaser 8400/8500/8550/8560 color printer service manual 8-31 service parts disassembly purge pump (pl2.0.7) 1. Remove the left side cover (page 8-6). 2. Disconnect the air hose from the purge pump. 3. Disconnect the harness from the purge pump. 4. Remove 3 screws to remove the purge pump. Replacemen...

  • Page 302: Paper Path

    8-32 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly paper path exit module (pl3.0.13) caution the drum temperature sensor harness is routed through the exit module. Use care during removal to avoid damaging the sensor. 1. Remove the exit cover (page 8-6). 2. Remove...

  • Page 303

    Phaser 8400/8500/8550/8560 color printer service manual 8-33 service parts disassembly inner simplex guide (pl3.0.1) 1. Open the front door to access the guide. 2. Using a small flatblade screwdriver, pry inward on one retainer to remove it from the mounting post then remove the other retainer. 3. S...

  • Page 304

    8-34 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly outer duplex guide with safety interlocks (pl3.0.4) 1. Remove the control panel (page 8-5). 2. Remove 4 screws and remove the guide. Replacement note seat the guide on the chassis. Torque the 4 screws to 12 in. Lb...

  • Page 305

    Phaser 8400/8500/8550/8560 color printer service manual 8-35 service parts disassembly replacement note route the stripper solenoid harness through the right side frame when replacing the upper duplex guide. Also, verify that the solenoid lever engages the hole in the stripper carriage. S8500-099 ho...

  • Page 306

    8-36 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly take away roller (pl3.0.7) 1. Remove the right side cover (page 8-5). 2. Remove the left side cover (page 8-5). 3. Remove the media drive (page 8-40). 4. Remove the lower simplex guide (page 8-33). 5. Remove the k...

  • Page 307

    Phaser 8400/8500/8550/8560 color printer service manual 8-37 service parts disassembly pick assembly (pl3.0.10) note replace the retard roller at the same time you replace the pick assembly. 1. Remove tray 2 from the printer. 2. Reach into the tray cavity and release the orange colored catch holding...

  • Page 308

    8-38 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly retard roller repalcement s8500-102 1 2 2 1 s8500-103.

  • Page 309

    Phaser 8400/8500/8550/8560 color printer service manual 8-39 service parts disassembly tray lift motor and gear (pl4.0.6) 1. Remove the electronics module (page 8-46). 2. Remove tray 2. 3. Disconnect the harness from the tray lift motor. 4. From the rear of the printer, inside the cavity, remove the...

  • Page 310

    8-40 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly motors, gears, solenoids, clutches, and fans media drive with two clutches and solenoid (pl4.0.5) 1. Remove the left side cover (page 8-6). 2. Remove the exit cover (page 8-6). 3. Disconnect the fan, media drive m...

  • Page 311

    Phaser 8400/8500/8550/8560 color printer service manual 8-41 service parts disassembly tray 1 pick solenoid (pl4.0.3) 1. Remove the left side cover (page 8-6). 2. Disconnect the solenoid harness. 3. Remove 1 screw from the solenoid, and remove the solenoid. Replacement note align the hole on the sol...

  • Page 312

    8-42 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly preheater lift solenoid (pl4.0.1) 1. Open the front door. 2. Remove the control panel and cover (page 8-5). 3. Remove 4 screws, disconnect 2 connectors, and remove the exit module (page 8-32). 4. Remove the outer ...

  • Page 313

    Phaser 8400/8500/8550/8560 color printer service manual 8-43 service parts disassembly process drive (pl4.0.14) caution replacement drives come with two pins to hold the gears in position. Use either the pins that come with replacement drives, or a paper clip, bent into a u shape to hold the gears i...

  • Page 314

    8-44 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly replacement note after replacing the process drive, drum maintenance pivot plate or the drum maintenance camshaft (or any component requiring removal of the process drive), the printer may experience front cover j...

  • Page 315

    Phaser 8400/8500/8550/8560 color printer service manual 8-45 service parts disassembly head tilt gear (pl4.0.9) 1. Remove the printhead (page 8-10). 2. At the left side, remove the kl-clip. 3. Remove the waste tray cover, without disconnecting the waste tray detect sensor harness. 4. Reach in to the...

  • Page 316: Electronics

    8-46 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly electronics electronics module (pl5.0.5) caution touch the back of the electronics module before starting this procedure to discharge any electrostatic charge present on the case. Also, do not completely remove em...

  • Page 317

    Phaser 8400/8500/8550/8560 color printer service manual 8-47 service parts disassembly wave amplifier (pl5.0.4) note do not fully remove emi tape, if included with any connector. 1. Remove the electronics module (page 8-46). 2. Remove the printhead (page 8-10). 3. Remove 3 screws. Caution route the ...

  • Page 318

    8-48 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly i/o board (pl5.0.13) 1. Remove the right side cover (page 8-5). 2. Disconnect all connections to the i/o board. 3. Remove 2 screws to remove the board. Replacement note locate the corner of the board behind the gr...

  • Page 319

    Phaser 8400/8500/8550/8560 color printer service manual 8-49 service parts disassembly drum heater relay board (pl5.0.17) warning this board is supplied with 120 vac, shut off printer power and disconnect the power cord before starting this procedure. 1. Remove the right side cover (page 8-5). 2. Di...

  • Page 320

    8-50 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly nvram (pl5.0.9) caution some semiconductor components, such as the nvram chip, are vulnerable to damage by electrostatic discharge (esd). Note observe the orientation of the nvram chip before removing it. 1. Remov...

  • Page 321

    Phaser 8400/8500/8550/8560 color printer service manual 8-51 service parts disassembly dimm memory (pl5.0.8) caution some semiconductor components, such as memory, are vulnerable to damage by electrostatic discharge (esd). Review the “electrostatic discharge (esd) precautions” on page 1-v before con...

  • Page 322

    8-52 phaser 8400/8500/8550/8560 color printer service manual service parts disassembly hard drive (pl5.0.7) caution some semiconductor components, such as the nvram chip, are vulnerable to damage by electrostatic discharge (esd). 1. Remove the back cover from the electronics module. 2. Disconnect th...

  • Page 323: In This Chapter...

    9 chapter parts lists in this chapter... ■ serial number format ■ using the parts list ■ xerox supplies.

  • Page 324: Serial Number Format

    9-2 phaser 8400/8500/8550/8560 color printer service manual parts lists serial number format changes to xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: ■ component's part number ■ product t...

  • Page 325: Using The Parts List

    Phaser 8400/8500/8550/8560 color printer service manual 9-3 parts lists using the parts list 1. No.: the callout number from the exploded part diagram. 2. Part number: the material part number used to order specific parts. 3. Qty: this number represents the parts per printer, not the number of parts...

  • Page 326: Pl 1.0 Covers

    9-4 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 1.0 covers s8500-117 9 13 5 6 7 8 12 11 10 4 1 3 2 3 4 14 2.

  • Page 327

    Phaser 8400/8500/8550/8560 color printer service manual 9-5 parts lists parts list 1.0 covers no. Name/description qty part number 1 front door (mpt) assembly 1 200467880 (8400) 848k06520 (8500/8550/8560) 2 front door stay retainer clip 2 120e29140 3 front door stay with spring 2 009k02390 4 hinge p...

  • Page 328: Pl 2.0 Imaging

    9-6 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 2.0 imaging 8500 118 1 2 3 7 12 13 14 15 16 17 8 11 10 9 4 19 20 21 18 18 5 6.

  • Page 329

    Phaser 8400/8500/8550/8560 color printer service manual 9-7 parts lists parts list 2.0 imaging no. Name/description qty part number 1 ink loader assembly and door 1 200469880 (8400) 133k27710 (8500/8550) 133k27770 (8560) 103k01600 (metered 8550/8560) 2 printhead 1 650430300 (8400) 046k00530 (8500/85...

  • Page 330: Pl 3.0 Paper Path

    9-8 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 3.0 paper path s8500-119 4 5 3 11 10 9 12 6 8 2 1 7 13.

  • Page 331

    Phaser 8400/8500/8550/8560 color printer service manual 9-9 parts lists parts list 3.0 paper path no. Name/description qty part number 1 inner simplex guide 1 351111480 (8400) 032e29480 (8500/8550/8560) 2 lower inner duplex guide 1 038k16870 3 lower exit guide assembly with strip flag 1 038k17800 4 ...

  • Page 332

    9-10 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 4.0 motors, gears, solenoids, clutches, and fans 13 14 6 3 9 12 11 10 7* 8 5 2 s8500-120 1 15 4.

  • Page 333

    Phaser 8400/8500/8550/8560 color printer service manual 9-11 parts lists parts list 4.0 motors, gears, solenoids, clutches, and fans no. Name/description qty part number 1 preheater lift solenoid 1 121k44430 (8500/8550/8560) 2 motor, y-axis drive 1 127k56520 3 pick solenoid, tray 1 1 121e20120 4 hea...

  • Page 334: Pl 5.0 Circuit Boards

    9-12 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 5.0 circuit boards 7 8 9 10 6 3 11 5 12 15 14 16 18 4 2 1 s8500-121 17 13 19.

  • Page 335

    Phaser 8400/8500/8550/8560 color printer service manual 9-13 parts lists parts list 5.0 circuit boards and cables no. Name/description qty part number 1 cable, y-axis motor ground 1 117e34880 2 wiring harness, left side power control 1 174449480 (8400) 117e29800 (8500/8550/8560) 3 cable, wave amp si...

  • Page 336

    9-14 phaser 8400/8500/8550/8560 color printer service manual parts lists pl 6.0 sensors and flags (actuators) s8500-122 3 6 1 4 8 7 2 5.

  • Page 337

    Phaser 8400/8500/8550/8560 color printer service manual 9-15 parts lists parts list 6.0 sensors and flags (actuators) no. Name/description qty part number 1 drum temperature sensor 1 130k75210 2 optical sensor (generic snap-in) 1 130e11530 3 safety interlock switch (mech) 1 110e20390 4 exit module s...

  • Page 338: Xerox Supplies

    9-16 phaser 8400/8500/8550/8560 color printer service manual parts lists xerox supplies kits description part number mechanical kit (hardware) ■ nut plate - 2 ea. ■ 6 mm press nut - 2 ea. ■ #8 sae washer - 5 ea. ■ thumbscrews - 2 ea. ■ m4 x 12 delta pt/ hexhead - 5 ea. ■ m4 x 32, partial thread flan...

  • Page 339

    Phaser 8400/8500/8550/8560 color printer service manual 9-17 parts lists memory (8400) 128 mb, 16m x 64, pc133; memory dimm 256 mb, 32m x 64, pc133; memory dimm zmd128 zmd256 memory (8500) 128 mb, sdram 256 mb, sdram 097s03380 097s03381 memory (8550/8560) 256 mb, sdram 512 mb, sdram 097s03381 097s03...

  • Page 340

    9-18 phaser 8400/8500/8550/8560 color printer service manual parts lists genuine xerox solid ink magenta (3 sticks) 108r00606 (8400) 108r00670 (8500/8550) 108r00724 (8560) genuine xerox solid ink yellow (3 sticks) 108r00607 (8400) 108r00671 (8500/8550) 108r00725 (8560) genuine xerox solid ink black ...

  • Page 341

    Phaser 8400/8500/8550/8560 color printer service manual 9-19 parts lists phaser premium cover paper, letter, 100 sheets 016182300 phaser premium cover paper, a4, 100 sheets 016182400 phaser professional solid ink transparency, letter, 50 sheets 103r01039 phaser professional solid ink transparency, a...

  • Page 342

    9-20 phaser 8400/8500/8550/8560 color printer service manual parts lists.

  • Page 343: In This Chapter...

    10 chapter wiring diagrams in this chapter... ■ main wiring diagram ■ right-side wiring diagram ■ left-side wiring diagram ■ inside front wiring diagram ■ inside top wiring diagram ■ inside top - printhead wiring diagram.

  • Page 344: Main Wiring Diagram

    10-2 phaser 8400/8500/8550/8560 color printer service manual main wiring diagram main processor ecb hard drive ecb printhead driver ecb wave amp ecb media tray sense ecb width sense (3) switch length sense (2) switch media tray sense ecb width sense (3) switch length sense (2) switch jet0 +/- jet1 +...

  • Page 345

    Phaser 8400/8500/8550/8560 color printer service manual 10-3 main wiring diagram (continued) (right side) power supply ecb ac generates: +/-50 v +/-15 v unreg +3.3 v power control ecb inkload ecb heaters (4) ink out opto ink low opto door open opto thermistor (4) pre-heat ecb deskew entry sense opto...

  • Page 346: Right-Side Wiring Diagram

    10-4 phaser 8400/8500/8550/8560 color printer service manual right-side wiring diagram the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. Wiring harness pass-through wiring harness pass-through 37016.4x 50v ps j680 13067.4x ...

  • Page 347

    Phaser 8400/8500/8550/8560 color printer service manual 10-5 right-side wiring diagram (continued) the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. 13387.4x 37027.4x x-motor ribbon cable (routed in middle of channel) route...

  • Page 348: Left-Side Wiring Diagram

    10-6 phaser 8400/8500/8550/8560 color printer service manual left-side wiring diagram the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. S8500-127 37023.4x purge valve 37022.4x purge motor 37013.4x electric fan j280 37032.4x...

  • Page 349

    Phaser 8400/8500/8550/8560 color printer service manual 10-7 left-side wiring diagram (continued) the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. S8500-128 37015.4x mp fan (8400 only) 37034.3x mp motor 370xx.4x preheater ...

  • Page 350: Inside Front Wiring Diagram

    10-8 phaser 8400/8500/8550/8560 color printer service manual inside front wiring diagram the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. S8500-129 37036.4x process motor 37008.4x preheat power (ac connector) j860 13131.41...

  • Page 351: Inside Top Wiring Diagram

    Phaser 8400/8500/8550/8560 color printer service manual 10-9 inside top wiring diagram the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. 37010.4x ink 1 heater j130 34062.4x (data cable) j1ac 37009.4x (ink load power) j2ac 3...

  • Page 352

    10-10 phaser 8400/8500/8550/8560 color printer service manual inside top - printhead wiring diagram the arrows indicate which connectors you should look at for the pest codes. The pest codes are displayed on the control panel. (8400 only) s8500-131 heater cable cable restraint out of ink j180 32064....

  • Page 353: Contents...

    A appendix reference contents... ■ menu map (8400) ■ menu map (8500/8550/8560) ■ paper weight equivalence table ■ on-site printhead troubleshooting checklist (8400) ■ on-site printhead troubleshooting checklist (8500/8550/8560).

  • Page 354: Menu Map (8400)

    A-2 phaser 8400/8500/8550/8560 color printer service manual reference menu map (8400) front panel buttons: main menu: up arrow ok information back cancel down arrow information walk-up tm features printer setup troubleshooting shut down information walk-up tm features printer setup troubleshooting s...

  • Page 355

    Phaser 8400/8500/8550/8560 color printer service manual a-3 reference page 2 of 2 * ** *** **** to minimize ink usage, leave the printer on. Requires: network configuration duplex configuration optional lower tray(s) 8400dx only with stored jobs present printer setup troubleshooting (continued) shut...

  • Page 356: Menu Map (8500/8550/8560)

    A-4 phaser 8400/8500/8550/8560 color printer service manual reference menu map (8500/8550/8560) control panel buttons: main menu: up arrow ok help back cancel down arrow walk-up features information paper tray setup printer setup troubleshooting walk-up features information paper tray setup printer ...

  • Page 357

    Phaser 8400/8500/8550/8560 color printer service manual a-5 reference networked printer duplex unit hard drive * ** *** requires: troubleshooting paper jams print quality problems network problems* service tools configuration page connection setup postscript setup pcl setup control panel setup print...

  • Page 358

    A-6 phaser 8400/8500/8550/8560 color printer service manual reference media margin specification table media size width (mm) length (mm) side margins (mm) top/ bottom margin (mm) image width (mm) image length (mm) legal 215.9 355.6 5 5 205.9 345.6 folio 215.9 330.2 5 5 205.9 320.2 a4 210 297 5 5 200...

  • Page 359

    Phaser 8400/8500/8550/8560 color printer service manual a-7 reference paper weight equivalence table us postcard thicknes s (mm) us bond weight (lb.) us text book weight (lb.) us cover weight (lb.) us bristol weight (lb.) us index weight (lb.) us tag weight (lb.) metric weight (g/m 2 ) 16 41 22 27 3...

  • Page 360

    A-8 phaser 8400/8500/8550/8560 color printer service manual reference on-site printhead troubleshooting checklist (8400) for the latest policy information on non-xerox supplies, visit the xerox service partners web site: https://www.Office.Xerox.Com/smart/sso index.Cfm?Fuseaction=sso.Partnerlogin pr...

  • Page 361

    Phaser 8400/8500/8550/8560 color printer service manual a-9 reference step 2 print the service usage profile. It is located in the front panel menu troubleshooting – service tools. If line 631 printhead id lists a date, record the date (month day year) here: printhead id: 00-09: _______________ 10-2...

  • Page 362

    A-10 phaser 8400/8500/8550/8560 color printer service manual reference step 6 is the wiper assembly correctly aligned? Yes no circle one is the wiper assembly out of alignment (not parallel with the printhead faceplate)? If yes, perform the wiper alignment procedure as described in the phaser 8400 c...

  • Page 363

    Phaser 8400/8500/8550/8560 color printer service manual a-11 reference step 11 print service test 1: weak and missing jets. Are there weak or missing jet(s)? Yes no circle one x if no go to step 12. X if yes, do the following: x check the exit area of the paper path for debris that could be scraping...

  • Page 364: Ink Failure Checklist

    A-12 phaser 8400/8500/8550/8560 color printer service manual reference ink failure checklist for the latest policy information on non-xerox supplies, visit the xerox service partners web site: https://www.Office.Xerox.Com/smart/sso index.Cfm?Fuseaction=sso.Partnerlogin generic ink failure checklist ...

  • Page 365

    Phaser 8400/8500/8550/8560 color printer service manual a-13 reference on-site printhead troubleshooting checklist (8500/8550/8560) printhead troubleshooting checklist phaser 8500/8550/8560/8560mfp version 2.0 important! This checklist outlines proper printhead troubleshooting procedures. All xerox ...

  • Page 366

    A-14 phaser 8400/8500/8550/8560 color printer service manual reference step 2 print the service usage profile. It is located in the front panel menu troubleshooting – service tools. If line 631 printhead id lists a date, record the date (month day year) here: printhead id: 00-09: _______________ 10-...

  • Page 367

    Phaser 8400/8500/8550/8560 color printer service manual a-15 reference step 6 is the cap/wipe/ purge assembly correctly aligned? Yes no circle one is the wiper assembly out of alignment (not parallel with the printhead faceplate)? If yes, perform the wiper alignment procedure as described in the pha...

  • Page 368

    A-16 phaser 8400/8500/8550/8560 color printer service manual reference step 11 print service test 2: weak and missing jets. Are there weak or missing jet(s)? Yes no circle one x if no go to step 12. X if yes, do the following: x check the exit area of the paper path for debris that could be scraping...

  • Page 369: Index

    Phaser 8400/8500/8550/8560 color printer service manual i – 1 index numerics 525-sheet feeder, parts list , 9-9 8-pin nvram, parts list , 9-13 a ac power , 2-20 adjust x-axis scale, service menu , 4-3 b back button , 1-5 basic positions, printhead , 2-10 basic printhead cleaning cycle , 2-33 belts d...

  • Page 370

    I – 2 phaser 8400/8500/8550/8560 color printer service manual cleaning cycle , 2-33 cleaning page , 2-14 , 2-33 , 5-44 cleaning procedures , 7-2 clear isc fault , 4-9 clevis pins , 8-23 , 8-28 , 8-30 communication ports , 2-19 , 4-71 configuration card 8400 series , 1-3 8500 series , 1-4 theory , 2-...

  • Page 371

    Phaser 8400/8500/8550/8560 color printer service manual i – 3 envelopes, printing on , 1-14 environmental specifications , 1-12 error codes 525-sheet feeder faults , 3-8 code version , 3-33 electronics module , 3-24 i/o board program , 3-9 i/o circuit board , 3-9 ink loader , 3-23 ipc program , 3-10...

  • Page 372

    I – 4 phaser 8400/8500/8550/8560 color printer service manual media drive assembly parts , 9-11 function , 2-2 gearbox removal , 8-40 theory , 2-5 media path drive , 2-2 media path faults , 3-34 miscellaneous error codes , 3-33 n nvram , 1-8 , 2-19 nvram, reset , 6-14 o oil streaks , 5-24 oiling cyc...

  • Page 373

    Phaser 8400/8500/8550/8560 color printer service manual i – 5 relation to printhead , 2-11 relation to transfix system , 2-18 process gear drive train, homing , 6-8 purge pump , 8-11 purge system , 2-3 , 2-14 purging , 2-33 r random light stripes , 5-3 remove print smears , 2-34 roll block , 8-12 ro...

  • Page 374

    I-6 phaser 8400/8500/8550/8560 color printer service manual index notes reference description.

  • Page 376

    701p27910