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Xerox PHASER 8560MFP Service Documentation

Summary of PHASER 8560MFP

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    701p01133 october 2006 phaser 8560mfp multifunction product service documentation.

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    10/2006 ii phaser 8510/8560mfp multifunction product introduction initial issue phaser 8560mfp multifunction product service documentation phaser 8560mfp multifunction product service manual 705p01133 bus updated november 1, 2006, reissue 10/2006 xerox corporation xog worldwide product training & in...

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    10/2006 iii phaser 8510/8560mfp multifunction product introduction initial issue introduction about this manual .......................................................................................................... Iii organization ...................................................................

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    10/2006 iv phaser 8510/8560mfp multifunction product initial issue introduction.

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    10/2006 v phaser 8510/8560mfp multifunction product about this manual, organization introduction initial issue about this manual the phaser 8510/8560mfp multifunction product service manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting the system. It is the...

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    10/2006 vi phaser 8510/8560mfp multifunction product power safety, service safety summary initial issue introduction power safety power source for 115 vac printers, do not apply more than 135 volts rms between the supply conductors or between either supply conductor and ground. For 230 vac printers,...

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    10/2006 vii phaser 8510/8560mfp multifunction product service safety summary introduction initial issue • do not burn any consumables or routine maintenance items. For information on xerox supplies recycling programs, go to www.Xerox.Com/gwa. Operational safety the system and supplies were designed ...

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    10/2006 viii phaser 8510/8560mfp multifunction product moving the system initial issue introduction moving the system warning parts of the system are hot. To avoid personal injury or damage to the system, allow the ink to solidify. Run the shut-down procedure to cool the system quickly. Wait at leas...

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    10/2006 ix phaser 8510/8560mfp multifunction product symbology and nomenclature introduction initial issue symbology and nomenclature the following reference symbols are used throughout the documentation. Warnings, cautions, and notes warnings, cautions, and notes will be found throughout the servic...

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    10/2006 x phaser 8510/8560mfp multifunction product symbology and nomenclature initial issue introduction the surface is hot while the printer is running. After turning off the power, wait 30 minutes. Figure 4 wait 30 minutes symbol avoid pinching fingers in the printer. Use caution to avoid persona...

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    10/2006 xi phaser 8510/8560mfp multifunction product electrostatic discharge precautions, regulatory introduction initial issue electrostatic discharge precautions some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by electrostatic discharge ...

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    10/2006 xii phaser 8510/8560mfp multifunction product regulatory specifications, phaser 8510/8560mfp initial issue introduction this product, if used properly in accordance with the user’s instructions, is neither dangerous for the consumer nor for the environment. A signed copy of the declaration o...

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    10/2006 xiii phaser 8510/8560mfp multifunction product system configurations introduction initial issue system configurations standard features the phaser 8510/8560mfp offers these standard features: • maximum print speed (pages per minute) based on letter-size plain paper: note: print speeds for me...

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    10/2006 xiv phaser 8510/8560mfp multifunction product parts of the product initial issue introduction parts of the product front view figure 1 front view 1. Tray 4 (optional) 2. Tray 3 (optional) 3. Tray 2 4. Tray 1 (mpt) 5. Output tray 6. Exit cover 7. Control panel 8. Duplex automatic document fee...

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    10/2006 xv phaser 8510/8560mfp multifunction product parts of the product introduction initial issue side view with interface connections figure 3 side view with interface connections 1. Drum maintenance kit 2. Waste tray 3. Ac power cord connection 4. Power switch 5. Scanner cable connection 6. Usb...

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    10/2006 xvi phaser 8510/8560mfp multifunction product parts of the product, control panel layout initial issue introduction routine maintenance items figure 5 routine maintenance items and consumables control panel layout the control panel functions are segregated into three areas. Figure 1 control ...

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    10/2006 xvii phaser 8510/8560mfp multifunction product control panel layout introduction initial issue 7. The down arrow reduces the reduce/enlarge percentage in one percent increments. 8. The up arrow increases the reduce/enlarge percentage in one percent increments. 9. Reduce/enlarge percentage di...

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    10/2006 xviii phaser 8510/8560mfp multifunction product specifications initial issue introduction specifications functional specifications memory specifications media tray capacity physical dimensions and clearances figure 1 minimum clearances table 1 functional specifications characteristic specifi...

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    10/2006 xix phaser 8510/8560mfp multifunction product specifications introduction initial issue print engine specifications scanner/dadf specifications electrical specifications environmental specifications table 6 print engine functional specifications characteristic specification printing process ...

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    10/2006 xx phaser 8510/8560mfp multifunction product specifications initial issue introduction image specifications note: to derive the skew specification for a particular media size, measure the width of the leading edge in millimeters. Next, divide the measured length by 1000, then multiply by the...

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    10/2006 1-1 phaser 8510/8560mfp multifunction product service call procedures initial issue 1 service call procedures service call procedures.................................................................................................. 1-3 initial actions ...........................................

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    10/2006 1-2 phaser 8510/8560mfp multifunction product initial issue service call procedures.

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    10/2006 1-3 phaser 8510/8560mfp multifunction product service call procedures service call procedures initial issue service call procedures this section describes an overview of the steps a service technician should take, using this manual, to service the system and attached options. The system’s di...

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    10/2006 1-4 phaser 8510/8560mfp multifunction product service call procedures, initial actions initial issue service call procedures initial actions purpose use the following procedure to determine the reason for the service call and to identify and organize the actions which must be performed. Proc...

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    10/2006 1-5 phaser 8510/8560mfp multifunction product routine maintenance activities, cleaning proce- service call procedures initial issue routine maintenance activities procedure 1. Clean the pick rollers on every call. 2. Use the control panel to check maintenance item counters. 3. Compare the co...

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    10/2006 1-6 phaser 8510/8560mfp multifunction product final actions initial issue service call procedures final actions purpose the intent of this procedure is to be used as a guide to follow at the end of every service call. Procedure 1. Check that the exterior of the system and the adjacent area i...

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    10/2006 2-1 phaser 8510/8560mfp multifunction product error messages and codes initial issue 2 error messages and codes power on self tests ....................................................................................................... 2-3 nvram reset ...........................................

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    10/2006 2-2 phaser 8510/8560mfp multifunction product initial issue error messages and codes.

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    10/2006 2-3 phaser 8510/8560mfp multifunction product power on self tests error messages and codes initial issue power on self tests this section covers the start-up, power on self test (post), service diagnostics, and power supply operations of the system to aid in troubleshooting problems not asso...

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    10/2006 2-4 phaser 8510/8560mfp multifunction product power on self tests initial issue error messages and codes note: before replacing the electronics module for any post errors, do the following: 1. Unplug all wiring and/or cables to the electronics module. 2. Plug in the ac power cable and power ...

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    10/2006 2-5 phaser 8510/8560mfp multifunction product nvram reset error messages and codes initial issue nvram reset many of the troubleshooting procedures in this section include an nvram reset as a proce- dural step. Following an nvram reset, the system is unable to communicate on the network and ...

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    10/2006 2-6 phaser 8510/8560mfp multifunction product nvram reset initial issue error messages and codes table 2 summarizes system parameters not affected by an nvram reset. Fax send setup transmission report never no reduced image (8560 only) off yes redial count 3 no redial time interval 15 no aut...

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    10/2006 2-7 phaser 8510/8560mfp multifunction product nvram reset, error message troubleshooting error messages and codes initial issue error message troubleshooting this section covers troubleshooting procedures utilizing control panel error messages and codes. Some procedures require running servi...

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    10/2006 2-8 phaser 8510/8560mfp multifunction product 1,00x.4x initial issue error messages and codes 1,00x.4x 525-sheet feeder faults the following troubleshooting procedure applies to these errors: initial actions • check the tray to ensure it is free of obstructions or debris. • check the operati...

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    10/2006 2-9 phaser 8510/8560mfp multifunction product 1,000.6x, 2,00x.Xx error messages and codes initial issue 1,000.6x 525-sheet feeder program faults a firmware error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if the ...

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    10/2006 2-10 phaser 8510/8560mfp multifunction product 2,006.Xx, 2,0xx.6x initial issue error messages and codes 2,006.Xx i/o board program faults the following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • check that all connections to the electronic...

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    10/2006 2-11 phaser 8510/8560mfp multifunction product 3,0xx.6x, 4,0xx.4x error messages and codes initial issue 3,0xx.6x ipc program faults a firmware communications error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if t...

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    10/2006 2-12 phaser 8510/8560mfp multifunction product 4,024.42, 4,025.46 initial issue error messages and codes 4,024.42 wiper alignment fault the following troubleshooting procedure applies to this error: initial actions • check wiper alignment. • check damage, debris, or ink build-up near the pri...

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    10/2006 2-13 phaser 8510/8560mfp multifunction product 4,0xx.6x, 5,0xx.4x error messages and codes initial issue 4,0xx.6x process control program faults a firmware communications error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and re...

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    10/2006 2-14 phaser 8510/8560mfp multifunction product 5,0xx.4x, 5,0xx.6x initial issue error messages and codes 5,0xx.6x y-axis sub-system program faults a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if th...

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    10/2006 2-15 phaser 8510/8560mfp multifunction product 6,0xx.4x, 6,0xx.6x error messages and codes initial issue 6,0xx.4x x-axis fault an x-axis drive error has occurred. The following troubleshooting procedure applies to this error: initial actions • check for ink build-up or other obstructions aro...

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    10/2006 2-16 phaser 8510/8560mfp multifunction product 7,002.44, 7,006.4x initial issue error messages and codes 7,002.44 process drive fault a process drive error has occurred. The following troubleshooting procedure applies to this error: initial actions • check that the process drive gear train i...

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    10/2006 2-17 phaser 8510/8560mfp multifunction product 7,007.49, 7,008.41 error messages and codes initial issue 7,007.49 process drive fault a process drive or printhead error has occurred. The following troubleshooting procedures applies to this error: initial actions • check that the process driv...

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    10/2006 2-18 phaser 8510/8560mfp multifunction product 7,008.41, 7,009.42 initial issue error messages and codes 7,009.42 printhead restraint fault a process drive or printhead error has occurred. The following troubleshooting procedure applies to this error: initial actions • check for obstructions...

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    10/2006 2-19 phaser 8510/8560mfp multifunction product 7,009.42, 7,01x.4x error messages and codes initial issue 7,01x.4x process faults a process drive or printhead error has occurred. The following troubleshooting procedures apply to these errors: initial actions • check that the process drive gea...

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    10/2006 2-20 phaser 8510/8560mfp multifunction product 7,01x.4x, 7,0xx.6x initial issue error messages and codes 7,0xx.6x program faults a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if the problem persists...

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    10/2006 2-21 phaser 8510/8560mfp multifunction product 8,0xx.4x error messages and codes initial issue 8,0xx.4x wiper or media drive faults a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • check for paper in the paper path. • check the...

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    10/2006 2-22 phaser 8510/8560mfp multifunction product 8,0xx.6x, 9,0xx.4x initial issue error messages and codes 8,0xx.6x media drive program faults a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if the prob...

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    10/2006 2-23 phaser 8510/8560mfp multifunction product 9,0xx.4x, 9,009.44 and 9,00x.6x error messages and codes initial issue troubleshooting procedure 9,009.44 and 9,00x.6x ink loader program faults a software error has occurred. The following troubleshooting procedure applies to these errors: init...

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    10/2006 2-24 phaser 8510/8560mfp multifunction product 11,0xx.Xx initial issue error messages and codes 11,0xx.Xx electronics module interface faults a communications error has occurred. The following troubleshooting procedure applies to these errors: initial actions • check that all system grounds ...

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    10/2006 2-25 phaser 8510/8560mfp multifunction product 11,100.60, 12,000.60 error messages and codes initial issue 11,100.60 electronics module temperature fault the root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting proc...

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    10/2006 2-26 phaser 8510/8560mfp multifunction product 13,000.48, 13,003.42 and 13,007.46 initial issue error messages and codes 13,000.48 printhead thermal fault a thermal error is detected in the printhead. The following troubleshooting procedure applies to this error: initial actions • check that...

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    10/2006 2-27 phaser 8510/8560mfp multifunction product 13,008.47 error messages and codes initial issue 13,008.47 and 13,010.49 drum thermal faults a drum assembly thermal error has occurred. The following troubleshooting procedures apply to these errors: initial actions • check that all system grou...

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    10/2006 2-28 phaser 8510/8560mfp multifunction product 13,067.43, 13,069.45, 13,071.47, 13,xxx.4x initial issue error messages and codes 13,067.43, 13,069.45, 13,071.47 drum temp sensor faults a drum temperature sensor error has occurred. The following troubleshooting procedures apply to these error...

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    10/2006 2-29 phaser 8510/8560mfp multifunction product 13,1xx.4x, 13,2xx.4x error messages and codes initial issue 13,1xx.4x left jetstack thermal faults a thermal error in the printhead jetstack has occurred. The following troubleshooting proce- dures apply to these errors: initial actions • check ...

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    10/2006 2-30 phaser 8510/8560mfp multifunction product 13,xxx.Xx printhead reservoir, 13,xxx.Xx initial issue error messages and codes 13,xxx.Xx printhead reservoir thermal faults a printhead reservoir thermal error has occurred. The following troubleshooting procedures apply to these errors: initia...

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    10/2006 2-31 phaser 8510/8560mfp multifunction product 13,xxx.Xx, 13,00x.6x error messages and codes initial issue troubleshooting procedures 13,00x.6x thermal program faults a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram...

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    10/2006 2-32 phaser 8510/8560mfp multifunction product 19,0xx.4x, 19,0xx.6x initial issue error messages and codes 19,0xx.4x printhead calibration faults the root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting procedure ap...

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    10/2006 2-33 phaser 8510/8560mfp multifunction product 21,000.69, 22,0xx.6x error messages and codes initial issue 21,000.69 diagnostic firmware version mismatch a software error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. ...

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    10/2006 2-34 phaser 8510/8560mfp multifunction product 23,0xx.6x, 26,0xx.6x initial issue error messages and codes 23,0xx.6x nvram faults an nvram error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if the problem persists,...

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    10/2006 2-35 phaser 8510/8560mfp multifunction product 27,0xx.6x, 29,0xx.6x error messages and codes initial issue 27,0xx.6x profile library a profile library error has occurred. The following troubleshooting procedure applies to these errors: initial actions • reset nvram and retest. • if the probl...

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    10/2006 2-36 phaser 8510/8560mfp multifunction product 31,001.40, 31,0xx.6x initial issue error messages and codes 31,001.40 mechanical initialization jam a software error has occurred. The following troubleshooting procedure applies to this error: initial actions • check routing of tray sensor harn...

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    10/2006 2-37 phaser 8510/8560mfp multifunction product 33,00x.4x, 34,00x.4x error messages and codes initial issue 33,00x.4x tray 1 width sensor faults the paper width sensor, located in the tray 1/front door assembly is reporting out of range values. The following troubleshooting procedure applies ...

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    10/2006 2-38 phaser 8510/8560mfp multifunction product 36,000.40, 36,001.67 initial issue error messages and codes 36,000.40 drum maintenance faults an error occurred while attempting to position the drum maintenance kit. The following trou- bleshooting procedure applies to these errors: initial act...

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    10/2006 2-39 phaser 8510/8560mfp multifunction product 36,002.44, 37,0xx.Xx error messages and codes initial issue 36,002.44 drum maintenance kit fault an error occurred while attempting to position the drum maintenance kit. The following trou- bleshooting procedure applies to this error: initial ac...

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    10/2006 2-40 phaser 8510/8560mfp multifunction product 37,01x.41, 37,016.43 initial issue error messages and codes 37,01x.41 pest fan faults an fan error has occurred. The following troubleshooting procedure applies to these errors: initial actions • check the electronics module and drum cooling fan...

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    10/2006 2-41 phaser 8510/8560mfp multifunction product 37,016.43, 37,0xx.4x error messages and codes initial issue 37,0xx.4x pest clutch/solenoid faults an heating error has occurred. The following troubleshooting procedure applies to these errors: initial actions • check the indicated component for...

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    10/2006 2-42 phaser 8510/8560mfp multifunction product 37,024.48, 37,026.44 initial issue error messages and codes 37,024.48 pest tray 2 lift motor fault an error has occurred related to the tray 2 lift motor. The following troubleshooting procedure applies to this error:. Initial actions • check th...

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    10/2006 2-43 phaser 8510/8560mfp multifunction product 37,02x.4x, 37,03x.4x error messages and codes initial issue 37,02x.4x pest relay board faults an relay board error has occurred. The following troubleshooting procedure applies to these errors: initial actions • check the relay board’s power con...

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    10/2006 2-44 phaser 8510/8560mfp multifunction product 37,035.44 and 37,036.45, 37,037.46 and 37,038.47 initial issue error messages and codes 37,035.44 and 37,036.45 pest y-axis motor faults a y-axis motor error has occurred. The following troubleshooting procedure applies to these errors: initial ...

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    10/2006 2-45 phaser 8510/8560mfp multifunction product 37,039.48 and 37,040.40, 37,0xx.4x error messages and codes initial issue 37,039.48 and 37,040.40 pest process drive faults a y-axis motor error has occurred. The following troubleshooting procedure applies to these errors: initial actions • che...

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    10/2006 2-46 phaser 8510/8560mfp multifunction product 37,0xx.4x, 39,002.40 and 39,003.41 initial issue error messages and codes troubleshooting procedure 39,002.40 and 39,003.41 scanner subsystem test faults a scanner dram or optical self test error has occurred. The following troubleshooting proce...

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    10/2006 2-47 phaser 8510/8560mfp multifunction product 39,004.42 , 39,005.43 error messages and codes initial issue 39,004.42 scanhead locked or shipping restraint faults a scanner self test determined the scanhead was either locked, or the shipping restraint remained. The following troubleshooting ...

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    10/2006 2-48 phaser 8510/8560mfp multifunction product 39,005.43 , 39,010.8 initial issue error messages and codes 39,010.8 document feeder disconnected or missing the system could not detect the dadf. The following troubleshooting procedure applies to this error: initial actions • check the dadf co...

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    10/2006 2-49 phaser 8510/8560mfp multifunction product 39,011.40 and 39,012.40, 39,013.42 error messages and codes initial issue 39,011.40 and 39,012.40 dadf subsystem test faults the dadf dram or optical self test error has occurred. The following troubleshooting proce- dure applies to these errors...

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    10/2006 2-50 phaser 8510/8560mfp multifunction product 39,014.43 , jam codes initial issue error messages and codes 39,014.43 document feeder calibration fault a calibration faults is detected in the dadf. The following troubleshooting procedure applies to this error: initial actions • check that th...

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    10/2006 2-51 phaser 8510/8560mfp multifunction product jam codes error messages and codes initial issue a2f deskew sensor in unexpected state. 1. Check system grounding. 2. Verify all doors and covers are fully closed and not moving during printing. A2j deskew flag sensor event during head purge. A2...

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    10/2006 2-52 phaser 8510/8560mfp multifunction product jam codes initial issue error messages and codes c2c c2d c2e c2f c2k c2m c2n c2p c2q c2r c2t strip flag unexpected event during mechanical recovery. Strip flag unexpected state during warm-up. Strip flag unexpected event during system ready. Str...

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    10/2006 2-53 phaser 8510/8560mfp multifunction product jam codes error messages and codes initial issue e2d e2e e2q tray 1 width sensor during warm-up. Tray 1 width sensor during operation. Tray 1 width sensor during tray 1 pick 1. Check the tray 1 width guides for proper operation. Verify the guide...

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    10/2006 2-54 phaser 8510/8560mfp multifunction product jam codes initial issue error messages and codes n4a n4b n4c n4d nfe n4f n4g n4h n4j n4k n4l n4s n4t n4v n4w n4x y-axis motor stalled on power-up following an abnormal shutdown. Y-axis motor stalled on power-up following a normal shutdown. Y-axi...

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    10/2006 2-55 phaser 8510/8560mfp multifunction product jam codes error messages and codes initial issue t2a t2b t2c t2d t2e t2f t2g t2h t2j t2k t2l t2m t2n t2p t2q t2r t2s t2t t2x t2z exit door interlock tripped following an abnormal shutdown. Exit door interlock tripped following a normal shutdown....

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    10/2006 2-56 phaser 8510/8560mfp multifunction product jam codes initial issue error messages and codes x3d x3e x3f x3k x3l x3m x3n x3p x3q x3r x3s x3t x3v x3w x3x tray 3 pick flag timed-out during warm-up. Tray 3 pick flag timed-out during ready state. Tray 3 pick flag timed-out during a fault stat...

  • Page 83

    10/2006 3-1 phaser 8510/8560mfp multifunction product image quality initial issue 3 image quality iq1 iot image quality entry rap .................................................................................. 3-3 iq2 dark streaks on copied image .....................................................

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    10/2006 3-2 phaser 8510/8560mfp multifunction product initial issue image quality.

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    10/2006 3-3 phaser 8510/8560mfp multifunction product iq1 image quality initial issue iq1 iot image quality entry rap the purpose of this rap is to establish the source of the imaging defect. After following the ini- tial actions, select the rap that best describes the observed defect. Initial actio...

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    10/2006 3-4 phaser 8510/8560mfp multifunction product iq2, iq3 initial issue image quality iq2 dark streaks on copied image this rap addresses image quality problems associated with the dadf. Initial actions 1. Check that supported media is being used. 2. Check for ink build-up or debris. Clean if n...

  • Page 87

    10/2006 3-5 phaser 8510/8560mfp multifunction product iq4, iq6 image quality initial issue iq4 skewed copy image this rap addresses image quality problems associated with the dadf. See the skew and margins test print discussion. Initial actions 1. Reset the media guides on the dadf input tray. 2. Ch...

  • Page 88

    10/2006 3-6 phaser 8510/8560mfp multifunction product iq5, iq7 initial issue image quality iq5 copy image is lighter or darker than the original this rap addresses image quality problems associated with the dadf. Initial actions 1. Check that supported media is being used. 2. Reseat all dadf connect...

  • Page 89

    10/2006 3-7 phaser 8510/8560mfp multifunction product iq8, iq9 image quality initial issue iq8 dark streaks on copied image this rap addresses image quality problems associated with the scanner assembly. Initial actions 1. Check that supported media is being used. 2. Reseat all cable connections bet...

  • Page 90

    10/2006 3-8 phaser 8510/8560mfp multifunction product iq10, iq11 initial issue image quality iq10 copy image is lighter or darker than the original this rap addresses image quality problems associated with the dadf. Initial actions 1. Check that supported media is being used. 2. Reseat all cable con...

  • Page 91

    10/2006 3-9 phaser 8510/8560mfp multifunction product iq12, iq13 image quality initial issue iq12 fuzzy text or image this rap addresses image quality problems associated with the dadf. Initial actions 1. Check that supported media is being used. 2. Reseat all cable connections between the scanner a...

  • Page 92

    10/2006 3-10 phaser 8510/8560mfp multifunction product iq13, iq14 initial issue image quality initial actions 1. Check that supported media is being used. 2. Run the eliminate light stripes routine from the control panel. Procedure note: if the eliminate light stripes page indicates that the missing...

  • Page 93

    10/2006 3-11 phaser 8510/8560mfp multifunction product iq15, iq16 image quality initial issue iq15 smudges or smears this rap addresses image quality problems associated with the print engine. Smudges or smears typically result from ink residue in the paper path. Residue can collect on the rollers, ...

  • Page 94

    10/2006 3-12 phaser 8510/8560mfp multifunction product iq17, iq18 initial issue image quality iq17 no image is printed this rap addresses image quality problems associated with the print engine. The printer pro- cesses a sheet of paper, but no image appears on the output. Note: blank sheets accompan...

  • Page 95

    10/2006 3-13 phaser 8510/8560mfp multifunction product iq18, iq19 image quality initial issue iq19 streaks or lines down the print this rap addresses image quality problems associated with the print engine. Streaking or lines typically result from parts in contact with the drum, dirty wiper blade, o...

  • Page 96

    10/2006 3-14 phaser 8510/8560mfp multifunction product iq19, iq20 initial issue image quality iq20 scratches or marks parallel to the long axis of printing this rap addresses image quality problems associated with the print engine. Scratches or marks typically result from debris in the paper path. I...

  • Page 97

    10/2006 3-15 phaser 8510/8560mfp multifunction product iq20, iq21 image quality initial issue iq21 ink on the white portion of the printed page this rap addresses image quality problems associated with the print engine. Color appearing on blank areas of the output is called latent image. Latent imag...

  • Page 98

    10/2006 3-16 phaser 8510/8560mfp multifunction product iq21, iq22 initial issue image quality iq22 fuzzy text this rap addresses image quality problems associated with the print engine. Fuzzy text typi- cally results from one of the three causes illustrated. An error in y-axis drum rotation results ...

  • Page 99

    10/2006 3-17 phaser 8510/8560mfp multifunction product iq22, iq23 image quality initial issue iq23 poor primary color fill this rap addresses image quality problems associated with the print engine. Poor primary color fills typically result from obstructed jets. X-axis errors may also cause banding....

  • Page 100

    10/2006 3-18 phaser 8510/8560mfp multifunction product iq23, iq24 initial issue image quality iq24 ghosting this rap addresses image quality problems associated with the print engine. Ghosting typi- cally results from stacked prints, faulty or expended drum maintenance kit, or drum thermal regulatio...

  • Page 101

    10/2006 3-19 phaser 8510/8560mfp multifunction product iq24, iq25 image quality initial issue iq25 poor small text resolution this rap addresses image quality problems associated with the print engine. Poor text resolu- tion typically results from drum thermal regulation, or x-axis drive problems. P...

  • Page 102

    10/2006 3-20 phaser 8510/8560mfp multifunction product iq26, iq27 initial issue image quality iq26 vertical lines appear wavy this rap addresses image quality problems associated with the print engine. Wavy or ill- formed vertical lines typically result from excessive drum oiling. An error in x-axis...

  • Page 103

    10/2006 3-21 phaser 8510/8560mfp multifunction product iq27, iq28 image quality initial issue iq28 incomplete image transfer this rap addresses image quality problems associated with the print engine. Incomplete image transfer typically results from coarse, underweight, or watermarked media. Incompl...

  • Page 104

    10/2006 3-22 phaser 8510/8560mfp multifunction product iq28, iq29 initial issue image quality iq29 ink smears on first side of duplex print this rap addresses image quality problems associated with the print engine. Ink smearing typically results from dirt or debris in the paper path, or the preheat...

  • Page 105

    10/2006 3-23 phaser 8510/8560mfp multifunction product iq30, iq31 image quality initial issue iq30 repeating print defects this rap addresses image quality problems associated with the print engine. Repeating defects typically result from dirt, debris, or damage to an imaging component. The interval...

  • Page 106

    10/2006 3-24 phaser 8510/8560mfp multifunction product iq32, iq33 initial issue image quality iq32 wrinkling this rap addresses image quality problems associated with the print engine. Wrinkling gen- erally appears in areas of solid fill near the image edge. This problem is more often seen on short-...

  • Page 107

    10/2006 3-25 phaser 8510/8560mfp multifunction product iq34, image quality initial issue iq34 poor ink adhesion, poor image durability this rap addresses image quality problems associated with the print engine. Poor ink adhe- sion generally appears as a result of a overly glossy media coatings, or i...

  • Page 108

    10/2006 3-26 phaser 8510/8560mfp multifunction product initial issue image quality x-axis motion (drop mass evaluation) for x-axis motion problems, see solid fill test prints. This print is used by engineering and manufacturing. The print must be printed on xerox photo paper. Using a lower grade pap...

  • Page 109

    10/2006 3-27 phaser 8510/8560mfp multifunction product image quality initial issue figure 5 test print 5 big bands ohp grey fill, dot size uniformity this print is made up of a 66% black fill. It reveals variations in the ink-drop-spread caused by thermal variations, transfix roller pressure variati...

  • Page 110

    10/2006 3-28 phaser 8510/8560mfp multifunction product initial issue image quality figure 7 ymckrgb solid fill test prints causes: • weak jets or improper drum heating can cause uneven fills. • to solve wrinkling, try different print media. Replace the maintenance kit to correct streak- ing. Check t...

  • Page 111

    10/2006 3-29 phaser 8510/8560mfp multifunction product image quality initial issue figure 9 single primary solid fill test prints look for: 1. Even, uniform fills throughout the print. 2. There should be no wrinkling or deformity of the paper throughout the print. 3. Poor transfer on one side. 4. Re...

  • Page 112

    10/2006 3-30 phaser 8510/8560mfp multifunction product initial issue image quality figure 10 skew and margin measurement banding this print is used by manufacturing. Head roll this print is used by manufacturing. Head height this print is used by manufacturing. X dot position this print is used by m...

  • Page 113

    10/2006 3-31 phaser 8510/8560mfp multifunction product jet substitution mode image quality initial issue jet substitution mode jet substitution mode provides a solution for print-quality problems when weak or missing jets are not recoverable by cleaning. This mode substitutes adjacent jets to print ...

  • Page 114

    10/2006 3-32 phaser 8510/8560mfp multifunction product jet substitution mode initial issue image quality.

  • Page 115

    10/2006 4-1 phaser 8510/8560mfp multifunction product repairs and adjustments initial issue 4 repairs and adjustments disassembly overview .................................................................................................... 4-3 rep 1.0.1 front door / tray 1 assembly.....................

  • Page 116

    10/2006 4-2 phaser 8510/8560mfp multifunction product initial issue repairs and adjustments.

  • Page 117

    10/2006 4-3 phaser 8510/8560mfp multifunction product disassembly overview repairs and adjustments initial issue disassembly overview this section contains the removal procedures for field-replaceable parts of the system listed in the parts list. In most cases, the replacement procedure is simply th...

  • Page 118

    10/2006 4-4 phaser 8510/8560mfp multifunction product disassembly overview, rep 1.0.1 initial issue repairs and adjustments recommended tool kit table 1 lists basic, recommended, and optional tools used to service this and other similar products. Rep 1.0.1 front door / tray 1 assembly parts list on ...

  • Page 119

    10/2006 4-5 phaser 8510/8560mfp multifunction product rep 1.0.6 repairs and adjustments initial issue rep 1.0.6 output tray parts list on pl 1.0 removal 1. Open the front cover. Figure 1 output paper tray retaining tabs 2. Spread the left and right sides of the output tray to release the 2 tabs on t...

  • Page 120

    10/2006 4-6 phaser 8510/8560mfp multifunction product rep 1.0.7, rep 1.0.8 initial issue repairs and adjustments rep 1.0.7 left side cover parts list on pl 1.0 removal 1. Open the front door. 2. Remove the output tray (rep 1.0.6). 3. Remove the scanner assembly with attached dadf (rep 1.0.11). 4. Re...

  • Page 121

    10/2006 4-7 phaser 8510/8560mfp multifunction product rep 1.0.8, rep 1.0.9 repairs and adjustments initial issue figure 2 removing the scanner hinges rep 1.0.9 control panel parts list on pl 1.0 removal 1. Open the scanner assembly. 2. Remove 2 (plastic, t-20) screws that secure the control panel to...

  • Page 122

    10/2006 4-8 phaser 8510/8560mfp multifunction product rep 1.0.11, rep 1.0.13 initial issue repairs and adjustments rep 1.0.11 scanner assembly parts list on pl 1.0 removal caution lock the scanhead before removing the assembly. A utility for locking the scanhead is pro- vided in the service tools me...

  • Page 123

    10/2006 4-9 phaser 8510/8560mfp multifunction product rep 1.0.13 , rep 1.0.15 repairs and adjustments initial issue figure 2 dadf front cover removal 4. Lift the dadf front cover to remove. Rep 1.0.15 duplex automatic document feeder parts list on pl 1.0 removal 1. Disconnect the dadf cable from the...

  • Page 124

    10/2006 4-10 phaser 8510/8560mfp multifunction product rep 1.0.19, rep 1.0.20 initial issue repairs and adjustments rep 1.0.19 duplex automatic document feeder hinges parts list on pl 1.0 removal 1. Remove the dadf (rep 1.0.11). 2. Remove the 4 (plastic, t-20) screws that secure each hinge to the da...

  • Page 125

    10/2006 4-11 phaser 8510/8560mfp multifunction product rep 1.0.21, rep 1.0.28 repairs and adjustments initial issue rep 1.0.21 right side cover parts list on pl 1.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Open the front door. 3. Remove the output tray (rep 1.0.6). ...

  • Page 126

    10/2006 4-12 phaser 8510/8560mfp multifunction product rep 1.0.29, rep 2.0.1 initial issue repairs and adjustments rep 1.0.29 document cover hinges parts list on pl 1.0 removal 1. Remove the document cover (rep 1.0.28). 2. Remove the 4 (plastic, t-20) screws that secure each hinge to the cover. Figu...

  • Page 127

    10/2006 4-13 phaser 8510/8560mfp multifunction product rep 2.0.1 repairs and adjustments initial issue figure 2 removing the ink loader 6. Disconnect the ink loader power harness p/j5 from the electronics module. 7. Remove the ink loader harness from the retaining clip on the right side, and then di...

  • Page 128

    10/2006 4-14 phaser 8510/8560mfp multifunction product rep 2.0.2 initial issue repairs and adjustments rep 2.0.2 printhead assembly parts list on pl 2.0 removal note: use the printhead troubleshooting checklist to troubleshoot printhead operation before replacement. A copy of this checklist is inclu...

  • Page 129

    10/2006 4-15 phaser 8510/8560mfp multifunction product rep 2.0.2 repairs and adjustments initial issue figure 2 lowering the printhead wiper assembly 9. Move the printhead tilt spring from its position on the printhead and hook it behind itself as shown in figure 3. Figure 3 releasing the printhead ...

  • Page 130

    10/2006 4-16 phaser 8510/8560mfp multifunction product rep 2.0.2 initial issue repairs and adjustments figure 4 x-axis bias spring hook 11. Disconnect the air hose from the purge pump. 12. Remove the left and right printhead restraints. To remove the restraints, remove 1 (plas- tic, t-20) screw that...

  • Page 131

    10/2006 4-17 phaser 8510/8560mfp multifunction product rep 2.0.2 repairs and adjustments initial issue figure 7 removing the roll block note: the check mark on the label indicates the proper orientation of the roll block. 14. Disconnect the printhead heater harness p/j3 and free the harness from the...

  • Page 132

    10/2006 4-18 phaser 8510/8560mfp multifunction product rep 2.0.2 initial issue repairs and adjustments 18. Disconnect the remaining 2 ribbon cables p/j180 and p/j240 from the printhead. Figure 10 printhead cable connections 19. Remove the printhead as shown in figure 11, using the finger recesses pr...

  • Page 133

    10/2006 4-19 phaser 8510/8560mfp multifunction product rep 2.0.2, rep 2.0.3 repairs and adjustments initial issue 12. Install the ink loader. 13. Perform adj 4.13.1 to home the head tilt gear. 14. Reassemble the remaining components, and turn system power on. 15. Print the light stripes page. Check ...

  • Page 134

    10/2006 4-20 phaser 8510/8560mfp multifunction product rep 2.0.3 initial issue repairs and adjustments 15. Unplug the drum heater harness p/j200 from the relay board and free the harness from the retaining hook. Figure 2 disconnecting the drum 16. Disconnect the drum encoder harness p/j120 from the ...

  • Page 135

    10/2006 4-21 phaser 8510/8560mfp multifunction product rep 2.0.3 repairs and adjustments initial issue 5. Install 1 (metal, hex-head) screw and washer at the rear position on the right-side to hold the drum assembly and torque the screw to 25 in.-lbs. 6. Install the remaining (metal, hex-head) screw...

  • Page 136

    10/2006 4-22 phaser 8510/8560mfp multifunction product rep 2.0.3 initial issue repairs and adjustments figure 5 exit module left side fasteners 14. Apply a small quantity of rheolube 768 grease (p/n 070e00890) to the groove on the transfix load arms. Note: ensure that you lever the spring cam toward...

  • Page 137

    10/2006 4-23 phaser 8510/8560mfp multifunction product rep 2.0.3, rep 2.0.4 repairs and adjustments initial issue 31. Install the inner simplex guide. 32. Install all covers, doors, and the output tray. 33. Install the scanner and dadf. 34. Perform the wiper alignment adjustment (adj 2.5.1). 35. Per...

  • Page 138

    10/2006 4-24 phaser 8510/8560mfp multifunction product rep 2.0.5 initial issue repairs and adjustments rep 2.0.5 printhead wiper blade and wiper belt parts list on pl 2.0 removal place several sheets of paper between the printhead and drum before servicing the printhead wiper. 1. Remove the printhea...

  • Page 139

    10/2006 4-25 phaser 8510/8560mfp multifunction product rep 2.0.7, rep 2.0.8 repairs and adjustments initial issue rep 2.0.7 purge pressure pump parts list on pl 2.0 removal 1. Remove the left side cover (rep 1.0.7). 2. Disconnect the purge pump hose from the pump. 3. Disconnect the harness from the ...

  • Page 140

    10/2006 4-26 phaser 8510/8560mfp multifunction product rep 2.0.8 initial issue repairs and adjustments figure 2 lowering the printhead wiper blade 9. Hold the printhead away from the drum and push down on the left and right printhead restraint arms to release the printhead tilt spring tension. Figur...

  • Page 141

    10/2006 4-27 phaser 8510/8560mfp multifunction product rep 2.0.8 repairs and adjustments initial issue figure 4 x-axis bias spring hook 11. Disconnect the air hose from the purge pump. 12. Remove 1 (plastic, t-20) screw that secures each printhead restraint, and then shift the restraint inwards towa...

  • Page 142

    10/2006 4-28 phaser 8510/8560mfp multifunction product rep 2.0.8, rep 2.0.10 initial issue repairs and adjustments replacement check that the left printhead restraint does not interfere with the roll block. Also, make sure the tilt spring on the left printhead restraint is properly positioned in the...

  • Page 143

    10/2006 4-29 phaser 8510/8560mfp multifunction product rep 2.0.10, rep 2.0.11 repairs and adjustments initial issue figure 2 removing the transfix camshaft rep 2.0.11 drum maintenance camshaft parts list on pl 2.0 removal 1. Remove the drum maintenance pivot plate (rep 2.0.16). 2. Remove the process...

  • Page 144

    10/2006 4-30 phaser 8510/8560mfp multifunction product rep 2.0.12 initial issue repairs and adjustments rep 2.0.12 stripper carriage assembly parts list on pl 2.0 removal 1. Remove the scanner assembly and attached dadf (rep 1.0.11). 2. Remove the right side cover (rep 1.0.21). 3. Remove the output ...

  • Page 145

    10/2006 4-31 phaser 8510/8560mfp multifunction product rep 2.0.13 repairs and adjustments initial issue rep 2.0.13 transfix roller parts list on pl 2.0 removal 1. Remove the scanner assembly and attached dadf (rep 1.0.11). 2. Remove the right side cover (rep 1.0.21). 3. Remove the output tray (rep 1...

  • Page 146

    10/2006 4-32 phaser 8510/8560mfp multifunction product rep 2.0.14, rep 2.0.15 initial issue repairs and adjustments rep 2.0.14 y-axis spring parts list on pl 2.0 removal 1. Remove the scanner assembly and attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left side cove...

  • Page 147

    10/2006 4-33 phaser 8510/8560mfp multifunction product rep 2.0.15 repairs and adjustments initial issue figure 2 removing the transfix load arm clevis pins 12. Disconnect the preheater lift solenoid p/j202 from the harness. 13. Remove the screw that secures the preheater lift solenoid to the transfi...

  • Page 148

    10/2006 4-34 phaser 8510/8560mfp multifunction product rep 2.0.15 initial issue repairs and adjustments figure 4 transfix load module ground strap removal 15. Remove 4 (metal, t-20) screws, 2 at each end, that secure the transfix load module to the chassis. Figure 5 transfix load module fasteners 16...

  • Page 149

    10/2006 4-35 phaser 8510/8560mfp multifunction product rep 2.0.15, rep 2.0.16 repairs and adjustments initial issue replacement place a small amount of rheolube 768 grease (p/n 070e00890) in the groove at the end of each transfix load arm before reattaching the spring hooks. Also, when replacing the...

  • Page 150

    10/2006 4-36 phaser 8510/8560mfp multifunction product rep 2.0.16, rep 2.0.17 initial issue repairs and adjustments figure 2 removing the drum maintenance pivot plate replacement lightly grease the metal plates on the underneath side of the pivot plate using a small amount of rheolube 768 grease (p/...

  • Page 151

    10/2006 4-37 phaser 8510/8560mfp multifunction product rep 2.0.17, rep 2.0.21 repairs and adjustments initial issue figure 2 removing the preheater 6. Slide the preheater out of the chassis. Replacement note: check that the connector p/j0670 on the back of the preheater board is secure before instal...

  • Page 152

    10/2006 4-38 phaser 8510/8560mfp multifunction product rep 2.0.22, rep 3.0.1 initial issue repairs and adjustments rep 2.0.22 preheater lift solenoid parts list on pl 2.0 removal 1. Remove the scanner assembly and attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left ...

  • Page 153

    10/2006 4-39 phaser 8510/8560mfp multifunction product rep 3.0.2, rep 3.0.3 repairs and adjustments initial issue rep 3.0.2 lower duplex guide parts list on pl 3.0 removal 1. Open the front door. 2. Pull outward on the tabs at the bottom of the guide and let the guide swing free. 3. Pry inward, towa...

  • Page 154

    10/2006 4-40 phaser 8510/8560mfp multifunction product rep 3.0.4, rep 3.0.5 initial issue repairs and adjustments rep 3.0.4 duplex roller parts list on pl 3.0 removal 1. Open the front door. 2. Remove the outer duplex guide (rep 3.0.6). 3. Remove the lower inner duplex guide (rep 3.0.2). 4. Remove t...

  • Page 155

    10/2006 4-41 phaser 8510/8560mfp multifunction product rep 3.0.5, rep 3.0.6 repairs and adjustments initial issue replacement route the solenoid harness through the right side of the frame. Also, route the guide under the edges of the exit module frame. Check that the stripper solenoid actuator enga...

  • Page 156

    10/2006 4-42 phaser 8510/8560mfp multifunction product rep 3.0.7 initial issue repairs and adjustments rep 3.0.7 exit module parts list on pl 3.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left side cover (rep 1.0.7). ...

  • Page 157

    10/2006 4-43 phaser 8510/8560mfp multifunction product rep 3.0.7, rep 3.0.14 repairs and adjustments initial issue figure 3 exit module harness connections 9. Lift the exit module from the chassis. Replacement transfer the front exit module harness to the replacement part, and perform adj 2.5.1 afte...

  • Page 158

    10/2006 4-44 phaser 8510/8560mfp multifunction product rep 3.0.18 initial issue repairs and adjustments rep 3.0.18 pick and retard rollers parts list on pl 3.0 removal the pick roller catch is located on the ceiling of the tray cavity about 1/4 of the way across the unit from the right side, and abo...

  • Page 159

    10/2006 4-45 phaser 8510/8560mfp multifunction product rep 4.0.3, rep 4.0.4 repairs and adjustments initial issue rep 4.0.3 scanner power supply fan parts list on pl 4.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left ...

  • Page 160

    10/2006 4-46 phaser 8510/8560mfp multifunction product rep 4.0.5, rep 4.0.6 initial issue repairs and adjustments rep 4.0.5 x-axis motor parts list on pl 4.0 removal 1. Remove the right side cover (rep 1.0.21). 2. Disconnect the x-axis motor (p/j150) from the right side harness. 3. Remove 4 (plastic...

  • Page 161

    10/2006 4-47 phaser 8510/8560mfp multifunction product rep 4.0.7 repairs and adjustments initial issue rep 4.0.7 process drive parts list on pl 4.0 removal caution if the process drive is being reinstalled, pin the gears using the holes provided in the process drive frame (figure 1) to maintain gear...

  • Page 162

    10/2006 4-48 phaser 8510/8560mfp multifunction product rep 4.0.8, rep 4.0.9 initial issue repairs and adjustments rep 4.0.8 exit roller motor parts list on pl 4.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the right side c...

  • Page 163

    10/2006 4-49 phaser 8510/8560mfp multifunction product rep 4.0.10, rep 4.0.11 repairs and adjustments initial issue rep 4.0.10 tray 2 lift motor gear parts list on pl 4.0 removal 1. Remove the electronics module (rep 5.0.5). 2. Remove tray 2. 3. Remove the lift motor gear by prying the push nut off ...

  • Page 164

    10/2006 4-50 phaser 8510/8560mfp multifunction product rep 4.0.11 initial issue repairs and adjustments 7. Disconnect the motor (p/j18) from the electronics module and remove the harness from the cable guide. 8. Disconnect the tray 1 pick solenoid (p/j241) from the harness. 9. Disconnect the tray 2 ...

  • Page 165

    10/2006 4-51 phaser 8510/8560mfp multifunction product rep 4.0.12, rep 4.0.13 repairs and adjustments initial issue rep 4.0.12 tray 1 pick solenoid parts list on pl 4.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left s...

  • Page 166

    10/2006 4-52 phaser 8510/8560mfp multifunction product rep 4.0.13, rep 4.0.14 initial issue repairs and adjustments figure 2 removing the tray 2 lift motor replacement check that the bushing tabs are properly seated in the chassis. To seat the new push nut, position the push nut so the fingers point...

  • Page 167

    10/2006 4-53 phaser 8510/8560mfp multifunction product rep 4.0.14 repairs and adjustments initial issue figure 1 media drive assembly electrical connections 7. Remove 6 (plastic, t-20) screws that secure the media drive assembly to the frame. Figure 2 removing the media drive assembly replacement to...

  • Page 168

    10/2006 4-54 phaser 8510/8560mfp multifunction product rep 4.0.15, rep 4.0.16 initial issue repairs and adjustments rep 4.0.15 electronics module cooling fan parts list on pl 4.0 removal 1. Remove the scanner assembly and attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove t...

  • Page 169

    10/2006 4-55 phaser 8510/8560mfp multifunction product rep 4.0.16 repairs and adjustments initial issue figure 2 removing the x-axis spring retainer 6. Unlock the wiper blade and raise the wiper blade to the top of its travel. 7. Raise the exit elevator. 8. Remove the waste tray cover without discon...

  • Page 170

    10/2006 4-56 phaser 8510/8560mfp multifunction product rep 4.0.16, rep 4.0.18 initial issue repairs and adjustments figure 5 head tilt spring alignment 4. Seat the gear by lifting the head tilt solenoid actuator. 5. Replace the kl-clip on the end of the head tilt gear shaft. 6. Perform the head tilt...

  • Page 171

    10/2006 4-57 phaser 8510/8560mfp multifunction product rep 4.0.20 repairs and adjustments initial issue rep 4.0.20 head tilt solenoid parts list on pl 4.0 removal 1. Remove the scanner assembly with attached dadf. 2. Remove the output tray (rep 1.0.6). 3. Remove the left side cover (rep 1.0.7). 4. R...

  • Page 172

    10/2006 4-58 phaser 8510/8560mfp multifunction product rep 5.0.1, rep 5.0.2 initial issue repairs and adjustments rep 5.0.1 exit module control board parts list on pl 5.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left...

  • Page 173

    10/2006 4-59 phaser 8510/8560mfp multifunction product rep 5.0.4 , rep 5.0.5 repairs and adjustments initial issue rep 5.0.4 wave amplifier parts list on pl 5.0 removal caution handle the ribbon cables carefully. Check that each cable is square to the socket and fully inserted. Damage to the wave am...

  • Page 174

    10/2006 4-60 phaser 8510/8560mfp multifunction product rep 5.0.7 initial issue repairs and adjustments rep 5.0.7 hard drive parts list on pl 5.0 removal 1. Loosen the thumbscrews on the back cover of the electronics module. 2. Disconnect the hard drive from the electronics module. Figure 1 removing ...

  • Page 175

    10/2006 4-61 phaser 8510/8560mfp multifunction product rep 5.0.8, rep 5.0.9 repairs and adjustments initial issue rep 5.0.8 ram parts list on pl 5.0 removal caution ram is vulnerable to esd. Review esd procedures presented in section 1. 1. Loosen the thumbscrews on the back cover of the electronics ...

  • Page 176

    10/2006 4-62 phaser 8510/8560mfp multifunction product rep 5.0.13, rep 5.0.19 initial issue repairs and adjustments rep 5.0.13 i/o board parts list on pl 5.0 removal 1. Remove the right side cover (rep 1.0.21). 2. Disconnect the harnesses from the board. 3. Remove 2 screws that secure the board to t...

  • Page 177

    10/2006 4-63 phaser 8510/8560mfp multifunction product rep 5.0.24 , rep 5.0.25 repairs and adjustments initial issue rep 5.0.24 back frame parts list on pl 5.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the left side cover...

  • Page 178

    10/2006 4-64 phaser 8510/8560mfp multifunction product rep 5.0.26, rep 6.0.1 initial issue repairs and adjustments rep 5.0.26 fdi board parts list on pl 5.0 removal 1. Remove the scanner assembly with attached dadf (rep 1.0.11). 2. Remove the output tray (rep 1.0.6). 3. Remove the right side cover (...

  • Page 179

    10/2006 4-65 phaser 8510/8560mfp multifunction product rep 6.0.2 repairs and adjustments initial issue rep 6.0.2 front door and exit door interlock switches parts list on pl 6.0 removal the same part is used for both the front door and exit door interlocks, use this procedure to replace either inter...

  • Page 180

    10/2006 4-66 phaser 8510/8560mfp multifunction product rep 6.0.4, rep 6.0.6 initial issue repairs and adjustments rep 6.0.4 drum temperature sensor parts list on pl 6.0 removal use this procedure to remove the drum temperature sensor located at the top, right side of the drum assembly. 1. Remove the...

  • Page 181

    10/2006 4-67 phaser 8510/8560mfp multifunction product rep 6.0.6, rep 6.0.7 repairs and adjustments initial issue figure 2 removing the waste tray cover 8. Disconnect the waste tray detect sensor (p/j110) from the i/o board. 9. Unlace the sensor harness from the retainers and guides. 10. Release the...

  • Page 182

    10/2006 4-68 phaser 8510/8560mfp multifunction product rep 6.0.8, rep 6.0.9 initial issue repairs and adjustments rep 6.0.8 no paper sensor parts list on pl 6.0 removal 1. Remove the front door (rep 1.0.1). 2. Remove tray 2. 3. Remove the pick roller assembly (rep 3.0.18). 4. Remove the lower duplex...

  • Page 183

    10/2006 4-69 phaser 8510/8560mfp multifunction product rep 6.0.11 repairs and adjustments initial issue rep 6.0.11 output tray full sensor parts list on pl 6.0 removal the output tray full sensor consists of two circuit boards mounted on either side of the output tray. Replace both boards when servi...

  • Page 184

    10/2006 4-70 phaser 8510/8560mfp multifunction product adj 1.15.1 initial issue repairs and adjustments adj 1.15.1 dadf to scanner calibration purpose use this adjustment procedure to calibrate a newly installed dadf to the scanner assembly. This procedure requires the scanner calibration page shown...

  • Page 185

    10/2006 4-71 phaser 8510/8560mfp multifunction product adj 1.15.1, adj 2.2.1 repairs and adjustments initial issue note: make sure the scanner calibration page is aligned correctly and the paper guides are adjusted to fit against the paper. If the page is misaligned, the calibration procedure fails....

  • Page 186

    10/2006 4-72 phaser 8510/8560mfp multifunction product adj 2.2.1 initial issue repairs and adjustments figure 1 printhead wiper blade drive 7. Rotate the drum maintenance camshaft until the printhead has moved to the parked position, which is the furthest point from the drum. Figure 2 rotating the d...

  • Page 187

    10/2006 4-73 phaser 8510/8560mfp multifunction product adj 2.5.1 repairs and adjustments initial issue adj 2.5.1 wiper blade alignment purpose to set the printhead wiper blade alignment or place the wiper blade in the home position. Adjustment to ensure wiper blade alignment, and place the blade in ...

  • Page 188

    10/2006 4-74 phaser 8510/8560mfp multifunction product adj 4.7.1, adj 4.13.1 initial issue repairs and adjustments adj 4.7.1 process drive alignment purpose to place the process drive in the home position. Caution place the printhead, head tilt gear, printhead wiper blade, and process drive in their...

  • Page 189

    10/2006 4-75 phaser 8510/8560mfp multifunction product adj 4.13.1 repairs and adjustments initial issue figure 1 disengaging the head tilt gear note: when the head tilt gear is disengaged, the two arrows on the left side of the printer align as shown in figure 1. Figure 2 head tilt gear indicator.

  • Page 190

    10/2006 4-76 phaser 8510/8560mfp multifunction product adj 4.13.1 initial issue repairs and adjustments printhead is installed adjustment 1. Remove the drum maintenance kit. 2. Rotate the drum maintenance camshaft 360 ° clockwise using a flat blade screwdriver as shown in figure 3. If the head tilt ...

  • Page 191

    10/2006 4-77 phaser 8510/8560mfp multifunction product adj 4.13.1 repairs and adjustments initial issue figure 4 head tilt gear indicator.

  • Page 192

    10/2006 4-78 phaser 8510/8560mfp multifunction product adj 4.13.1 initial issue repairs and adjustments.

  • Page 193

    10/2006 5-1 phaser 8510/8560mfp multifunction product parts list initial issue 5 parts list parts list overview ......................................................................................................... 5-3 serial number format.............................................................

  • Page 194

    10/2006 5-2 phaser 8510/8560mfp multifunction product initial issue parts list.

  • Page 195

    10/2006 5-3 phaser 8510/8560mfp multifunction product parts list overview, serial number format parts list initial issue parts list overview the parts list section identifies all part numbers and the corresponding location of all spared subsystem components. Use of the term “assembly” the term “asse...

  • Page 196

    10/2006 5-4 phaser 8510/8560mfp multifunction product pl 1.0 initial issue parts list pl 1.0 covers item part description 1 848k06520 front door / tray 1 assembly 2 120e29140 front door stay retainer 3 009k02390 front door stay with spring 4 029e49330 hinge pins, front door 5 – front door (p/o pl 1....

  • Page 197

    10/2006 5-5 phaser 8510/8560mfp multifunction product pl 2.0 parts list initial issue pl 2.0 imaging item part description 1 848k06380 ink loader – 848k06390 ink loader (metered) 2 017k04540 printhead 3 020k15090 drum assembly 4 023e30670 y-axis belt 5 033e05210 printhead wiper blade 6 023e30660 wip...

  • Page 198

    10/2006 5-6 phaser 8510/8560mfp multifunction product pl 3.0 initial issue parts list pl 3.0 paper path item part description 1 032e29480 inner simplex guide 2 038k16870 lower inner duplex guide 3 022e32420 take away roller 4 022e32410 duplex roller 5 032k04630 upper duplex guide with solenoid 6 032...

  • Page 199

    10/2006 5-7 phaser 8510/8560mfp multifunction product pl 4.0 parts list initial issue pl 4.0 drive item part description 1 – asm, motor (not spared) (dadf) 2 – dadf belt kit (not spared) 3 127e15910 scanner power supply fan 4 033e05190 head maintenance clutch 5 127k53580 x-axis motor assembly 6 127e...

  • Page 200

    10/2006 5-8 phaser 8510/8560mfp multifunction product pl 5.0 initial issue parts list pl 5.0 electrical item part description 1 960k34960 exit module control board 2 105e23670 scanner power supply 3 117e34870 cable, wave amp signal 4 960k21181 wave amplifier 5 084k35870 electronics module (w/o ram, ...

  • Page 201

    10/2006 5-9 phaser 8510/8560mfp multifunction product pl 6.0 parts list initial issue pl 6.0 sensors and actuators item part description 1 130e12570 iit cover sensor (scanner detect) 2 110e20390 front door interlock switch 3 137e24280 engine exit flag 4 130k75210 drum temperature sensor assembly 5 1...

  • Page 202

    10/2006 5-10 phaser 8510/8560mfp multifunction product xerox supplies initial issue parts list xerox supplies table 1 kits, supplies, and options description part number mechanical kit print engine: • backframe cable clamps (2 ea.) • exit module kl-clips 5 mm (5 ea.) • exit module plastic washers (2...

  • Page 203

    10/2006 6-1 phaser 8510/8560mfp multifunction product diagnostics initial issue 6 diagnostics system power on process ............................................................................................. 6-3 hidden service menu ...................................................................

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    10/2006 6-2 phaser 8510/8560mfp multifunction product initial issue diagnostics.

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    10/2006 6-3 phaser 8510/8560mfp multifunction product system power on process diagnostics initial issue system power on process use the power on sequence timing chart to troubleshoot failures that occur during the power- on sequence. The chart provides typical timing of mechanical events that occur ...

  • Page 206

    10/2006 6-4 phaser 8510/8560mfp multifunction product system power on process initial issue diagnostics mechanical engine initialization diagram figure 1 mechanical engine initialization (1/2) figure 2 mechanical engine initialization (2/2).

  • Page 207

    10/2006 6-5 phaser 8510/8560mfp multifunction product hidden service menu, service diagnostics diagnostics initial issue hidden service menu the hidden service menu provides access to a large group of information pages and functions usable for diagnosing and correcting system malfunctions and access...

  • Page 208

    10/2006 6-6 phaser 8510/8560mfp multifunction product service diagnostics initial issue diagnostics entering service diagnostics print engine tests: in general, diagnostic testing is assumed to be done with the system in a “diagnostic configuration.” this means the following applies: • doors are clo...

  • Page 209

    10/2006 6-7 phaser 8510/8560mfp multifunction product service diagnostics diagnostics initial issue from system off directly to diagnostic mode: when the system powers up in diagnostic mode, the current printhead temperature is mea- sured. If printhead reservoir temperature is greater than 110 degre...

  • Page 210

    10/2006 6-8 phaser 8510/8560mfp multifunction product service diagnostics initial issue diagnostics figure 1 service diagnostics menu (1/3) figure 2 service diagnostics menu (2/3).

  • Page 211

    10/2006 6-9 phaser 8510/8560mfp multifunction product service diagnostics diagnostics initial issue figure 3 service diagnostics menu (3/3) service diagnostics menu definitions table 3 provides a description, behavior, and preconditions for service diagnostic tests. Table 3 service diagnostics menu ...

  • Page 212

    10/2006 6-10 phaser 8510/8560mfp multifunction product service diagnostics initial issue diagnostics scanner menu report fw version reports current firmware version. Report status reports the current scanner assembly status: • ok- (no errors detected) • internal target failure • optical test error •...

  • Page 213

    10/2006 6-11 phaser 8510/8560mfp multifunction product service diagnostics diagnostics initial issue print engine monitor menu the print engine monitor tests report current values (temperatures, positions, etc.), and dem- onstrate the ability to read the values without changing the current state of ...

  • Page 214

    10/2006 6-12 phaser 8510/8560mfp multifunction product service diagnostics initial issue diagnostics print engine exercise menu this submenu contains a group of functions intended to stimulate a specific portion of the print engine system in such a way that the test can be observed. Listening observ...

  • Page 215

    10/2006 6-13 phaser 8510/8560mfp multifunction product service diagnostics, print engine check menu diagnostics initial issue print engine function menu this submenu contains a group of functions that either perform higher-level exercise functions involving multiple print engine subsystems, or speci...

  • Page 216

    10/2006 6-14 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics head maintenance clutch test this test briefly energizes the head maintenance clutch coil and measures parameters. Peak power is expected to be very close to the average power level. An app...

  • Page 217

    10/2006 6-15 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue tray 2~4 pick clutch tests these tests briefly energize the tray 2, 3, or 4 pick clutch and measures parameters. Peak power is expected to be very close to the average power level. An appre...

  • Page 218

    10/2006 6-16 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics wiper shaft test this test exercises the head maintenance clutch and wiper assembly. The test raises the wiper to just under the tilt engage point, and then moves the wiper to home position...

  • Page 219

    10/2006 6-17 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue tray 1 pick shaft test this test exercises the tray 1 pick mechanism to determine if the shaft can be engaged/disen- gaged and to measure the friction between the pick roller and the separa...

  • Page 220

    10/2006 6-18 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics tray 2, 3, or 4 pick shaft test this test determines if the specified tray pick shaft is operating normally. The test is the same for each pick shaft, although for tray 2, the media drive a...

  • Page 221

    10/2006 6-19 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue fans menu these tests determine if the specified fan is operating properly. The selected fan is turned on for a short interval while the power is measured. Drum fan test the drum fan is tur...

  • Page 222

    10/2006 6-20 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics left jetstack heater test the left jetstack heater test characteristics and descriptions are listed in the following table. Right jetstack heater test the right jetstack heater test charact...

  • Page 223

    10/2006 6-21 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue drum heater test the drum heater test characteristics and descriptions are listed in the following table. Ink melt heater tests the four ink melt heater (ycmk) test characteristics and desc...

  • Page 224

    10/2006 6-22 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics paper drive power / duplex drive power this test measures required drive power (in watts). Paper leading edge times / duplex paper leading edge times the test measures the paper leading edg...

  • Page 225

    10/2006 6-23 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue paper trailing edge times / duplex paper trailing edge times this test measures the paper trailing edge arrival time (in microseconds) at each paper path sensor. An out of range value could...

  • Page 226

    10/2006 6-24 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics drive menu these tests exercise each subsystems driven by a motor and measure the power required (in watts). The exception being the y-axis tests which are included under the drum menu. X-a...

  • Page 227

    10/2006 6-25 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue drum maintenance drive test this test determines if the drum maintenance mechanism is operating by placing the drum maintenance kit against the drum for a short time. First with the roller ...

  • Page 228

    10/2006 6-26 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics if the printhead does not reach the standby position, the wiper blade can contact or interfere with the printhead. Problems with the wiper or media drive assemblies (including the clutch) c...

  • Page 229

    10/2006 6-27 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue note: the test requires that the tray be cycled (pulled out and pushed in) and emptied. How- ever there are no sensors to detect if the required actions were taken. The test runs with the t...

  • Page 230

    10/2006 6-28 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics y-axis geometry test this test measures the dynamic stability of the y-axis drive system. The test rotates the drum at a constant velocity and measures drum and y-axis motor vibration. A ve...

  • Page 231

    10/2006 6-29 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue y-axis drive belt slippage test this test does a chase (pick/transfix), of a special sheet of preprinted media and records the y-axis following error (fe). Y-axis drive belt tension test th...

  • Page 232

    10/2006 6-30 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics drum maintenance contact test this test exercises the drum maintenance kit. The drum is driven by a low amplitude vibration and the drum maintenance kit is advanced through its cycle. The r...

  • Page 233

    10/2006 6-31 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue media path motor test the media drive motor is run slowly ccw for one revolution. The slow motion removes the effect of inertia from the test, and the one revolution avoids a large system s...

  • Page 234

    10/2006 6-32 phaser 8510/8560mfp multifunction product print engine check menu tests initial issue diagnostics voltages test this test provides averaged readings for key voltages produced in the electronics module. For the ac line voltage, the value measured is read as either 110 volts or 220 volts ...

  • Page 235

    10/2006 6-33 phaser 8510/8560mfp multifunction product print engine check menu tests diagnostics initial issue drive problems on either axis could cause the respective motor to stall and the test to abort. The wiper drive and drum maintenance drive tests would test the basic drive mechanisms. If the...

  • Page 236

    10/2006 6-34 phaser 8510/8560mfp multifunction product print engine check menu tests, general trouble- initial issue diagnostics transfix gap test caution this test does not clean the drum before lowering the transfix roller. To prevent contamination of the transfix roller, check that the drum is cl...

  • Page 237

    10/2006 6-35 phaser 8510/8560mfp multifunction product general troubleshooting diagnostics initial issue when executed from the print engine function menu, the diagnostic fault history displays on the control panel and updates as each error event is detected. Fault history events are recorded only w...

  • Page 238

    10/2006 6-36 phaser 8510/8560mfp multifunction product electrical troubleshooting initial issue diagnostics electrical troubleshooting the electronics module contains the power supply, main board containing the image proces- sor, and power control boards. The backframe contains the scanner power sup...

  • Page 239

    10/2006 6-37 phaser 8510/8560mfp multifunction product electrical troubleshooting diagnostics initial issue system fails to power up the system fails to power up and the ps, pe and the 3.3 v indicator leds are not illuminated. Note: the 3.3 v led is located inside the electronics module. View the le...

  • Page 240

    10/2006 6-38 phaser 8510/8560mfp multifunction product electrical troubleshooting initial issue diagnostics system resets unexpectedly 1. Check the main ac voltage. Connect the system directly to the wall outlet. 2. Disconnect the network cable, if this corrects the problem go to network troubleshoo...

  • Page 241

    10/2006 6-39 phaser 8510/8560mfp multifunction product electrical troubleshooting, dadf malfunction diagnostics initial issue 7. Measure between the right most pin under the ink loader and (again) the lowest pin on the ac input connector (j8). If the meter measures 0 ohms, f2 has not been damaged. 8...

  • Page 242

    10/2006 6-40 phaser 8510/8560mfp multifunction product scanner malfunction, control panel malfunction initial issue diagnostics scanner malfunction scanhead does not move 1. Verify the scanhead shipping lock is in the “unlocked” position. Reboot the system. 2. Is there power to the scanner assembly?...

  • Page 243

    10/2006 6-41 phaser 8510/8560mfp multifunction product exit module malfunction, media path and transport diagnostics initial issue exit module malfunction exit module elevator inoperative 1. Is there scanner power supply working properly? Lift the dadf and observe the scanner lamps. If the lamps are...

  • Page 244

    10/2006 6-42 phaser 8510/8560mfp multifunction product media path and transport problems, operating sys- initial issue diagnostics preheater and transfix jams 1. Remove the preheater (rep 2.0.17) and check for damage, debris or obstructions. 2. Replace the preheater and check for excessive media ske...

  • Page 245

    10/2006 6-43 phaser 8510/8560mfp multifunction product operating system and application problems, net- diagnostics initial issue f. If you still cannot connect to the system via network, try another computer. 4. In mac os x, open printer setup utility, located at applications --> utilities at the ro...

  • Page 246

    10/2006 6-44 phaser 8510/8560mfp multifunction product network problems initial issue diagnostics 1. Connect a crossover cable between the pc and system. 2. Verify the system is ready. 3. Use the system’s control panel to enable autoip: a. Select the system setup menu. B. Select the connection setup...

  • Page 247

    10/2006 6-45 phaser 8510/8560mfp multifunction product usb port testing, fax troubleshooting diagnostics initial issue usb port testing in situations where usb communications fail, test the system’s usb port directly using a usb cable and a second, known good, usb port. A successful test using this ...

  • Page 248

    10/2006 6-46 phaser 8510/8560mfp multifunction product fax troubleshooting initial issue diagnostics fax protocol report the protocol report provides transmission results, timing, and communications activity infor- mation about each fax transmission. Accessed from the system -> information -> troubl...

  • Page 249

    10/2006 6-47 phaser 8510/8560mfp multifunction product fax troubleshooting, remote fax does not ring diagnostics initial issue fax troubleshooting procedures the following provides procedures and suggestions for correcting some common problems. 1. Disable junk fax prevention. This may prevent a fax ...

  • Page 250

    10/2006 6-48 phaser 8510/8560mfp multifunction product remote fax answers then fails, fax does not an- initial issue diagnostics remote fax answers then fails the remote machine answers the call, but the fax transmission sometimes fails to complete. Initial actions • check that fax is enabled and co...

  • Page 251

    10/2006 6-49 phaser 8510/8560mfp multifunction product fax answers then fails, printhead troubleshoot- diagnostics initial issue fax answers then fails the system answer the incoming call, but the transmission fails. Initial actions • check that fax is enabled and configured properly for the local p...

  • Page 252

    10/2006 6-50 phaser 8510/8560mfp multifunction product printhead troubleshooting checklist initial issue diagnostics figure 2 printhead checklist page 2 figure 3 printhead checklist page 3.

  • Page 253

    10/2006 6-51 phaser 8510/8560mfp multifunction product printhead troubleshooting checklist, printhead diagnostics initial issue figure 4 printhead checklist page 4 note: an adobe pdf version of this checklist is included on the edoc cd. Print and com- plete this checklist as part of the printhead re...

  • Page 254

    10/2006 6-52 phaser 8510/8560mfp multifunction product printhead troubleshooting checklist, printhead initial issue diagnostics.

  • Page 255

    10/2006 7-1 phaser 8510/8560mfp multifunction product wiring data initial issue 7 wiring data how to use the plug/jack location list .......................................................................... 7-3 plug/jack locations .......................................................................

  • Page 256

    10/2006 7-2 phaser 8510/8560mfp multifunction product initial issue wiring data.

  • Page 257

    10/2006 7-3 phaser 8510/8560mfp multifunction product wiring data initial issue how to use the plug/jack location list the p/j locator diagrams show the location of primary connections within the system. Use these illustrations to locate connections called out in the procedures presented in sections...

  • Page 258

    10/2006 7-4 phaser 8510/8560mfp multifunction product plug/jack locations initial issue wiring data plug/jack locations figure 1 left side p/j locations 600 figure 9 b-108 connects the paper size switch to the i/o board. 610 figure 9 c-108 connects the i/o board to the front door/tray 1 assy. 650 fi...

  • Page 259

    10/2006 7-5 phaser 8510/8560mfp multifunction product plug/jack locations wiring data initial issue figure 2 right side p/j locations figure 3 front side p/j locations.

  • Page 260

    10/2006 7-6 phaser 8510/8560mfp multifunction product plug/jack locations initial issue wiring data figure 4 right side electronics module p/j locations figure 5 left side electronics module p/j locations.

  • Page 261

    10/2006 7-7 phaser 8510/8560mfp multifunction product plug/jack locations wiring data initial issue figure 6 top electronics module p/j locations figure 7 exit module control board p/j locations.

  • Page 262

    10/2006 7-8 phaser 8510/8560mfp multifunction product plug/jack locations initial issue wiring data figure 8 scanner power supply p/j locations figure 9 i/o board p/j locations.

  • Page 263

    10/2006 7-9 phaser 8510/8560mfp multifunction product plug/jack locations wiring data initial issue figure 10 drum heater relay board p/j locations figure 11 underside of the preheater board p/j locations.

  • Page 264

    10/2006 7-10 phaser 8510/8560mfp multifunction product wire routing initial issue wiring data wire routing figure 1 back frame wire routing figure 2 right side wire routing (1/2).

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    10/2006 7-11 phaser 8510/8560mfp multifunction product wire routing wiring data initial issue figure 3 right side wire routing (2/2) figure 4 left side wire routing (1/2).

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    10/2006 7-12 phaser 8510/8560mfp multifunction product wire routing initial issue wiring data figure 5 left side wire routing (2/2) figure 6 front wire routing.

  • Page 267

    10/2006 7-13 phaser 8510/8560mfp multifunction product wire routing, wiring diagrams wiring data initial issue figure 7 top wire routing (1/2) wiring diagrams figure 1 scanner/dadf block diagram.

  • Page 268

    10/2006 7-14 phaser 8510/8560mfp multifunction product wiring diagrams initial issue wiring data figure 2 system block diagram (1/2) figure 3 system block diagram (2/2).

  • Page 269

    10/2006 7-15 phaser 8510/8560mfp multifunction product wiring diagrams wiring data initial issue figure 4 left side harness (1/2) figure 5 left side harness (2/2).

  • Page 270

    10/2006 7-16 phaser 8510/8560mfp multifunction product wiring diagrams initial issue wiring data figure 6 electronics module figure 7 electronics module power.

  • Page 271

    10/2006 7-17 phaser 8510/8560mfp multifunction product wiring diagrams wiring data initial issue figure 8 right side harness / i/o control figure 9 i/o board.

  • Page 272

    10/2006 7-18 phaser 8510/8560mfp multifunction product wiring diagrams initial issue wiring data figure 10 i/o board 2 figure 11 exit module control board.

  • Page 273

    10/2006 8-1 phaser 8510/8560mfp multifunction product theory of operation initial issue 8 theory of operation system overview ............................................................................................................ 8-3 image input terminal ...........................................

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    10/2006 8-2 phaser 8510/8560mfp multifunction product initial issue theory of operation.

  • Page 275

    10/2006 8-3 phaser 8510/8560mfp multifunction product system overview, image input terminal theory of operation initial issue system overview the system is divided into two main components: the image input terminal (iit - document feeder/scanner) and the image output terminal (iot - print engine). F...

  • Page 276

    10/2006 8-4 phaser 8510/8560mfp multifunction product image input terminal initial issue theory of operation document feeder functions the duplex automatic document feeder (dadf) is capable of automatically feeding original documents from the input tray and scanning either side document or both side...

  • Page 277

    10/2006 8-5 phaser 8510/8560mfp multifunction product image input terminal theory of operation initial issue scanner assembly functions scanner and document feeder calibration automatic calibration the automatic calibration performed by the system is a “white balance” calibration performed during st...

  • Page 278

    10/2006 8-6 phaser 8510/8560mfp multifunction product system electronics initial issue theory of operation system electronics the phaser 8510/8560mfp has two controller boards: the main board, contained in the elec- tronics module, and the exit module control board. The main board, controls all imag...

  • Page 279

    10/2006 8-7 phaser 8510/8560mfp multifunction product system electronics theory of operation initial issue memory the main board supports two pc3200 compatible ddr sdram memory modules (512 mb). The system requires a minimum of 512 mb of system memory to operate. The system has been tested with up t...

  • Page 280

    10/2006 8-8 phaser 8510/8560mfp multifunction product system electronics, image output terminal initial issue theory of operation figure 2 power supply wiring diagram image output terminal the image output terminal (commonly referred to as the print engine) is made up of nine major subsystems: • the...

  • Page 281

    10/2006 8-9 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue note: the electronics module is also a subsystem of the iot but was discussed previously. For more information on the electronics module, see electronics module. Figure 1 iot subassemblies p...

  • Page 282

    10/2006 8-10 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation figure 2 tray 1 pick mechanism paper pick for trays 2 ~ 4 note: trays 3 and 4 are optional 525-sheet feeders. To pick a sheet of paper, the media path drive starts the process. The pick clu...

  • Page 283

    10/2006 8-11 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue figure 4 duplex drive components sensors the system contains sensors of various types that perform a variety of functions. One group of sensors track the progress of the paper along the pap...

  • Page 284

    10/2006 8-12 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation two types of photo sensors are used, photo-reflective and photo-receptive. Photo-reflective sensors use light reflected back from an object to detect its presence. Photo-receptive sensors u...

  • Page 285

    10/2006 8-13 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue process drive the process drive is an open loop system that transmits torque to two main camshaft assem- blies. One camshaft assembly controls the transfix roller loading, and the other con...

  • Page 286

    10/2006 8-14 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation the print process once an image has been processed and a printing bitmap created, the print cycle begins. The printhead and drum are brought up to their operating temperatures and the ink l...

  • Page 287

    10/2006 8-15 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue if the ink level sensors inside the printhead detect that the printhead has run out of ink, but the ink low/out sensors are not activated, the control panel reports an “ink jam” error. Figu...

  • Page 288

    10/2006 8-16 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation figure 12 printhead detail 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 sta...

  • Page 289

    10/2006 8-17 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue the tilt cam tilts the head into the basic four positions listed above. The cam has five special features and associated functions: 1. The cam is combined with a missing tooth gear that all...

  • Page 290

    10/2006 8-18 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation the latching mechanism is actuated by a small movement of the wiper coupled with the head tilt solenoid. The action of the solenoid ensures that the head-tilt gear engages the tilt drive ge...

  • Page 291

    10/2006 8-19 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue note: the drum rotates cw for transfix, ccw for maintenance and printing. Figure 17 drum assembly components warning always keep your fingers away from the drum drive system; it uses a clos...

  • Page 292

    10/2006 8-20 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation figure 19 drum maintenance 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 a...

  • Page 293

    10/2006 8-21 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue warning when servicing the system be careful of the purge system as it passes the printhead. If a damaged wiper blade of the purge system catches on the printhead, it could propel hot liqui...

  • Page 294

    10/2006 8-22 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation figure 22 transfix components after the leading edge of the paper is beyond the paper release guide, the paper release sole- noid is de-energized. Once the solenoid is de-energized, the sol...

  • Page 295

    10/2006 8-23 phaser 8510/8560mfp multifunction product image output terminal theory of operation initial issue figure 23 exit path transfix and print speeds configuration card parameters information stored on the configuration card includes the ethernet address, and personality parameters. The syste...

  • Page 296

    10/2006 8-24 phaser 8510/8560mfp multifunction product image output terminal initial issue theory of operation personality parameters are a subset of network configuration parameters, which are populated to the configuration card over time as the system is configured by the customer. The personal- i...