Xerox Phaser 8400 Service Manual
. Service Manual 701P27910 Phaser 8400/8500/8550/8560 ® Color Printer. Service Manual 701P27910 Phaser 8400/8500/8550/8560 ® Color Printer Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so. Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation. Service Terms Manual Terms Common Acronyms: Product Terms Phaser 8400/8500/8550/8560 Color Printer Service Manual Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action.
Service Manual 701P27910 Phaser ®8400/8500/8550/8560 Color Printer Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing.
Be aware of all symbols and terms when they are used, and always read Note, Caution, and Warning statements. Symbols Marked on the Product Power Safety Precautions Power Source Disconnecting Power Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place. Use caution (or draws attention to a particular component).
Electrostatic Discharge (ESD) Precautions Phaser 8400/8500/8550/8560 Color Printer Service Manual Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. Service Safety Summary General Guidelines Warning Labels Safety Interlocks Servicing Electrical Components For qualified service personnel only: Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Servicing Mechanical Components Servicing Heated Components Phaser 8400/8500/8550/8560 Color Printer Service Manual When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
■ Consult the dealer or an experienced radio/television technician for help. Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment.
To ensure compliance with Part 15 of the FCC rules, use shielded interface cables. European Union Phaser 8400/8500/8550/8560 Color Printer Service Manual The CE mark applied to this product symbolizes Xerox’s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated: ■ January 1, 1995: Low Voltage Directive 73/23/EEC as amended by 93/68/EEC ■. Manual Organization The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.
Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the print engine and attached options. Service Terms.iii Symbols Marked on the Product. Printer Self-Maintenance.2-33 Printhead Maintenance Cycle (Eliminate Light Stripes). Jam Codes. 3-48 Jam Code Definition Table.
5 Print-Quality Troubleshooting Print-Quality Problems Overview.5-2 Random Light Stripes. 7 Cleaning and Maintenance Service Cleaning Maintenance Procedure.7-2 Cleaning. Xerox Supplies. General Information In this chapter. ■ Printer Introduction and Overview ■ Printer Configurations ■ Control Panel Configuration ■ Parts of the Printer ■ Routine Maintenance Items and Consumables ■ Printer Specifications Chapter. Printer Introduction and Overview The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer.
To ensure understanding of this product, complete the Phaser 8400/8500/ 8550/8560 Service Training and self-study guide. Left Front Phaser 8400/8500/8550/8560 Color Printer Service Manual Back. Printer Configurations Phaser 8400/8500/8550/8560 Color Printer Service Manual The Configuration Card holds configuration information that enables or disables built-in features as described in the following tables. Features 8400B Maximum Print Speed Memory 128 MB Hard Drive PostScript Fonts PCL Fonts Japanese Fonts.
Job Pipelining Automatic 2-Sided. 525-Sheet Feeder Tray 4 USB Connection Standard Ethernet Connection. The following features are included with the Phaser 8500/8550 printers with a hard drive: proof print, saved print, secure print, personal print, and font storage.
Phaser 8560 Printer Configurations Phaser Features. Control Panel Configuration LED Indicators Control Panel Feature Descriptions Phaser 8400/8500/8550/8560 Color Printer Service Manual The Control Panel consists of one tricolor LED, a display window, and six functional buttons. These buttons navigate the menu system, perform functions, and select modes of operation for the printer.
Green = Ready to Print Flashing Green = Receiving, Processing Data, ■. Ready) temperatures to reach the proper operating values. On power- up, when the Xerox splash screen displays, press and release the Up Arrow button, then press the Down Arrow button. If the printer detects ink on the drum, the display indicates a warming-up status. Parts of the Printer Front View Right Side View with Printer Interfaces Phaser 8400/8500/8550/8560 Color Printer Service Manual This section shows the main external components of the printer, including interfaces, the electronics module, and the internal sensors.
Optional 525-Sheet Feeder Tray 4 2. Rear View The rear view consists of the printer’s main electronics and power supply, which are enclosed in a metal case called the Electronics Module. The rear panel allows access to the Electronics Module, RAM, and NVRAM. The printer’s Hard Drive is also mounted on the rear panel.
When installing a new electronic module in the printer, the following components need to be transferred from the old board. 10,000 prints regardless of the colors used. Extended-capacity Drum Maintenance Kits for 8400 and 8550/ 8560 models produce 30,000 pages up to 20% coverage and 20,000 pages when coverage exceeds 20%. Phaser 8500 models do not support the 8550/ 8560 extended-capacity kit Routine Maintenance. Printer Specifications Physical Dimensions and Clearances 1-10 Print Engine Only Value Width: 422 mm (16.6 in.) Depth: 514 mm (20.24 in.) Height: 368 mm (14.48 in.) Weight: 26.8 kg (59 lb.) Optional 525-Sheet Feeder Value Width: 422 mm (16.6 in.) Depth: 514 mm (20.24 in.) Height. Phaser 8400/8500/8550/8560 Color Printer Service Manual Print Engine Only 10 cm (4 in.) 56 cm (22 in.) 60 cm (24 in.) Note Check that the printer is on a stable, non-vibrating suface.
Advise the customer to use care not to shake the printer excessively when loading media or closing the Front Door. Functional Specifications Electrical Specifications Environmental Specifications 1-12 Characteristic Specification Printing Process Solid-ink Color Medium Yellow, cyan, magenta, and black ink sticks, each shape- coded. The printer uses the subtractive color system to produce the colors red, green, and blue. Operating Modes and (8400) Resolutions Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced.
Media and Tray Specifications Phaser 8400/8500/8550/8560 Color Printer Service Manual Paper Size Paper Type Paper Weight/Media Type Letter (8.5 x Plain Paper 60–120 g/m 11 in.) or 121–220 g/m A4 (210 x Letterhead 297 mm) Transparency Phaser Professional Solid Ink Transparencies Card Stock 100–120 g/m. 1-14 Paper Size Paper Type Paper Weight/Media Type Custom NOTE Print custom size media from Tray 1 only. Maximum: 216 mm wide x 355 mm long (8.5 in. Wide x 14 in. Long) Minimum: 75 mm wide x 127 mm long (3 in.
Theory of Operation In this chapter. ■ Main Printer Subsystems ■ Print Process ■ Printer Self-Maintenance ■ Configuration Card Personality Parameters Chapter. Main Printer Subsystems Printer Subsystem Overview Transfix System Drum Preheater Drum Maintenance Kit Wiper Assembly The printer is made up of eight major subsystems, which are described in this section: ■ Process Drive ■ Media Drive ■ Ink Loader ■ Printhead ■. Theory of Operation The Ink Loader: Stores and melts the ink. The melted ink drops into the Printhead ink reservoirs underneath the ink loader. The Printhead: Delivers ink onto the drum surface to create an image. The Printhead includes 1236 interleaved jets (309 of each primary color) to provide the ability to electronically turn off a weak or missing jet to restore image quality.
Process Drive A small DC servomotor powers the Process Drive gearbox to rotate the gears to specific positions during the printing process. The Process Drive is able to actuate each camshaft system independently through the use of the swing arm in the gear train. The rotational direction of the motor controls the operation of the transfix and drum maintenance system.
Media Drive Phaser 8400/8500/8550/8560 Color Printer Service Manual The Media Drive assembly drives each roller in the media transport path. A gear train located behind the motor connects it to the Exit Rollers, which are built into the Exit Module. Gear trains located within the Media Drive, along with two clutches and a solenoid, allow the motor to control the Pick, Take Away, Duplex, and Deskew rollers. Theory of Operation Ink Loader The Ink Loader consists of four parallel channels with an ink melting element at the end of each channel. Coil springs exert pressure on four ink sticks to load one unique color in each channel.
When the Printhead requires ink, the melting element of the appropriate color melts the end of the ink stick. Theory of Operation Printhead The Printhead is the heart of the printer, spanning nearly the length of the drum. Using its 1236 jet nozzles (309 jets for each primary color), with a horizontal motion of slightly less than 5 mm (0.2 inches), the Printhead can print the entire image on the rotating drum.
Theory of Operation Printhead Ink Loader Black Yellow Funnel Filter Level Sense Probe Purge Valve Cyan Magenta s8500-013 The Printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array. Channels formed by the stacked plates route ink past the 1236 individual, piezo-electric crystal-driven diaphragms, which force the ink in droplets out the 1236 corresponding nozzles. Phaser 8400/8500/8550/8560 Color Printer Service Manual X-Axis Hook X-Axis Shaft Tension Spring Drum X-Axis or lateral movement of the Printhead is accomplished using a stepper motor driving a fine-thread screw system. The Printhead, mounted to the X- Axis shaft, moves laterally across the surface of the drum. To find the Printhead home position, the X-Axis system drives the Printhead in an open-loop.
Printhead Tilt 2-10 The Printhead is able to rotate into four basic positions: Printhead lock / ship position (19.5 degrees): The Printhead restraint pins are resting against the right and left locks. In this position, the Printhead tilt arm/follower is free of the tilt cam, and the head is secured for shipping.
Printhead is in print position. When the arrows on the latching mechanism and frame align, the Printhead is in the print position and the tilt gear disengages from the Process Drive. Phaser 8500/8550/8560 printers have a solenoid (Head Tilt Solenoid) that is actuated and deactuated when the tilt cam gear rotates to the respective engaged and disengaged positions.
Theory of Operation As viewed from the left side of the printer, when the arrows are not aligned, the tilt gear is engaged. Head Tilt Compond Gear Tilt Drive Gear Tilt Gear Engaged s8500-133 To accommodate Printhead maintenance, the Printhead is tilted back away from the Drum. Drum Maintenance Kit Phaser 8400/8500/8550/8560 Color Printer Service Manual The Drum Maintenance Kit creates a thin layer of silicone oil on the surface of the Drum prior to printing.
The oil keeps the ink from sticking to the Drum’s surface and facilitates image transfer to the media. The oil is contained in porous foam rollers made from rolled paper/fiber material. Theory of Operation Purge System Proper Printhead operation is dependant on the correct operation of the purge system. The purge system uses air pressure and a Wiper Blade to purge any debris or air bubbles that may be obstructing the Printhead nozzles.
The waste ink that is expelled during the purge is funneled into the Waste Tray. Theory of Operation Warning When servicing the printer be careful of the purge system as it passes the Printhead. If a damaged Wiper Blade catches on the Printhead, it could propel hot liquid ink upward into your face. 30 Sec Printhead Purge Tube Solenoid Valve. Drum Assembly And Transfix System 2-16 The Drum Assembly and Transfix Module form the key portion of the printer where imaging takes place.
The Drum Assembly and Transfix Module are separate, yet interrelated. This section discusses the Drum.
The next section provides more detail on the Transfix Module. Phaser 8400/8500/8550/8560 Color Printer Service Manual Single Reduction Belt Drive Pulley Y-Axis Motor Tension Spring Warning Always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system, which is inherently dangerous. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured. Theory of Operation Transfix System The Transfix Roller applies pressure to the back side of the media as it moves between the Transfix Roller and Drum. This pressure transfers the image from the drum to the paper. A set of springs in the Transfix Load Module determines how much pressure the Transfix Roller applies to the Drum.
Electronics Module Main Board Configuration Card Phaser 8400/8500/8550/8560 Color Printer Service Manual The Electronics Module includes the main board, the power control board, and the power supply. The Electronics Module is a Field Replaceable Unit (FRU). The main board performs the image processing functions. Communication ports on the board receive the print job image data and convert it to drive signals for the Printhead. Power Control Board Power Supply 2-20 Information stored on the Configuration Card includes the feature value, ethernet address, and personality parameters.
The card reads a combination of feature values and the printer hardware capabilities; this will determine the printer model configuration.You can migrate the Configuration Card from one printer to another to transfer the printer configuration. Phaser 8400/8500/8550/8560 Color Printer Service Manual The DC power supply generates + 3.3 V, +/- 15 V, and +/- 50 V. These voltages provide direct or regulated voltage values to various circuits in the printer. The power control board regulates +/- 15 V to +/- 12 and other voltages. I/O Board Sensors 2-22 All sensor and switch readings are input into the I/O Board. The I/O Board translates these states into encoded information that it sends over a serial data bus (I/O Board data cable) to the Electronics Module.
The Electronics Module has no direct connection to sensors, switches, or solenoids. Print Process Drum Preparation Phaser 8400/8500/8550/8560 Color Printer Service Manual Once the printer processes an image and creates a printing bitmap, the print cycle begins. Sensors maintain correct operating temperatures for the Printhead and Drum. Sensors also monitor ink levels in the reservoirs. If necessary, the ink loader adds ink.
Theory of Operation Printing To print, the Drum rotates at a speed dependent upon print resolution. As the Drum reaches the correct speed, the jets begin to fire to deposit the image on the oiled portion of the Drum. As the jets fire, the Printhead moves from right to left to complete the image on the drum. Paper Pick for Tray 1 Phaser 8400/8500/8550/8560 Color Printer Service Manual To pick a sheet of paper, the Tray 1 solenoid actuates, and the drive gear rotates slightly to engage with the drive train. A bias force from the lift plate against a rotating cam causes the roller to rotate enough so the missing tooth gear engages the drive train. Theory of Operation Paper Pick for Trays 2 - 4 Note Trays 3 and 4 are 525-Sheet Feeders.
For Trays 2 through 4, the paper pick process is different than the pick process used by Tray 1. To pick a sheet of paper, the Media Path Drive starts, and the pick clutch engages, which turns the Pick Roller and the Nudger Roller. Transfixing and Exiting Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfixing and exiting consists of four major functions: Staging the paper for rendezvous with the image on the drum and transfix roller nip.
Loading the transfix roller and engaging the drum stripper blade assembly. 2-28 Transfix Load Arm Transfix Load Module Transfix Load Spring Transfix Drum Transfix Roller Gear Transfix Cam Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfer Roller Process Drive Swing Arm Gear s8500-026. Theory of Operation Release Blade Strip Solenoid Exit Sensor Transfix Roller Preheat Sensor Strip Sensor Paper Preheater s8500-027 Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-29. From this point on, the print is processed through the Preheater and transfix system to the Output Tray in the same manner as a single-sided print. Phaser 8500/8550/8560 models include a Preheater Lift Solenoid, mounted to the Transfix Load Module, that increases the physical spacing between the Preheater plates when printing the second side of duplex prints. Transfix and Print Speeds Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfix Speeds Characteristic Fast Color Peak Transfix Speed, 20 ips (8400) Simplex tray feed 25 ips (8500/ 8550/8560) Peak Transfix Speed, 5 ips (8400) Duplex 10 ips (8500/ 8550/8560) Peak Transfix Speed, 20 ips Legal Peak Transfix Speed. 2-32 Approximate Print Speeds (8500/8550/8560) Tray (Source) / Simplex, A4 Paper Resolution Tray 1 Fast Color (225 x 400 dpi) 12 pages per minute Standard (300 x 450 dpi) Enhanced (525 x 450 dpi) High Res/Photo (525 x 2400 dpi) PCL 600 x 300 Mode PCL 600 x 600 Mode Trays 2 - 4.
Printer Self-Maintenance Printhead Maintenance Cycle (Eliminate Light Stripes) Phaser 8400/8500/8550/8560 Color Printer Service Manual The printer has several automatic or semi-automatic maintenance functions. These functions may be started automatically after a certain number of prints or during printer startup, or they may be started by the customer if a print- quality defect is noted. Paper Preheater Cleaning (Remove Print Smears) Transfix Roller Oiling Drum Cleaning - Chase Page 2-34 This customer-initiated cleaning procedure is selected by choosing Print Smears on the Control Panel’s procedure cleans ink out of the Preheater that may have been deposited there. Configuration Card Personality Parameters Phaser 8400/8500/8550/8560 Color Printer Service Manual Configuration Card “Shadowed” Personality Parameters Attribute Parameter N/A “version” not version (of the layout of parameter personality parameters) NEST Base Printer Name NEST SysAdmin Contact NEST Printer Location NEST Asset Identifier Host Name Domain Name Network Mask. 2-36 Configuration Card “Shadowed” Personality Parameters (Continued) Attribute Parameter HTTP KeyUserUsername HTTP AdminHostAccessList HTTP KeyUserHostAccessList Notify Authentication Scheme IPP user name IPP password Login Password Security Print Hosts AppSocket AppSocket Enabled Enabled Enabled Enabled MIME MIME Enabled EtherTalk EtherTalk Enabled PSERVER PSERVER Enabled. Error Messages and Codes In this chapter. ■ Introduction ■ Power-Up Error Messages and LED Codes ■ BIST Error Reporting ■ POST Error Reporting ■ PEST Error Reporting ■ Fault Code Error Message Troubleshooting ■ Jam Codes Chapter.
Introduction This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running Service Diagnostics test functions to verify that a specific printer component is operating correctly.
For information on Service Diagnostics and all internal printer test functions see “Service Diagnostics Mode Menu”. Power-Up Error Messages and LED Codes BIST Error Reporting Phaser 8400/8500/8550/8560 Color Printer Service Manual The printer has three sets of tests that are run when first powered on: ■ Built-In Self Tests (BIST) ■ Power On Self Tests (POST) ■. POST Error Reporting 8400 Error Code 01.01 02.01 02.02 03.01 03.02 03.03 03.04 04.01 04.02 04.03 04.04 05.01 05.02 POST checks the communication paths within the Electronics Module and to other various printer components. POST testing initializes the Control Panel, and in most cases if an error occurs, a text message is displayed on the Control Panel along with an LED blink code flashing on all three LEDs (Control Panel LED, PS LED and PE LED). 8400 Error Code 6.08 07.01 07.02 08.01 09.01 10.01 10.02 11.01 11.02 11.03 11.04 12.xx 13.01 13.02 14.xx 15.01 15.02 15.03 Phaser 8400/8500/8550/8560 Color Printer Service Manual POST Error Reporting Blink Pattern Definition Table (Continued) PS, PE and Control POST Panel LEDs (for Error 8400).
8400 Error Code 15.04 15.05 15.06 15.07 15.08 15.09 15.10 15.11 16.01 16.02 16.03 16.04 17.01 18.01 18.02 18.03 18.04 19.01 PEST Error Reporting POST Error Reporting Blink Pattern Definition Table (Continued) PS, PE and Control POST Panel LEDs (for Error 8400) Type. Fault Code Error Message Troubleshooting Fault Code Error Reporting Interpreting Fault Codes Phaser 8400/8500/8550/8560 Color Printer Service Manual Fault codes are saved to NVRAM and can be retrieved from the printer’s fault history. All procedures that ask for a test to be run are referencing tests from within the “hidden”. 1,000.4x Errors - 525-Sheet Feeder Faults 1,0XX.6x Errors - 525-Sheet Feeder Program Faults 1,001.46: The upper 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted. 1,002.47: The lower 525-sheet feeder had an overcurrent condition.
The lift motor or clutch may be shorted. 2,0XX.4x Errors - I/O Circuit Board Fault 2,0XX.6x Errors - I/O Board Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 2,001.47: The print engine cannot detect the presence of the I/O Board. Troubleshooting Procedure for I/O Board Step Questions or Actions Are all I/O Board connections properly seated? Reseat the connections and power On the.
3,0XX.6x Errors - IPC Program Faults 4,0XX.4x Errors - Process Control System Fault 3-10 There is a communication problem between the engine and PostScript regions. Reset NVRAM, and then retest.
Replace the EEPROM chip. 4,017.47: This fault code indicates a problem with the process control system. The ambient temperature is considered too cold to warm up the printer (less than 10 4,018.48. Phaser 8400/8500/8550/8560 Color Printer Service Manual 4,024.42: This fault code indicates a problem with the wiper.
The wiper is not aligned properly and engaged the headtilt while in the waste lock position. Troubleshooting Procedure for 4,024 Error Code Step Questions and Actions Ensure the Process Drive is correctly homed as described in “Homing the Process Drive Train”.
4,0XX.6x Errors - Process Control Software Fault 3-12 Troubleshooting Procedure for 4,025 Error Code (Continued) Step Questions and Actions Remove the Waste Tray and Printhead and look for ink build-up. Is there ink build-up anywhere in the printer? Check the Process Drive for damage. 5,0XX.4x Errors - Y-Axis Sub-System Fault 5,0XX.6x Errors - Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 5,001.41: The Drum turned one full revolution without seeing the Drum home sensor activate. 5,002.42: The Y-Axis encoder is not working properly or the Drum has stalled.
5,003.43: There is a general problem with the Y-Axis sub-system. 6,0XX.4x Errors - X-Axis Fault 6,0XX.6x Errors - Program Faults 3-14 6,000.41: An X-Axis Motor current error occurred. Troubleshooting Procedure for X-Axis Motor Step Questions and Actions 1. Inspect the Printhead power cable and heater wiring. Verify the Printhead travels smoothly from left to right. 7,0XX.4x Errors - Process Motor Gearbox Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,002.44: There is a problem with the process motor sub-system.
The process motor stalled during operation. Troubleshooting Procedure for 7,002 Error Code Step Questions and Actions Verify the Process Drive system is properly homed, see “Homing the Process Drive Train”. 7,0XX.4x Errors- Printhead Tilt Faults 3-16 Troubleshooting Procedure for 7,006 Error Code (Continued) Step Questions and Actions Review instructions for 7,008.xx and 7,010.xx fault codes. The 7,007.49, 7,008.41, 7009.42, and 7,010.43 errors indicate that the Printhead was unable to tilt normally on its axis. Possible causes include: ■. Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,007.49: The process motor stalled while tilting the head. Troubleshooting Procedure for 7,007 Error Code Step Questions and Actions 1.
Check the Printhead wire routing. Remove the Printhead and inspect the Printhead tilt and drive gears for ink spills. 3-18 Troubleshooting Procedure for 7,008 Error Code (Continued) Step Questions and Actions Perform the Wiper Alignment procedure (see “Wiper Alignment Procedure” on page 6-2).
Did this correct the problem? Use Service Diagnostics to run the Wiper Drive test. Did the test fail? 7,009.42: The Printhead is tilted back but not properly restrained in the park arms. Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,010.43: The Printhead is stuck in the tilted position, or is not able to tilt forward to the print position, due to problems.
7,011.44: This is a soft fault and will not halt the printer. 7,012.45: The Drum transfix is not in home position, after the return home motion has been completed. 7,0XX.6x Errors - Program Faults 3-20 Troubleshooting Procedure for 7,010 to 7,015 Error Code (Continued) Step Questions and Actions Use Service Diagnostics to run the Head Maintenance Wiper Clutch test. Did the test fail? Align the Wiper Assembly (page 6-2).
Xerox Phaser 8400 Service Manual
8,0XX.xx Errors - Wiper/Media Drive Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 8,005.48: The Media Drive stalled while moving the Wiper to home position. 8,006.49: The Wiper cannot verify the home position. 8,007.41: The Wiper stalled finding home.
8,008.42: The Wiper stalled while trying to move away from home position. 8,009.43: The Media Drive stalled while moving without the Head Maintenance Clutch engaged.
8,0XX.6x Errors - Program Faults 3-22 Troubleshooting Procedure for Wiper/Media Gearbox (Continued) Step Questions and Actions Run the Wiper Alignment test (see “Wiper Alignment Procedure” on page 6-2). Did the test pass? Inspect the wiper system for improper operation, obstructions, or damage (broken gear or belt). 5 for cyan, 6 for magenta, 7 for yellow, and 8 for black. Features on the bottom of genuine Xerox ink sticks actuate the Ink Out Sensor located at the forward end of each ink channel of the Ink Loader. The sensor indicates the passage of ink to provide a count of ink consumption. 3 = Magenta 4 = Black Did the test pass?
Note Xerox is not financially responsible for the incorrect operation of its products caused by the use of non- Xerox ink. 9,009.44: This fault indicates a device failure attempting to access NVRAM. Phaser 8400/8500/8550/8560 Color Printer Service Manual 11,006.43: Printhead broken serial link detected.
11,006.45: Printhead broken serial link detected. 11,007.44: PCI error detected. 11,008.45: The DMA hardware is not responding. 11,009.46: Communication timeout failure detected. 11,010.47: Hardware version mismatch. 11,010.48: Hardware version mismatch. 11,011.48: Software version mismatch.
11,100.60 Errors - Temperature Error 12,000.60 Errors - Program Faults 13,0XX.xx Errors - Thermal Faults 3-26 The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Check that the room temperature does not exceed specifications and the fans run correctly. If OK, then replace the Electronics Module. Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,008 to 13,010 Error Code (Drum Heater) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12).
Is the room too cold or too hot? Ensure ground integrity (see “Ensuring Ground Integrity”. 3-28 13,067.43: The Drum Temperature Sensor circuit is open.
13,069.45: The Drum Temperature Sensor circuit is shorted. 13,071.47: The Drum Temperature Sensor returned a bad reading, or the reading was corrupted by ESD (Electrostatic Discharge). Troubleshooting Procedure for 13,067 to 13,071 Error Code (Drum Thermistor) Step Questions and Actions Using Service Diagnostics, run the Drum. Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,136 to 13,199 Error Code (Printhead) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12). Is the room too cold or too hot?
Ensure ground integrity (see “Ensuring Ground Integrity”. 3-30 13,327.42: The Printhead reservoir thermistor returned a bad reading, or the reading was corrupted by ESD. Troubleshooting Procedure for 13,264 to 13,327 Error Code (Printhead) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications”. 13,000.6x Errors - Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,326 to 13,583 Error Code (Ink Loader) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12). Is the room too cold or too hot? Ensure ground integrity (see “Ensuring Ground Integrity”.
19,0XX.xx Errors - Printhead Calibration faults. 3-32 19,001.46: HFD server failed due to NVRAM operation. This fault only occurs when the printer is set in manufacturing mode. Program fault.
19,002.47: Attempted to perform a Printhead operation without the Printhead NVRAM data being loaded. 19,003.48: Scale and offset error is too large. 19,0XX.6x Errors - Waveform Program Faults 21,000.69 Errors - Diagnostic Code Version Mismatch 22,0XX.6x Errors - Jam Codes 23,0XX.6x Errors - NVRAM Fault 26,0XX.6x Errors - Printing Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 19,005.63: Wave Amplifier overcurrent. This error can occur in too-low humidity environments.
26,962.6x Errors - “Fall Out” Code 27,0XX.6x Errors - Profile Library 29,0XX.6x Errors - Jam Manager 31,0XX.4x Errors - Mechanical Initialization Jam 3-34 Check the previous error in the fault history and troubleshoot that code. Ensure the ground integrity of the printer (see “Ensuring Ground Integrity” on page 4-65). 31,0XX.6x Errors - Program Faults 33,0XX.xx Errors - Tray Manager Device Faults 34,0XX.xx Errors - Printhead NVRAM Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual Reset NVRAM, and then retest. Ensure ground integrity for the printer (see “Ensuring Ground Integrity” on page 4-65). 36,000.40 Errors - Drum Maintenance Faults 36,001.67 Errors - Drum Maintenance Fault 36,002.44 Errors - Drum Maintenance Program Fault 37,0XX.xx Errors - PEST Faults 3-36 Troubleshooting Procedure for Drum Maintenance Step Questions and Actions Ensure ground integrity (see “Ensuring Ground Integrity” on page 4-65).
Did this correct the problem? Ensure the Process Drive system is correctly homed as described in “Homing.
Phaser 8400/8500/8550/8560 Color Printer Service Manual ■ Reservoir heater, 37,004.40 or 37,005.41 ■ Drum heater error 37,006.42 ■ Preheater error 37,008.44 ■ Ink melters errors 37,009.45 thru 37,013.40 The printer includes several heaters powered by AC. The printer itself can power up despite insufficient or irregular AC voltage but it may fail its AC heater tests. 3-38 8400 PEST Description Inkmelt 3 (Black) disconnect. 37,012.48: The inkmelt heater is not drawing the expected power from the supply. 37,013.40: Troubleshooting Procedure for Heaters Step Questions and Actions Check the wiring running from the problem component to the Printhead. Is the wiring damaged? Run the appropriate diagnostic test: 37,002.47 = Left Jetstack Heater.
Phaser 8400/8500/8550/8560 Color Printer Service Manual 8400 PEST Description Drum Fan disconnect. The 37,014.41: Drum Fan is not drawing the expected power. 37,015.42: Troubleshooting Procedure for Fans Step Questions and Actions Run the appropriate diagnostic test: 37,013.40 = (8400) Electronics Fan 37,014.40 = (8500/8550/8560) Electronics Fan 37,014.41 = (8400) Drum Fan.
3-40 50V Power Supply Fault Troubleshooting Procedure Step Questions and Actions Check for a short in the Electronics Module. NOTE Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge. NOTE It is possible that the power supply is not shorted, but instead is out of spec and can lead to an error condition. Phaser 8400/8500/8550/8560 Color Printer Service Manual 50V Power Supply Fault Troubleshooting Procedure (Continued) Step Questions and Actions To isolate the problem to the I/O Board or its related cabling, unplug these I/O Board connectors. Umbilical Right J1 ■ Waste Tray Sense J110 ■. 3-42 8400 PEST Description 37,022.40: 37,023.41: Solenoid or Clutch Troubleshooting Procedure Step Questions and Actions Run the appropriate diagnostic test: 37,017.44 = Head Maintenance Clutch ■ 37,018.45 = Deskew Clutch ■ 37,019.46 = (8500/8550/8560) Main tray ■ pick Clutch 37,019.46 =(8400) Pick Solenoid ■.
Phaser 8400/8500/8550/8560 Color Printer Service Manual 8500/8550/ 8400 8560 8400 PEST Description 37,022.40: 37,025.43: Pressure pump motor disconnect. The Purge Pump is not drawing the expected power. Troubleshooting Procedure for Purge Pump Step Questions and Actions Run the Pressure Pump Motor test. Did the test pass? Check the Purge Pump wiring.
3-44 Troubleshooting Procedures for Drum Heater Relay Board Step Questions and Actions Run the Drum Heater Relay test. Did the test pass? Check the wiring for damage. 8500/8550/ 8400 8560/8560 PEST Description 37,027.45: 37,030.48: X-Axis Motor disconnect. The X-Axis motor is not drawing the expected power.
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Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for Y-Axis Motor Step Questions and Actions 1. Remove any obstructions interfering with Drum rotation. Inspect the Drum and ensure the Drum rotates smoothly, if not replace the Drum Assembly and retest.
Did this correct the problem? Disconnect the Y-Axis Belt. 3-46 Troubleshooting Procedure for Process Drive Step Questions and Actions Do the Process Drive gears, Transfix Camshaft, and Drum Maintenance Camshaft rotate freely? Run the Process Motor test.
Did the test pass? Check the wiring for damage. 8400 PEST Description The power supply did not reset 37,038.47: properly. Phaser 8400/8500/8550/8560 Color Printer Service Manual 8400 PEST Description Power supply -50 volt under limit. 37,056.47: 37,057.48: Power supply +15 volt over limit. Power supply +15 volt under limit. Power supply +15 volt under 37,058.40: 37,059.41: Power supply -15 volt over limit.
Power supply -15 volt under limit. Jam History and press OK to display the most recent jam list. Phaser 8500/8550/8560 models have improved jam reporting.
When the printer is in a jam condition (in Customer Mode), pressing HELP displays the jam code. The jam code contains 4-digits compared to the 3-digit codes produced by 8400 models.
Note The following table only shows the 3-digit jam code. For Phaser 8500/ 8550/8560, a 4th digit represents the tray number (5 represents a chase page and 6 represents duplex).
Numbers following the 4th digit represent. 3-50 Jam Code Troubleshooting Procedures (Continued) Deskew sensor in unexpected state at ready. Ensure ground integrity, see page 4-65. Replace Tray 1 Pick Solenoid. Deskew Sensor in unexpected state. Ensure ground integrity of the printer, see page 4-65.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Deskew Sensor time-out during movement from Exit Roller to deskew roller when duplexing print. Ensure the media is appropriate for two-sided printing. Not too short, not too smooth. Check printer specifications.
3-52 Jam Code Troubleshooting Procedures (Continued) Strip flag unexpected event during fault. Strip flag unexpected event during transfix roller oiling. The strip flag actuated unexpectedly when paper picked from Tray 2. The strip flag actuated unexpectedly when paper picked from Tray 3. The strip flag actuated unexpectedly when paper picked from Tray 4. Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Print pulled back into transfix nip during exit.
Ensure the media is not too thick and that it is supported by the printer. Use a less glossy media. 3-54 Jam Code Troubleshooting Procedures (Continued) Tray 1 width sensor during Tray 1 pick. Examine the Tray 1 width guides for proper movement and ensure the side guides are not being adjusted while printing. Ensure the Front Door is closed and the wiring is connected and seated.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Media Drive stalled while the printer was in standby mode. M4M Media Drive stalled while the printer picked from Tray 2. Media Drive stalled while the printer picked from Tray 3. Media Drive stalled while the printer picked from Tray 4. 3-56 Jam Code Troubleshooting Procedures (Continued) Y-Axis Motor stalled while the print exited the printer.
Check the media, generally label, trifold or envelopes cause this error. Try running fewer sheets through the tray. Ensure the Process Drive is correctly aligned, refer to “Homing the Process Drive Train”. Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Process motor stalled while the printer performed an auto Drum maintenance cycle.
Process motor stalled while the printer performed Printhead maintenance. Process motor stalled while the printer performed Printhead purge. Process motor stalled while the printer performed an oil transfix roller cycle. 3-58 Jam Code Troubleshooting Procedures (Continued) The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 2.
The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 3. The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 4.
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Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Tray 2 media size sensor unexpectedly activated while exiting print. Ensure ground integrity of the printer, see page 4-65. Ensure the Tray 2 paper guides are correctly set. 3-60 Jam Code Troubleshooting Procedures (Continued) Tray 3 pick flag triggered unexpectedly while printer was in a fault state. Tray 3 pick flag triggered unexpectedly while printer in standby. Tray 3 pick flag triggered unexpectedly while picking from Tray 2. Tray 3 pick flag triggered unexpectedly while picking from Tray 3.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Tray 3 pick flag sensor timed out while exiting print. Verify the paper loaded in Tray 3 is supported media. Reduce the amount of media in the tray and reposition the guides to fit firmly against the media. 3-62 Jam Code Troubleshooting Procedures (Continued) Tray 4 pick flag triggered unexpectedly while pick from Tray 2. Tray 4 pick flag triggered unexpectedly while pick from Tray 4.
Tray 4 pick flag triggered unexpectedly while pick from Tray 4. Tray 4 pick flag triggered unexpectedly while pick from Tray 1. Tray 4 pick flag triggered unexpectedly while duplexing. General Troubleshooting In this chapter.
■ Service Diagnostics ■ Service Diagnostics Mode Menu ■ Check Menu Definition Tables ■ Electronics Troubleshooting ■ Ensuring Ground Integrity ■ Paper Path and Media-Based Problems ■ Operating System and Application Problems Chapter. Introduction Hidden Service Menu This chapter covers the general start-up, Power On Self Test (POST), and power supply operations of the printer to aid in troubleshooting problems not associated with a Control Panel error message or error code. For troubleshooting problems associated with an error code or Control Panel error message, notes on how to use the troubleshooting procedure tables, and how to use service diagnostics, see Chapter 3 “Error Messages and Codes”. Phaser 8400/8500/8550/8560 Color Printer Service Manual Menu Item Description Reset NVRAM Provides access to reset the printer back to its factory-default settings and erase all network settings. If possible, print the Configuration Page before resetting NVRAM.
Power Saver Timeout Selects the Power Saver Timeout, the amount of time the printer must be idle before changing to Power Saver low-energy consumption mode, per ENERGY STAR 256 guidelines. 30 seconds until the Control Panel indicates Turn the printer power On. Wait for the Xerox logo to begin moving across the display. Before the logo is centered on the display (stops moving), press and hold the Back and Help buttons on the Control Panel. Service Diagnostic Control Panel Button Descriptions Service Diagnostics Mode Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual Button Function Back Returns to the prior higher level menu structure, if available. Cancels the display of test results on the Control Panel.
If help text is displayed on the Control Panel, pressing BACK will restore the current menu item and remove the help text. Service Diagnostics Menu Map Service Diagnostics Menu Map Menu Main Menu Displays general help text describing the general operation of the Control Panel/menu system. Development Menu A temporary submenu containing some development functions and access to tests still under development. Return to Customer Exits service diagnostics and runs through POST to Ready.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Service Diagnostics Menu Map (Continued) Menu Exercise Menu Functions for causing mechanical actions which may then be observed. Press a Control Panel button to stop the test Activators Menu Exercise All Tray 1 Pick Solenoid Cycles the activator repeatedly. Tray 2 Pick Clutch Tray 3 Pick Clutch Tray 4 Pick Clutch. Service Diagnostics Menu Map (Continued) Menu Drum Maintenance Cam Shaft Deskew Shaft Wiper Shaft Tray 1 Pick Shaft Tray 2 Pick Shaft Tray 2 Lift Motor Tray 3 Pick Shaft Tray 4 Pick Shaft Tray 3 Lift Motor Tray 3 Motor & Shafts Tray 4 Pick Shaft Tray 4 Lift Motor. Phaser 8400/8500/8550/8560 Color Printer Service Manual Service Diagnostics Menu Map (Continued) Menu Function Menu Functions for commanding more complex actions by portions of the printer mechanism. Initialize Mechanism Print DMU Blot Display Fault History Access PE NVRAM Parameters Clear Fault History Clear ISC Fault Clear PS NVRAM Clear PE NVRAM. Check Menu Definition Tables Check / Activators Menu 4-10 A submenu containing a set of extensive tests that return measured mechanism parameters for comparison against stated limits.
Refer to the table associated with each test for their normal operating ranges. In cases where insufficient baseline data is available, the Typical Values have been left blank. Phaser 8400/8500/8550/8560 Color Printer Service Manual The Deskew Clutch test gathers data on the performance of the Deskew Clutch coil. Deskew Clutch Typical Value Definition (8400) Peak Power (watts) 2.5 to 5.3 3.0 to 5.8 Average Power 2.2 to 5.3 1.5 to 3.0 (watts) Gathers data on the performance of the Tray 1 Pick Solenoid coil and flapper. 4-12 Gathers data on the performance of the stripper solenoid coil and plunger. Strip Solenoid Typical Value Definition (8400) Peak Power (watts) 8.0 to 15 Average Power 8.0 to 15 (watts) Gathers data on the performance of the purge vent solenoid coil. Purge Vent Solenoid Typical Value.
Check Shafts Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual Drum Heater Relay (Continued) Typical Value Definition (8400) 110 V Coil Average Power (watts) 110 V Coil Min Power (watts) 110 V Coil Peak Power Time (sec) 110 V Coil Initial Average Power (watts) Runs the Media Path Drive train and engages the Deskew Clutch on the fly. 4-14 Deskew Shaft (Continued) Typical Value R# Definition (8400) CCW On average fe. 250 to 600 1.0 to 2.5 CCW On fe ripple. 115 to 360 0 to 2.0 CCW Off fe settling 0.010 to time (sec). 0.20 Time to CW On 0.010 to peak fe (sec). Phaser 8400/8500/8550/8560 Color Printer Service Manual Deskew Shaft (Continued) Typical Value R# Definition (8400) CW On fe settling 0.010 to time (sec).
0.20 CW On average fe.610 to -220 10 CW On fe ripple. 110 to 400 -2.25 to 11 CW Off fe settling 0.010 to time (sec). Check Paper Path Menu 4-16 Runs the Media Path Drive train and engages the Head Maintenance Clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Wiper Shaft (Continued) Typical Value R# Definition (8400) CCW On fe ripple. 25 to 100 CCW Off fe setting 0.004 to time (sec). 0.15 Time to CW On 0.005 to peak fe (sec). 0.20 CW On peak fe.
4-18 Wiper Shaft (Continued) Typical Value R# Definition (8400) CW On average fe.50 to 15 10 CW On fe ripple. 20 to 75 11 CW Off fe settling -5 to.01 time (sec). Runs the Media Path Drive train and engages the Tray 1 Pick SAolenoid on the fly.
Phaser 8400/8500/8550/8560 Color Printer Service Manual Tray 1 Pick Shaft (Continued) Typical Value (8400) R# Definition On response time.1.5 to 0.95 (sec). Initial average MP -1 to 1400 fe. Transition MP fe 750 to 1800 min. Typical Value (8500/ 8550/8560) Actions.
4-20 Tray 1 Pick Shaft (Continued) Typical Value (8400) R# Definition Contact average fe. 120 to 2000 Pushdown MP fe 750 to 2000 max. Final average MP 900 to 1500 fe. Test is the same for each pick shaft although for Tray 2 the Media Path Drive motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used. Phaser 8400/8500/8550/8560 Color Printer Service Manual Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Typical Value (8400) R# Definition On fe settling time (sec). On average fe. On fe ripple.
Off fe settling time (sec). Time to lift plate up (sec). 4-22 Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Typical Value (8400) R# Definition Plate lifted average Test picks paper from selected tray (test currently supports picking from Tray 2 only) and moves it through either the simplex or duplex paper path to determine paper path power requirements.
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