Page 1 8400 P h a s e r ® C o l o r P r i n t e r Service Manual...
Page 3 ® Phaser 8400 Color Printer Service Manual 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.
Page 4 Copyright Copyright © 2004, Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now...
Page 5: User Safety Summary
User Safety Summary Terms in manual Caution Conditions that can result in damage to the product. Warning Conditions that can result in personal injury or loss of life. Power source: For 110 VAC printers, do not apply more than 130 volts RMS between the supply conductors or between either supply conductor and ground.
Page 6 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation. Phaser 8400 Color Printer...
Page 7: Regulatory Specifications
The equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with Xerox' instructions, it may cause interference with radio and television reception or may not function properly due to interference from another device.
Page 8: European Union
Réglement sur le brouillage radioélectrique édicté par le ministere des Communications du Canada, NMB-003. European Union Xerox Corporation declares, under our sole responsibility, that the printer to which this declaration relates is in conformity with the following standards and other normative documents:...
Page 9 @ 50 Hz 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 of Conformity for this product can be obtained from Xerox. Service Manual...
Page 10: Electrostatic Discharge (Esd) Precautions
Handle IC’s and EPROM’s carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCB’s). Phaser 8400 Color Printer...
Page 11: Table Of Contents
Contents User Safety Summary ......... i Regulatory Specifications.
Page 12 Measuring DC Power Supply Voltages....4-66 Ensuring Ground Integrity ......4-67 viii Phaser 8400 Color Printer...
Page 13 Testing Motor and Solenoid Resistances ....4-69 Paper Path and Media-Based Problems ......4-70 Media-Based Problems.
Page 14 Paper Guides ........8-40 Phaser 8400 Color Printer...
Page 15 Xerox Supplies ........
Page 17: General Information
General Information In this chapter... Printer Introduction and Overview Printer Configurations Front Panel Configuration Parts of the Printer Routine Maintenance Items and Consumables Printer Specifications Section...
Page 18: Printer Introduction And Overview
Printer Introduction and Overview The Xerox Phaser 8400 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure understanding of this product, complete the Xerox Phaser 8400 Color Printer Service Training and self study guide.
Page 19: Printer Configurations
Printer Configurations The Configuration Card holds configuration information that enables or disables built-in features as described below. Note Some features are not included as options to a configuration but they are included when you upgrade the configuration. Printer Configuration Features 8400B 8400BD 8400N...
Page 20: Front Panel Configuration
Up Arrow button - scrolls up the menu system Graphic front panel display Down Arrow button - scrolls down the menu system Cancel button OK (select) button Back button Information button - for additional explanation or help Phaser 8400 Color Printer...
Page 21: Front Panel Shortcuts
Front Panel Shortcuts To access the Service Tools menu: From anywhere within the menu (not diagnostics): press and hold the Up Arrow button, then press the OK button. You can also press and hold the Cancel button, then press the OK button. To set the front panel language: Press and hold the Cancel button, then press the Information button.
Page 22: Parts Of The Printer
10.Legal/A4 Output Tray Extension s8400-003 Side View with Printer Interfaces 1. Maintenance Kit 2. Waste Tray 3. Power Cord 4. On/Off Switch 5. Parallel Cable Connection 6. USB Connection 7. Configuration Card 8. Ethernet Connection s8400 004 Phaser 8400 Color Printer...
Page 23: Electronics Module
Electronics Module The printer’s main electronics and power supply are enclosed in a metal case called the Electronics Module. The rear panel allows access to the Electronics module, RAM, and NVRAM chips. The printer’s hard drive is 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.
Page 24: Sensors
The following graphic identifies the location of the printer’s sensors. Strip sensor Paper exit sensor Exit door sensor Drum temperature sensor Preheater Drum sensor position encoder Front door sensor Deskew Tray paper sensor size sensor board Pick sensor (525-sheet feeder) s8400-198 Phaser 8400 Color Printer...
Page 25: Routine Maintenance Items And Consumables
Routine Maintenance Items and Consumables s8400-134 Routine Maintenance Items Consumable 1. Maintenance Kit 3. Ink 2. Waste Tray Routine Maintenance: Consumable: Extended 30,000 cycles (0-20% 1140 prints per stick* Maintenance Kit coverage) 20,000 (20-100% coverage) Startup 10,000 cycles Maintenance Kit Waste Tray Empty every 7 Purges *Consumable capacity is based on 5% coverage per color on plain A4 paper.
Page 26: Printer Specifications
Min. install width - 711 mm (28 in.) Requires placing printer at an angle to remove waste tray. A. Absolute Minimum B. Recommended Minimum 15.5 35.5 28.0 Front Note: All dimensions in inches 1-10 Phaser 8400 Color Printer...
Page 27: Functional Specifications
Functional Specifications 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 Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced Resolutions (563x400 dpi), High Resolution/Photo (525x2400) Maximum Operating...
Page 28: Media And Tray Specifications
210 mm) Statement (5.5 x 8.5 in.) US Folio (8.5 x 13 in.) A6 (105 x 148 mm) B5 ISO (176 x 250 mm) B5 JIS (182 x 257 mm) Index Cards (3 x 5 in.) 1-12 Phaser 8400 Color Printer...
Page 29 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.
Page 30 1-14 Phaser 8400 Color Printer...
Page 31: Theory Of Operation
Theory of Operation In this chapter... Main Printer Sub-Systems Print Process Printer Self-Maintenance Section...
Page 32: Main Printer Subsystems
*Part of the Electronics Module s8400-117 Overview The printer is made up of nine major subsystems, which are described in this chapter: Electronics Module Process Drive Media Path Drive Printhead Drum Assembly Transfix System Drum Maintenance System Ink Loader Phaser 8400 Color Printer...
Page 33 Purge System The electronics module includes the main board, the power control board, and the power supply. An important component of the electronics module is the configuration card. Printer model configuration is determined by a combination of the configuration card feature value and other printer hardware capabilities. The process drive is an open loop system that transmits torque to two main camshaft assemblies.
Page 34: Electronics Module
Feature value and ethernet address are configured at the factory, and are “read only”. The feature value is fixed in Phaser 8400 Color Printer...
Page 35: Power Supply
the configuration card, and does not change. Ethernet address is stored only on the configuration card, and cannot be rewritten. The ethernet address is not written to the NVRAM chip. Personality parameters are a subset of network configuration parameters which are populated to the configuration card over time, as the printer is configured by the customer.
Page 36 Do not touch the power supply; AC line voltages are present. The power switch does not disconnect power from the printer. The power switch signals the supply and the printer logic to begin a shutdown sequence. Phaser 8400 Color Printer...
Page 37 AC Line Line Gnd Ref Neutral AC Neutral AC Line AC Neutral Serial Control Interface Switcher +3.3 V uProcessor +15 V -15 V +50 V -50 V s8400-164 Service Manual...
Page 38: Process Drive
These gear orientations allow the printer subsystems to self home during operation. If either the gearbox or cam gears is out of home during installation, the printer does not function properly. Process drive Swing gear s8400-188 Phaser 8400 Color Printer...
Page 39: Media Path Drive
Media Path Drive The media path drive gearbox and motor assembly controls each roller in the paper transport system. 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 path drive assembly, along with two clutches and a solenoid, allow the motor to control the pick, take-away, duplex, and deskew rollers.
Page 40: Printhead
5 mm (0.2 inches), the printhead can print the entire image on the rotating drum. The printhead provides one size ink drop, which is used for all print- quality modes. Reservoir Drum Printhead Jet stack Head driver board Purge Tube s8400-122 2-10 Phaser 8400 Color Printer...
Page 41 Printhead Ink Loader Black Funnel Yellow Level sense Filter probe Purge Valve Cyan Magenta s8400-182 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.
Page 42 The printhead is driven against the left printer frame for a few seconds, and then reversed a set distance. A tension spring links to the printhead’s left shaft, and provides a preloaded tension so the printhead moves smoothly. 2-12 Phaser 8400 Color Printer...
Page 43: Printhead Tilt
Printhead Tilt 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. Wipe position (12 degrees) The printhead tilt arm/follower is engaged with the tilt cam, and the head overload spring contact is engaged with the overload spring-plate to provide the correct force for the wiper.
Page 44 When the arrows on the latching mechanism and frame are aligned, it indicates that the printhead is in print position, and the tilt gear is disengaged from the process drive. 2-14 Phaser 8400 Color Printer...
Page 45 The latching mechanism is actuated by a small movement of the wiper. Through a follower gear, the compound gear drives the tilt cam gear clockwise. A cam follower, mounted on the lower end of the tilt arm, follows the rotating tilt cam gear, which tilts the printhead.
Page 46: Drum Assembly
The main board interprets the sensor’s signal and turns on the drum heater and drum fan to heat the drum, or turns on the drum fan alone to cool the drum. 2-16 Phaser 8400 Color Printer...
Page 47 The drum is driven by a closed-loop servo motor which, through a single reduction belt drive, rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper. The Y-Axis is on an active tension system, which allows the pulley to float and the spring to actively adjust the tension during operation.
Page 48: Transfix System
Warning Never attempt to adjust or increase the transfix pressure on the springs. Transfer roller Transfix load arm Transfix load module Transfix load spring Transfix Drum s8400-119 2-18 Phaser 8400 Color Printer...
Page 49: Drum Maintenance System
Drum Maintenance System The drum maintenance system creates a thin intermediate liquid transfer surface, a 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 its transfer to the sheet of paper or transparency film.
Page 50: Ink Loader
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 front panel reports an “Ink Jam” error. Ink loader door Ink stick Ink low sensors Ink melt units Ink out sensors Printhead s8400-136 2-20 Phaser 8400 Color Printer...
Page 51: Purge System
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.
Page 52 If a damaged wiper blade of the purge system catches on the printhead, it could propel hot liquid ink upward into your face. 30 sec Printhead Purge tube Solenoid valve Purge pump (Open during wiper action) Wiper assembly Printhead Drum Wiper s8400-148 2-22 Phaser 8400 Color Printer...
Page 53: Print Process
Print Process Once an image has been processed and a printing bitmap created, a print cycle begins. The printhead and drum are brought up to their operating temperatures and the ink levels in the ink reservoirs are checked. Ink is added from the ink loader, if necessary. At the ready state, the print process consists of the following steps, which are described in this section: Drum Preparation...
Page 54: Drum Preparation
The drum is rotated against the oil saturated roller. Drum Oil on drum Blade Maintenance roller Drum maintenance camshaft Drum maintenance pivot plate s8400-121 2-24 Phaser 8400 Color Printer...
Page 55: Printing
Printing To print, the drum starts rotating 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.
Page 56: Paper Pick For Trays 2 - 4
The deskew rollers do not reverse during duplex printing. Exit sensor Strip sensor Deskew sensor Preheat sensor s8400-167 2-26 Phaser 8400 Color Printer...
Page 57: Paper Pick For Tray 1
Paper Pick for Tray 1 For Tray 1, the paper pick process is different than the pick process used by the other trays. To pick a sheet of paper, the Tray 1 solenoid is fired, and the drive gear rotates slightly to engage with the drive train.
Page 58: Transfixing And Exiting
Timing is based on the sensor ensuring the image is perfectly aligned for transfix to the paper. The transfix roller is lifted and lowered by the process drive. 2-28 Phaser 8400 Color Printer...
Page 59 Transfer roller Transfix load arm Transfix load module Transfix load spring Transfix Drum Transfix roller Process drive gear Transfix cam s8400-192 Service Manual 2-29...
Page 60 As the process drive lifts the transfix roller, the exit rollers deposit the paper into the output tray, ending the print cycle. 2-30 Phaser 8400 Color Printer...
Page 61 Release blade Strip solenoid Exit sensor Transfix roller Preheat sensor Strip sensor Paper preheater s8400-204 Service Manual 2-31...
Page 62: Duplex Printing
From this point on, the print is processed through the paper preheater and transfix system to the exit tray in the same manner as a single-sided print. Exit sensor Strip sensor Preheat sensor Duplex Roller Deskew sensor Exit roller Duplex roller s8400-191 2-32 Phaser 8400 Color Printer...
Page 63: Transfix And Print Speeds
Transfix and Print Speeds Transfix Speeds Characteristic Setpoint, Paper Media Fast Color Standard Enhanced High Res/ Photo Peak Transfix Speed, 20 inches per 17 ips 13 ips 7 ips Simplex tray feed second (ips) Peak Transfix Speed, Duplex 5 ips 5 ips 5 ips 5 ips...
Page 64: Printer Self-Maintenance
When servicing the printer 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 liquid ink upward into your face. 2-34 Phaser 8400 Color Printer...
Page 65: Paper Preheater Cleaning (Remove Print Smears)
Paper Preheater Cleaning (Remove Print Smears) Remove Print This customer-initiated cleaning procedure is selected by choosing Smears on the front panel’s Print Quality Problems menu. This procedure cleans ink out of the paper preheater that may have been deposited there. Heavier-weight, high-grade quality paper works best for this procedure.
Page 66: Configuration Card Personality Parameters
Primary Name Server IP Address DNS RESOLVER Secondary Name Server IP Address DNS RESOLVER MulticastDNS NBNS (WINS) Enable NBNS (WINS) WINS Note Type NBNS (WINS) Primary WINS Server NBNS (WINS) Secondary WINS Server Ethernet Speed HTTP 2-36 Phaser 8400 Color Printer...
Page 67 Configuration Card “Shadowed” Personality Parameters (Continued) NCL Subject NCL Item Size (bytes) HTTP Information Forwarding HTTP SMTP Server Automatic HTTP Legal Settings HTTP Admin_Password HTTP Admin_Username HTTP KeyUser_Password HTTP KeyUser_Username HTTP Admin_HostAccessList HTTP KeyUser_HostAccessList Notify Authentication Scheme IPP user name IPP password Login Password Security...
Page 68 NCL Item Size (bytes) PSERVER Enabled PSERVER_IPX Enabled Notes: 1. “Parallel” and “USB”, “On” and “Enabled” parameters have not been identified as personality parameters. They are not tied to networking. 2. NCL = Nest Configuration Library 2-38 Phaser 8400 Color Printer...
Page 69: Error Messages And Codes
Error Messages and Codes In this chapter... Power-Up Error Messages and LED Codes POST (Power On Self Test) Fault Code Definitions and Troubleshooting The BIST (Built-In Self Test) Fault Code Definition Table 3-Digit Jam Codes Definition Table Section...
Page 70: Introduction
The Jam Codes provide a basis for troubleshooting printer problems that occur as the result of misfeeds or jams within the paper path. Refer to the "3-Digit Jam Codes" on page 3-35 and to the Xerox infoSMART knowledge base at www.xerox.com/office/ infoSMART for the latest information on Jam Code interpretation.
Page 71: The Bist (Built-In Self Test)
The BIST (Built-In Self Test) These tests occur immediately at power-up, before the front panel is initialized. BIST Rear Panel LED Codes PE LED PS LED Description Off or 1 Off or 1 The power supply could not remain regulated when the DC power Blink and Blink and was applied so it was shut down.
Page 72: Post (Power On Self Test)
* Bandit TMVH mismatch, write/read failed, POST hard error. 04 blinks 05.01 Flutter then * Communications error. PLD I/O Board serial, link down/bad 05 blinks parity, POST hard error. 05.02 Flutter only Communications error. PLD I/O Board serial, mismatch, POST soft error. Phaser 8400 Color Printer...
Page 73 POST (Power On Self Test) Error Messages (Continued) Description * Before replacing the electronics module do the following: 1. Unplug all cables. 2. Plug in the AC power cable and power on the electronics Front PS, PE module. Panel and Front If the error blink pattern has changed, the problem may not be in Error Panel...
Page 74 Real-time clock does not tick, POST soft error. 17.01 Flutter then Memory test, less than 128 MB of RAM detected. This is the 17 blinks minimum RAM required. Add more RAM. Reseat the RAM SODIMM(s), then replace the RAM SODIMM(s), POST hard error. Phaser 8400 Color Printer...
Page 75: Pest (Print Engine Self Test)
PEST (Print Engine Self Test) These tests occur after the POST tests have been run and postscript has been initialized. Error codes for the PEST tests are displayed on the front panel and are all in the 37,xxx series. Definitions for the PEST tests are provided in the Error Code Definition Table beginning on page 3-8.
Page 76: Fault Code Definitions And Troubleshooting
4. Unknown problem? Replace the 525-Sheet Feeder. 1,000.6x: These faults are associated with the 525-Sheet Feeder HCF_PROG_FAULT software. 1. Ensure ground integrity of the printer, see page 4-67. 2. Reseat the printer onto the 525-Sheet Feeder. 3. Reset NVRAM. Phaser 8400 Color Printer...
Page 77 Error Code Definition Table (Continued) Error code Definition 2,000: SYSTEM FAULT I/O BOARD 2,001.40: SY_DEV_FAULT_IO The engine cannot detect the presence of the I/O board. 1. Ensure all connections to and from the I/O board are sound. 2,001.6x: SY_ECM_INIT_FAILURE Failed to initialize Engine Control Module hardware and control structures. 2,002.6x: SY_QUEUE_INIT_FAILURE Queue Initialization failure during execution of sy_app_init() (early initialization code), the engine firmware was unable to initialize the queues used for inter-task communication.
Page 78 Replace the process gearbox if damaged. 5. Run the X-Axis Motor test to check the X-Axis motor current. Replace the X-Axis motor if the test fails. 6. Run the Tilt Drive test. 3-10 Phaser 8400 Color Printer...
Page 79 Error Code Definition Table (Continued) Error code Definition 5,000: Y-AXIS PROGRAM FAULT CODES 5,001.4x: YA_FAULT_HOME_FAIL This fault code indicates a problem with the Y-Axis sub-system. Declared when the Y-Axis home sensor is not found. Drum home sensor failure: the drum turned one full revolution without seeing the drum home sensor activate.
Page 80 Unknown X-Axis device fault argument. Reset NVRAM and retest. 6,013.6x: XA_PROGFAULT_XD Unknown X-Axis device fault argument. Reset NVRAM and retest. 1. Reset NVRAM and retest. 2. Ensure the ground integrity of the printer, see page 4-67. 3-12 Phaser 8400 Color Printer...
Page 81 Error Code Definition Table (Continued) Error code Definition 6,017.6x: XA_PROGFAULT_X11 An attempt was made to drive the X-Axis using the wrong server (not xa). 6,018.6x: YA_PROGFAULT_X12 An attempt was made to move with the X-Axis uninitialized. 6,019.6x: XA_PROGFAULT_X13 An attempt was made to move to home from a state where homing is not allowed. The mechanism must be placed in a home position first.
Page 82 3. Run the Head Maintenance Clutch test, if it fails replace the clutch. 4. Run the Wiper Drive test. If the test fails, inspect the maintenance drive system. 5. Replace the exit assembly. 3-14 Phaser 8400 Color Printer...
Page 83 Error Code Definition Table (Continued) Error code Definition 7,010.4x: PM_FAULT_HEADTILT_HOME_ERROR The printhead is stuck in the tilt position by the tilt arms. The process motor gearbox being out of sync can also cause this error. 1. Reboot the printer. 2. Verify the lock arms rotate correctly. 3.
Page 84 8,035.4x: CAP_FAULT_MOVEUP_STALL The media path drive module has stalled while moving the wiper down. 8,045.4x: CAP_FAULT_MOVEDOWN_STALL The media path drive module has stalled while moving the wiper down. Follow the procedures listed on the following page. 3-16 Phaser 8400 Color Printer...
Page 85 Error Code Definition Table (Continued) Error code Definition 8,0##.4x: (continued) 1. Look for obstructions and/or spilled ink in the media path. 2. Check for a broken wiper drive belt or gear. 3. Check the wiper alignment, physically and run the Wiper Alignment test.
Page 86 Error code Definition 9,008.4x: (continued) 1. Ensure the ink is Xerox branded ink. 2. Check that the ink stick is able to advance in the chute. 3. Run the appropriate Ink Melt # Heaters test. If the test fails, replace the ink loader assembly and door.
Page 87 Error Code Definition Table (Continued) Error code Definition 13,001.6x: TH_NVRAM_READ_FAILURE Thermals failed to read from system NVRAM. Reboot the printer. 1. Ensure the ground integrity of the printer, see page 4-67. 2. Reset the NVRAM and retest. 3. Check and reseat the data cable to the printhead. 4.
Page 88 The preheat thermistor is bad. 1. Check the ambient temperature of the room. 2. Run the Preheater test. 3. Check the wiring from the preheater. 4. Replace the preheater board. 5. Replace the I/O Board. 3-20 Phaser 8400 Color Printer...
Page 89 Error Code Definition Table (Continued) Error code Definition 13,136.4x: TH_DEV_FAULT_JET_L_TOO_HOT The left jetstack heater became too hot. 13,138.4x: TH_DEV_FAULT_JET_L_TOO_SLOW The left jetstack heater took too long to reach its setpoint. 1. Ensure the ground integrity of the printer, see page 4-67. 2.
Page 90 2. Check and reseat all wiring to the printhead. 3. Reverse the printhead data cable, if the error reappears the cable is bad and needs to be replaced. 4. If the test fails, replace the printhead and/or wiring. 3-22 Phaser 8400 Color Printer...
Page 91 Error Code Definition Table (Continued) Error code Definition 13,328.4x - TH_DEV_FAULT_CYAN_TOO_HOT The cyan ink load heater became too hot. 13,330.4x - TH_DEV_FAULT_CYAN_TOO_SLOW The cyan ink load heater took too long to reach its setpoint 13,387.4x - TH_DEV_FAULT_CYAN_THERMISTOR_OPEN The cyan ink load thermistor circuit is open. 13,389.4x - TH_DEV_FAULT_CYAN_THERMISTOR_SHORTED The cyan ink load thermistor circuit is shorted.
Page 92 2. Run the Ink Melt 1 test. 3. Check and reseat wiring to the ink loader. 4. Replace the ink loader. 5. Replace the I/O board. 3-24 Phaser 8400 Color Printer...
Page 93 Error Code Definition Table (Continued) Error code Definition 19,000: HEAD CALIBRATION 19,001.4x - HC_DEV_FAULT_1 HFD server failed because of a failed NVRAM operation. This fault only occurs when the printer is set in Manufacturing mode. 19,002.4x - HC_DEV_FAULT_2 Attempted to perform a head operation without the head NVRAM data being loaded from hardware.
Page 94 PRN_PROG_FAULT: FAULTS WHILE PRINTING Reboot the printer if one of these faults should appear. 27,000.6x - PF_FAULT_BASE Profile library has experience a program fault. 1. Ensure the ground integrity of the printer, see page 4-67. 3-26 Phaser 8400 Color Printer...
Page 95 Error Code Definition Table (Continued) Error code Definition 29,000.6x - JM_PROG_FAULT Jam manager has experienced a program fault. 1. Reseat NVRAM. 31,000.4x - MP_FAULT_MECH_INIT_JAM There is too much drag in the media path drive system. 1. Ensure all main tray paper path sensor wires are clear of the take away rollers.
Page 96 1. Run the printhead Right Jetstack Heater test. 2. Verify printhead wiring. 37,004.4x - PEST_FAULT_RESERVOIR0_HEATER_DISCONNECT PEST - Reservoir0 Disconnect Reservoir0 is not drawing the expected power from the supply. 1. Run the printhead Reservoir Heater test. 2. Verify printhead wiring. 3-28 Phaser 8400 Color Printer...
Page 97 Error Code Definition Table (Continued) Error code Definition 37,005.4x - PEST_FAULT_RESERVOIR1_HEATER_DISCONNECT PEST - Reservoir1 Disconnect Reservoir1 is not drawing the expected power from the supply. 1. Run the printhead Reservoir Heater test. 2. Verify printhead wiring. 37,006.4x - PEST_FAULT_DRUM_HEATER_DISCONNECT PEST - Drum Disconnect Drum is not drawing the expected power from the supply 1.
Page 98 PEST - Tray 1 Pick Solenoid disconnect. The Tray 1 pick solenoid is not drawing the expected power from the supply. 1. Run the Tray 1 Pick Solenoid test. 2. Check the Tray 1 Pick Solenoid wiring. 3. Replace the solenoid if the test fails. 3-30 Phaser 8400 Color Printer...
Page 99 Error Code Definition Table (Continued) Error code Definition 37,020.4x - PEST_FAULT_STRIP_SOL_DISCONNECT PEST - Strip solenoid disconnect. The strip solenoid is not drawing the expected power from the supply. 1. Run the Strip Solenoid test. 2. Check the strip solenoid wiring. 3.
Page 100 PEST - Process motor short. The process motor is drawing to much power from the supply. 1. Run the Process Motor test. 2. Check the process motor wiring. 3. Replace the process drive assembly if the test fails. 3-32 Phaser 8400 Color Printer...
Page 101 Error Code Definition Table (Continued) Error code Definition 37,038.4x - PEST_FAULT_PWR_RESET_DISCONNECT PEST - The power supply did not reset properly as requested. The reset line may not be connected. 37,039.4x - PEST_FAULT_PWR_P5_0_OVER PEST - Power Supply +5.0 OVER LIMIT 37,040.4x - PEST_FAULT_PWR_P5_0_UNDER PEST - Power Supply +5.0 UNDER LIMIT 37,41.4x - PEST_FAULT_PWR_P1_8_OVER PEST - Power Supply +1.8 OVER LIMIT...
Page 102 PEST - Vss measurement too low, head power cable may be disconnected. 37,063.4x - PEST_FAULT_HEAD_VPP_DISCONNECT PEST - Vpp measurement too low, head power cable may be disconnected. 1. Verify the printhead power cable is connected. 3-34 Phaser 8400 Color Printer...
Page 103: 3-Digit Jam Codes
3-Digit Jam Codes The printer stores the most recent 20 events in Jam History. To access this information press the Up arrow button when the jam code is displayed, scroll to History, and press OK. The information is presented with most recent jam at the top of the list. Jam Code Key Table Print Process Basis for Declaring a...
Page 104: Jam Code Definition Table
5. Ensure ground integrity of the printer, see page 4-67. 6. Verify all doors and covers are fully closed and not moving during printing. 7. Replace the Tray 2 - 4 pick clutch. 8. Replace the retard roller. 9. Replace the preheater. 3-36 Phaser 8400 Color Printer...
Page 105 Jam Code Troubleshooting Procedures (Continued) Deskew Sensor time-out event during an auto drum maintenance cycle. The deskew flag timed out waiting for the paper picked from Tray 2. The deskew flag timed out waiting for the paper picked from Tray 3 The deskew flag timed out waiting for the paper picked from Tray 4.
Page 106 The strip flag actuated unexpectedly when paper picked from Tray 3. The strip flag actuated unexpectedly when paper picked from Tray 4. The strip flag actuated unexpectedly when paper picked from Tray 1. Strip flag unexpected event during pick from the duplex path. 3-38 Phaser 8400 Color Printer...
Page 107 Jam Code Troubleshooting Procedures (Continued) C2x (continued) Strip flag unexpected event during transfix. 1. Ensure ground integrity of the printer, see page 4-67. 2. Check the paper tray for overfill. 3. Run the Stripper sensor test. 4. Inspect the stripper blade for damage or debris. 5.
Page 108 Exit flag timed out following Tray 2 Pick. Exit flag timed out following Tray 3 Pick. Exit flag timed out following Tray 4 Pick. Exit flag timed out following Tray 1 Pick. Exit flag timed out during duplexing. 3-40 Phaser 8400 Color Printer...
Page 109 Jam Code Troubleshooting Procedures (Continued) D3x (continued) Exit flag time-out during transfix. 1. Inspect the exit path for obstructions. 2. Inspect and clean the exit roller, ensure the exit roller rotates. 3. Inspect and clean the stripper blade. 4. Replace the drum maintenance unit. 5.
Page 110 Paper path motor stalled while the printer picked from Tray 1. Paper path motor stalled while the printer duplexed the print. Paper path motor stalled while the printer staged the print for transfix. M4x (continued) 3-42 Phaser 8400 Color Printer...
Page 111 Jam Code Troubleshooting Procedures (Continued) Paper path motor stalled during transfix. 1. Verify the media in the tray is supported by the printer. 2. Inspect the paper path for obstructions. 3. Run the Paper Drive Power test. 4. Run the Media Path Motor and Shafts test. 5.
Page 112 6. Run the clean ink smears and check the preheater exit flag for debris. 7. Replace the Tray 1 Separator Pad Assembly. Process motor stalled on abnormal shutdown. Process motor stalled on power-up following a normal printer shutdown. 3-44 Phaser 8400 Color Printer...
Page 113 Jam Code Troubleshooting Procedures (Continued) Process motor stalled during mechanical recovery. Process motor stalled during an printer warmup. Process motor stalled while the printer was in its ready state. Process motor stalled while the printer was in a fault state. Process motor stalled while the printer performed an auto drum maintenance cycle.
Page 114 6. Replace the drum maintenance unit. 7. Replace the transfix roller. Tray 2 media size sensor unexpectedly activated during warm-up. Tray 2 media size sensor unexpectedly activated during printer ready. 3-46 Phaser 8400 Color Printer...
Page 115 Jam Code Troubleshooting Procedures (Continued) Tray 2 media size sensor unexpectedly activated while printer was in a fault state. Tray 2 media size sensor unexpected event during oil transfix. Tray 2 media size sensor unexpectedly activated while the printer was in standby. Tray 2 media size sensor unexpectedly activated while picking from Tray 2.
Page 116 Tray 3 pick flag triggered unexpectedly while duplexing. Tray 3 pick flag triggered unexpectedly while transfixing. Tray 3 pick flag triggered unexpectedly while print drum maintenance cycle was being performed. Tray 3 pick flag triggered unexpectedly during printer imaging. X2x (continued) 3-48 Phaser 8400 Color Printer...
Page 117 Jam Code Troubleshooting Procedures (Continued) Tray 3 pick flag triggered unexpectedly while exiting print. 1. Ensure ground integrity of the printer, see page 4-67. 2. Ensure the paper guides are correctly set. 3. Run the Monitor Sensors test to test the media size sensor. 4.
Page 118 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. Z2x (continued) 3-50 Phaser 8400 Color Printer...
Page 119 Jam Code Troubleshooting Procedures (Continued) Tray 4 pick flag triggered unexpectedly while duplexing. Tray 4 pick flag triggered unexpectedly while paper staged for print. Tray 4 pick flag triggered unexpectedly while transfixing the print. Tray 4 pick flag triggered unexpectedly while the printer drum maintenance cycle was being performed.
Page 120 3-52 Phaser 8400 Color Printer...
Page 121: General Troubleshooting
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 Section...
Page 122: Introduction
Fault History Displays available information regarding the last 15 faults reported by a test and/or the print engine. Jam History Displays available information regarding the last 20 Jams reported by a test and/or the print engine. Phaser 8400 Color Printer...
Page 123 Menu Item Description Enter Diagnostic Mode See "Service Diagnostics Mode Menu" on page 4-5 for a complete explanation of each diagnostic routine. 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.
Page 124: Service Diagnostics
This control does not ‘wrap’. Enters the highlighted menu. Executes the current test item. NOTE: Pressing any key may cause an abort if allowed by the test being performed. A power cycle is used to arbitrarily stop a test. Phaser 8400 Color Printer...
Page 125: Service Diagnostics Mode Menu
Service Diagnostics Mode Menu This mode can be entered from the hidden service menu. All diagnostics are available in this mode. The printer reboots after entering or exiting all diagnostic modes. The printer will keep the printer thermals hot during diagnostics to avoid unnecessary cleaning cycles. If a diagnostic test runs into a problem while initializing the heaters a message will display, “Test Fault, can’t warm up - press any button”, you can still continue to run diagnostics under this condition.
Page 126 Cycles the activator repeatedly until Clutch interrupted by a front panel button press. Tray 3 Pick Cycles the activator repeatedly until Clutch interrupted by a front panel button press. If not installed generates an “Option not detected” message. Phaser 8400 Color Printer...
Page 127 Menu Map (Continued) Menu Description Tray 4 Pick Cycles the activator repeatedly until Clutch interrupted by a front panel button press. If not installed generates an “Option not detected” message. Deskew Clutch Cycles the activator repeatedly until interrupted by a front panel button press.
Page 128 If not installed generates an “Option not detected” message. Tray 3 Lift Motor Cycles the motor/shaft repeatedly until interrupted by a front panel button press. If not installed generates an “Option not detected” message. Phaser 8400 Color Printer...
Page 129 Menu Map (Continued) Menu Description Tray 3 Motor & Cycles the motor/shaft repeatedly until Shafts interrupted by a front panel button press. If not installed generates an “Option not detected” message. Tray 4 Pick Shaft Cycles the motor/shaft repeatedly until interrupted by a front panel button press.
Page 130 A restricted function that clears the PE NVRAM to be rebuilt with defaults at the next power up. Set PE NVRAM to A restricted function that sets the PE Defaults NVRAM parameters to the default values. 4-10 Phaser 8400 Color Printer...
Page 131: Check Menu Definition Tables
Check Menu Definition Tables A submenu containing a set of extensive tests that return measured mechanism parameters for comparison against stated limits. Refer to the table associated with each test for their normal operating ranges. In cases where insufficient baseline data is available, the results have been left blank. All results from tests that move paper through the printer were collected using 24 lb.
Page 132 Strip Solenoid Gathers data on the performance of the stripper solenoid coil and plunger. Typical Definition Value Actions Peak Power (watts) 8.0 to 15 Reports the profile max power value. 4-12 Phaser 8400 Color Printer...
Page 133 Strip Solenoid Gathers data on the performance of the stripper solenoid coil and plunger. Typical Definition Value Actions Average Power 8.0 to 15 Reports the average power during the (watts) constant portion of the profile. Purge Vent Solenoid Gathers data on the performance of the purge vent solenoid coil. Typical Definition Value...
Page 134 Reports the min power following power off. Power (watts) 110 V Coil Peak Reports time after solenoid power on that the Power Time (sec) peak power occurred. 110 V Coil Initial Reports the average power following power on. Average Power (watts) 4-14 Phaser 8400 Color Printer...
Page 135: Check Shafts Menu
Check Shafts Menu Deskew Shaft Runs the media path drive train and engages the deskew clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc. Typical Definition Value...
Page 136 Reports the time it takes the MP motor servo time (sec). 0.20 system to "settle down" after the sudden release of the deskew shaft load. A larger value could indicate a dragging or slow to release clutch. 4-16 Phaser 8400 Color Printer...
Page 137 Wiper Shaft 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. Typical Definition Value Actions...
Page 138 Reports the time it takes the MP motor servo time (sec). system to "settle down" after the sudden release of the wiper shaft load. A larger value could indicate a dragging or slow to release clutch. 4-18 Phaser 8400 Color Printer...
Page 139 Tray 1 Pick Shaft Runs the media path drive train and engages the tray 1 pick solenoid on the fly. The pick shaft goes through 2 full revolutions while drive requirements are determined. Typical Definition Value Actions Off average MP fe. 800 to Reports the average MP fe during the run in interval before the pick shaft is engaged.
Page 140 Reports the variation of effort required to rotate the Tray 2 pick shaft in the pick direction at a constant velocity. A larger value could indicate particles in the gears or non uniform contamination of a roller (causing a lump). 4-20 Phaser 8400 Color Printer...
Page 141 Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Test is the same for each pick shaft although for tray 2 the media path motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used. Test determines if the shaft can be driven by the clutch, if the nudger rollers are being driven, and the pick pad/nudger roller friction.
Page 142: Check Fans Menu
Constant 0.25 to 1.5 to 5.0 -0.01 to 7 Reports the time from On Velocity until the fan reaches constant Time (sec) velocity. Could indicate a weak fan/fan drive or extra drag (bearings, brushes, blade). 4-22 Phaser 8400 Color Printer...
Page 143: Check Heaters Menu
Check Heaters Menu Reservoir Heater, Jetstack Left Heater, Jetstack Right Heater, Paper Preheater, Drum Heater, Ink Melt 1 (yellow) Heater, Ink Melt 2 (cyan) Heater, Ink Melt 3 (magenta) Heater, Ink Melt 4 (Black) Heater This test sequentially applies power to each of the heaters to verify the relationship between power applied and heating/cooling and to check the current drawn by each heater.
Page 144: Check Paper Path Menu
Reports the tray from which the test paper was picked. Paper Size Reports the size of the picked paper. Unused Unused Tray 2 Pick Average Reports average of the power over the pick Power (watts) interval (begin pick to Deskew sensor). 4-24 Phaser 8400 Color Printer...
Page 145 Paper Lead Edge Times Paper is picked and moved through either simplex or duplex paper path to determine leading edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Definition Value...
Page 146 Typical Definition Value Actions Common Tray Reports the tray from which the test paper was picked. Paper Size Reports the size of the picked paper. 4-26 Phaser 8400 Color Printer...
Page 147 Paper Trail Edge Times (Continued) Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Definition Value...
Page 148 Reports the interval during which the Preheat Interval (us) sensor bounces following the passage of the paper trailing edge. Strip Bounce Reports the interval during which the Strip Interval (us) sensor bounces following the passage of the paper trailing edge. 4-28 Phaser 8400 Color Printer...
Page 149 Paper Sensor Bounce Times (Continued) Paper is picked and moved through either the simplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Definition Value...
Page 150 (part way through the paper transfix motion). Duplex Strip Trailing Reports the interval from the time the engine software is commanded to start the exit Edge Interval (us) process until the Strip sensor deactivates. (part way through the paper exit motion). 4-30 Phaser 8400 Color Printer...
Page 151 Duplex Paper Trail Edge Times (Continued) Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Definition Value...
Page 152: Check Drive Menu
Turnaround 0.001 to Reports the time following the start of the Recovery time (sec) 0.250 turnaround motion that the motion drive error return to normal in the opposite direction. 4-32 Phaser 8400 Color Printer...
Page 153 Paper Path Drive This test moves the gear train in one direction while capturing data, does a reversal to capture reversal transient data, then operates in the other direction. Typical Definition Value Actions Forward Drive Power Reports the average drive power level in the Level (watts) foreword direction.
Page 154 Transfix Roller Down interval (mpts) Time to last -0.001 to 0.30 to Reports the time from the unload command to contact (sec) 0.800 0.80 the engine until the drum indicates no further contact. 4-34 Phaser 8400 Color Printer...
Page 155 Drum Maintenance Drive With the Y-axis rotating, the drum maintenance unit is loaded against the drum for a short time in each configuration (roller and blade/blade only) Typical Definition Value Actions Time to blade first .01 to .35 Reports the time from the load command to the contact (sec) engine until the drum indicates blade contact.
Page 156 (sec) min (when the plate is not yet engaged), and the point where the lifting power becomes a constant. Average Lift Power Reports the average power over the center ¾ (watts) of the lifting interval. 4-36 Phaser 8400 Color Printer...
Page 157: Check Drum Menu
Tray 2, Tray 3, Tray 4, Lift Plate Drive (Continued) This test raises the lift plate to verify motion and sensor operation. If the test is requested for a 525-sheet feeder that is not installed, an “Option Not Detected” message is generated. Typical Definition Value...
Page 158 FFT Power Ratio 2 Reports the ratio of the FFT power amplitude (none) of the second most powerful FFT frequency (not including the drum or motor), to the FFT power amplitude of the drum frequency. 4-38 Phaser 8400 Color Printer...
Page 159 Y-axis Geometry Rotates the drum at a constant velocity and samples the Y-axis position. Uses the data to determine Y-axis motor and drum vibration and the most significant other vibrational frequencies. Typical Definition Value Actions Frequency 2 Reports the frequency of the second most Frequency (hz) powerful FFT frequency (not including the drum or motor).
Page 160 Reports the number of full Y-axis revs required Frequency Revs to locate the min frequency configuration. (revs) Min Resonant -0.001 to Reports the amount of additional Y-axis Frequency Angle -0.2 rotation required to locate the min frequency (deg) configuration. 4-40 Phaser 8400 Color Printer...
Page 161 Stripper Contact This test holds the drum stationary while the stripper solenoid is activated and released. The drum servo error signal illustrates activation/deactivation timing and how strongly the drum was contacted by the blade. Typical Definition Value Actions Engage -10 to 2 Reports the static difference between the Displacement (mpts) average ya_fe before and after the blade...
Page 162: Check Motors Menu
Motor drive power 0.25 to Reports variation of motor drive power over the ripple (watts). recording interval. Motor drive power 1.25 to Reports average value of motor drive power average (watts) over the recording interval. 4-42 Phaser 8400 Color Printer...
Page 163 X-Axis Motor This test turns on the X-axis motor and runs it very slowly for one revolution. Typical Definition Value Actions Motor Voltage A 84 to 86 Reports amount of variation of the motor Ripple (volts). phase A drive voltage over the recording interval.
Page 164 Reports the average motor drive power over Power (watts) the last half of the run interval. Brake Average .10 to .20 Reports the average motor brake power over Power (watts) the stop with brake interval. 4-44 Phaser 8400 Color Printer...
Page 165: Check Misc Menu
Tray 3 and Tray 4 Pick/Feed Motor This test turns on the specified motor and runs it at constant velocity for approximately 25 revolutions while recording drive data. The test is the same for each motor. Requesting a test for a 525-sheet feeder that is not installed will generate an “Option Not Detected”...
Page 166 2, 3, 4 - media length top 2, 3, 3 - media length bottom 2, 3, 2 - Media width top 2, 3, 1 - media width middle 2, 3, 0 - Media width bottom 4-46 Phaser 8400 Color Printer...
Page 167 Temperature Status This test scans the thermocouples and reports data on the current temperature with the goal of providing a picture of the current temperature state of the printer. All degrees are reported in celsius. Typical Definition Value Actions Reservoir Temp Reports the current temperature ~127.7 Left Jetstack...
Page 168 (plugged, etc.). Voltages This test determines averaged readings for key system voltages. Typical Definition Value Actions Main Board Voltages 5 Volts (volts) 1.8 Volts (volts) ~1.8V 2.5 Volts (volts) ~2.5V 4-48 Phaser 8400 Color Printer...
Page 169 Voltages (Continued) This test determines averaged readings for key system voltages. Typical Definition Value Actions 3.3 Volts (volts) +/-2.5% unregulated12 Volts +/- 20% (volts) 2.5 Volts (volts) ~ 2.5 unregulated +/- 20% Negative 12 Volts (volts) Control Board Voltages DC Power (watts) 50 Volts 47 to 52 Negative 50 Volts...
Page 170 Reports the height of the initial peak when (pm motor counts) starting rotation of the tf drive gear. TF Initial FE Peak Reports the time since the start of CW motion Time (sec) until the peak was detected. 4-50 Phaser 8400 Color Printer...
Page 171: Electronics Troubleshooting
This test takes about 8 seconds All LEDs are off during the test. If POST diagnostics pass, the front panel displays the Xerox logo and turns on the green LED. If an error is detected, the error message is displayed on the LCD and the printer flashes the LEDs with a repeating error code pattern.
Page 172: Mechanical Initialization
Mechanical Initialization 4-52 Phaser 8400 Color Printer...
Page 173 Service Manual 4-53...
Page 174 A cleaning page is printed at this time, if a purge was performed. A start page is printed (if enabled). The front panel displays a message that the printer is initializing and then ready. The print engine is initialized and is ready to print. 4-54 Phaser 8400 Color Printer...
Page 175: Miscellaneous Electrical Troubleshooting
Miscellaneous Electrical Troubleshooting The electronics module contains the Power Supply, Image Processor board and the Power Control board. If a component of the electronics module fails, and service is necessary, the entire electronics module is replaced as a unit - no individual board troubleshooting is needed.
Page 176 Unplug the front panel connector (J220) on the I/O board. This removes the front panel from the I/O board. Plug in the Power Control to I/O board connector (J800). This step adds the I/O board back to the working electronics module - nothing else is connected. 4-56 Phaser 8400 Color Printer...
Page 177 Turn on power to the printer If the PE and PS indicators do not flash, the short is on the I/O board or related cabling. Skip the rest of this section if the PE and PS indicators flash because the problem is elsewhere in the printer.
Page 178 Plug in all cables removed during service. Trace through all service steps performed to reattach any cables that were unplugged during debugging. Attach printer covers. Perform full test of printer. 4-58 Phaser 8400 Color Printer...
Page 179 Printer Is on and Can Print Pages, but the Front Panel Appears Frozen and No Error Messages Are Displayed Note Opening and closing the front door of the printer causes a reset of the entire front panel. Electrostatic Discharge. If the printer is currently powered on and frozen, open then close the front door of the printer and see if the LCD responds.
Page 180 Cycle power to ensure printer initializes during stable AC power. Internal fault Record any error codes and report to Xerox Office Group. If the printer detects an error, the printer will attempt to correct the problem by rebooting and reinitializing (for up to three times). After the third cycle of rebooting, an error code will be displayed on the LCD and flashed on the PS and PE indicators.
Page 181 Printer Fails to Enter E Mode NERGY Model not certified as an E model. NERGY Use the front panel to enable Energy Star mode (Printer Setup -> Printer Control -> Select Power Saver Timeout). Many printers are not shipped as Energy Star compliant and don't have the power saving mode enabled by default.
Page 182 If the PS & PE indicators are blinking, brightly-on, or totally off, continue debugging. A dim but steady on condition indicates some firmware was not properly loaded into a logic circuit. With power cord connected, touch the metal electronics module to discharge any static electricity. 4-62 Phaser 8400 Color Printer...
Page 183 Turn off printer and wait 30 seconds for power supply capacitors to discharge. Unplug power cord and remove printer's covers. Unplug the following electronics module connectors: Power Control to I/O board (J800) Power Control right (J400) Printhead data (J130) Waveamp signal (J790) Power Control left (J390) Y-Axis motor (J280) This step removes all other circuits so the electronics module can be tested...
Page 184 Print it is now possible to print any built-in pages. If the printer prints the Page, the print engine is working correctly. If the printer does not print the Page, then a problem exists with the print engine. 4-64 Phaser 8400 Color Printer...
Page 185: Verifying Power Supply Operation
Verifying Power Supply Operation Required tools TORX T-20 screwdriver Digital Multi-Meter (DMM) The power supply is divided into two sections: the AC section used for heaters and the DC section for control logic, printhead drivers and motors. Verifying the power supply involves three steps: Checking for proper AC voltage.
Page 186: Measuring Dc Power Supply Voltages
Replace the Inkloader Assembly and Door following the test. Measuring DC Power Supply Voltages Check the power supply status LEDs, they should be bright. If the printer is operational, use the diagnostic test Monitor Voltages. 4-66 Phaser 8400 Color Printer...
Page 187: Ensuring Ground Integrity
Ensuring Ground Integrity Intermittent or missing ground connections can result in minor interferences in the printer. As examples: Front panel display can be affected (blank) I/O board errors False jam reporting Erroneous thermistor readings Major interruptions Damage to the electrical boards Key Ground Connections The following illustration shows the grounding points in the printer that need to be checked.
Page 188 DM Ground I/O Board Transfix roller clip ground ground springs X-Axis return Y-Axis motor spring ground ground s8400-206 4-68 Phaser 8400 Color Printer...
Page 189: Testing Motor And Solenoid Resistances
Testing Motor and Solenoid Resistances Turn off the printer and disconnect the power cord. With a DMM set for measuring resistance, test each motor's windings for correct resistance (disconnected from the printer). Rotate the motor's drive shaft slightly while taking the measurement. Motor and Solenoid Resistances Motor or Solenoid Resistance (Approximate)
Page 190: Paper Path And Media-Based Problems
Clean the pick roller using the cleaning procedures. Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of the tray. Also clean the transport rollers if they are visibly dirty. Refer to page 7-4 for proper cleaning procedures. 4-70 Phaser 8400 Color Printer...
Page 191: Preheater And Transfix Jams
Check that the pick roller is being rotated. Run the Paper Path test. Replace the pick roller if damaged. Inspect the rollers, bushings and gears of the paper path. Paper-Pick Errors - Tray 1 Verify the media being used is the correct size and weight. Clean the Tray 1 pick roller and separator pad, refer to the cleaning procedure.
Page 192: Checking The Process And Media Path Drive
Check and clean or replace, as required, the preheater and/or take away rollers. Also make sure that the front door is properly closed. The printer should be installed on a flat, level surface. Ensure the paper preheater assembly is clean and properly seated into the printer frame. 4-72 Phaser 8400 Color Printer...
Page 193: Operating System And Application Problems
Operating System and Application Problems Print an internal test print from the printer’s front panel to ensure the problem is not printer related. There is additional help available at www.xerox.com/office/support. You can access the infoSMART Knowledge Base, PhaserSMART Technical Support, Technical Support via email, driver downloads, and much more.
Page 194 “LOCAL LINK” value within the 169.254.xxx.xxx range. Note To comply with industry standards, Phaser 8400 printers cannot be manually configured for IP addresses within the LOCAL LINK range. Note Always print the Configuration Page to obtain a record of the printer settings before changing the IP address.
Page 195: Network Problems
To test the connection, click the START button. Select SETTINGS and then PRINTERS. Locate the Phaser 8400 Color Printer icon and display its properties. From the General tab, click the Print Test Page button to generate the test print. If the test page prints, the USB port is functioning normally.
Page 196: Obtaining Serial Back Channel Trace
Programs:Accessories:Communications:HyperTerminal). Ensure the serial port settings, usually COM1: is correct. Turn on the printer. The trace should appear in the terminal dialog window. Examine the trace to troubleshoot the problem. Save the trace as a file, if necessary. 4-76 Phaser 8400 Color Printer...
Page 197: Print-Quality Troubleshooting
Print-Quality Troubleshooting In this chapter... Print-Quality Problems Overview Analyzing Service Test Prints Section...
Page 198: Print-Quality Problems Overview
The paper should be from an unopened ream that has been acclimated to room temperature. See the approved media list from, "Xerox Supplies" on page 9-16 for media that has been tested and approved for use in this printer. If the print-quality defect is still present when printing on approved media from an unopened ream of paper, then media, software applications, and environmental conditions need to be researched.
Page 199: Random Light Stripes
Random Light Stripes One or more color bars are missing on the test page. Light Stripes Test Step Question and Actions At the printer’s front panel, select Troubleshooting, select Print Quality Problems, select Eliminate Light Stripes, then press the OK button. Under the exit cover, lift the green guide, wipe the plastic paper release blade with a lint-free cloth, then close the exit cover.
Page 200: Predominate Light Stripes
Open the side door on the right panel, remove the orange maintenance kit, wipe the clear plastic wiper blade with a lint-free cloth, reinsert the maintenance kit, then close the side door. If the problem continues, follow the steps for “Random Light Stripes” on page 3. Phaser 8400 Color Printer...
Page 201: Smudges Or Smears
Smudges or Smears Smudges or smears appear on the page. Step Question and Actions Under the exit cover, lift the green guide, carefully wipe the plastic paper release blade with a lint-free cloth, then close the exit cover. At the printer’s front panel, select Troubleshooting, select Print Quality Problems, select...
Page 202: Printing Too Light Or Too Dark
Confirm that you are using media from the approved media list. For information about the approved media list, see "Xerox Supplies" on page 9-16. Try a different print mode. If some improvement is seen, the ink may be discolored due to a long time without use.
Page 203: Not Printing
Not Printing The printer processes a sheet of paper, but no image is printed on it. Note Blank sheets accompanying multi-picks or chase pages following a jam are a part of normal operation. Step Question and Actions Ensure that no paper is jammed between the printhead and the drum. Inspect the wave amp cables and the data cables going to the printhead, replace if necessary.
Page 204: Color Is Uneven Or Color Is Wrong
This may be due to incorrect colors in the ink loader, old ink in the printhead, color mixing at the faceplate, or drum thermal problems. Note Using non-Xerox ink may cause unpredictable color results. 0388-45 Step Question and Actions Remove discolored jets in the printhead jets by printing the solid fill test print in the color with the discolored jets.
Page 205: Streaks Or Lines Down The Print
Streaks or Lines Down the Print There are several possible causes of streaks running down the length of a print. 0388-41 Step Question and Actions Check for media in the exit path. Clean the maintenance kit wiper blade. Inspect the operation of the maintenance kit. If necessary, replace the maintenance kit.
Page 206: Scratches Or Marks Parallel To The Long Axis Of Printing, Particularly With Film
Be careful of the paper-sensor flags. Inspect all paper guides (for example the exit guide) for nicks and cuts. Replace if necessary. 5-10 Phaser 8400 Color Printer...
Page 207: White Portion Of Print Is Colored
White Portion of Print is Colored Color on a print where no color should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. An insufficient amount of oil on the drum, provided by a dirty, defective, or old maintenance kit may be the problem.
Page 208: Fuzzy Text
Verify the operation of the Y-Axis encoder using diagnostics. Replace the drum assembly if needed. Verify the head is tilted forward against the drum in the print position. Follow the instructions on the “Printhead Troubleshooting Checklist”. 5-12 Phaser 8400 Color Printer...
Page 209: Poor Primary Color Fills
Poor Primary Color Fills Primary fills appear banded and inconsistent. 0388-47 Step Question and Actions Possible missing, weak, or discolored jet. Print the Service Test Print 1: Weak/Missing Jet to determine if a jet is not missing or weak. If there are discolored jets, print the solid fill test print in the color with the discolored jets.
Page 210: Ghosting
Inspect the maintenance kit. Replace the maintenance kit if necessary. Run diagnostics to verify the drum maintenance system is operating correctly. Replace the defective parts. Ensure that the drum temperature sensor is clean and properly positioned. Clean, realign, or replace the sensor. 5-14 Phaser 8400 Color Printer...
Page 211: Poor Small Text Resolution
Poor Small Text Resolution Small characters appear heavy and “plug up.” 0388-70 Step Question and Actions Use a higher resolution print mode, such as Enhanced or High Resolution/Photo mode. Inspect and clean the drum temperature sensor. Verify the drum temperature using diagnostics. Ensure that the drum temperature sensor is properly positioned.
Page 212: Vertical Lines Appear Wavy
Confirm that nothing is interfering with the X-Axis motion, such as a poorly dressed cable or a loose screw. Very that the drum maintenance cam roller and pivot plate are operating correctly. Test them using diagnostics. 5-16 Phaser 8400 Color Printer...
Page 213: Oil Streaks On Print
Oil Streaks on Print Oil stains the edge of the print. 0388-51 Step Question and Actions Run chase pages through the printer to clean the drum. Use the front panel menu item Remove Print Smears. Clean the paper release blade and the exit guide. Verify that the drum maintenance cam roller and pivot plate are operating correctly.
Page 214: Incomplete Image Transfer To Paper
Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface. Verify the paper preheater temperature using diagnostics. Transfix load system may be worn, resulting in low transfix pressure. Replace the Transfix load assembly and transfix load arm. 5-18 Phaser 8400 Color Printer...
Page 215: Ink Smears On First Printed Side Of Duplex Print
Ink Smears on First Printed Side of Duplex Print Preheater temperature is too high. 0388-73 Step Question and Actions Clean the paper release blade. Inspect the duplex paper path for obstruction, contamination, debris, or damage. Clean Print Smears. Verify the paper preheater temperature using diagnostics. If necessary, replace the paper preheater.
Page 216: Repeating Print Defects On Print
A single repeating defect on the page with the defect on each page having a different Y-Axis position and is always in the same X-position is probably due to a defect on the drum. home position of the drum changes every print. Clean or replace the drum assembly. 5-20 Phaser 8400 Color Printer...
Page 217: White Stripes (Pinstripes)
White Stripes (Pinstripes) This print-quality problem has a series of regularly spaced white stripes approximately 6 mm (.25 in.) apart. If the X-Axis Drive does not move the printhead smoothly and evenly during printing, vertical lines appear in the print. s8400-200 Step Question and Actions...
Page 218: Wrinkling
Increase the margin size of the image, if feasible. Wrinkling generally occurs in solid fills near the print’s edge. Inspect the maintenance kit wiper blade. If necessary, replace the maintenance kit. Replace the transfix roller, transfix cam, transfix load arm, and transfix load module. 5-22 Phaser 8400 Color Printer...
Page 219: Image Is Offset Or Cut-Off
Follow these steps if the ink is flaking off the print after the print is complete. If a specialty coated paper is being used (for example, glossy media), try a different paper. Xerox transparency film provides the best ink adhesion versus off-the-shelf transparency film.
Page 220: Analyzing Service Test Prints
This section shows how to select and analyze all test prints available to the Phaser 8400 printer. To access the Service Tools menu: From anywhere within the menu (not diagnostics), press and hold the Up Arrow button, then press the OK button.
Page 221 Manufacturing. The print must be printed on This is a text print This is a text print Xerox Photo Paper. Using a lower grade paper This is a text print This is a text print This is a text print...
Page 222 If necessary, remove the sensor and check it for an accumulation of debris at its contact point. Replace the drum temperature sensor. Ensure the printhead drive voltage is set to the default 128. 5-26 Phaser 8400 Color Printer...
Page 223 Test Print Examples (Continued) 5: Big Bands OHP This print allows you to evaluate transparency printing. It prints two transparencies from Tray 1, one with primary color fills and one with secondary color fills and a band of 50% blue, as this is a popular background color for overhead transparencies.
Page 224 Verify that the maintenance kit returns home between prints. Inspect the cam shaft surfaces for damage. If all of these items are working correctly, replace the process drive module. 7: Manuf. Five Duplex GSF This print is used by Manufacturing and Engineering. 5-28 Phaser 8400 Color Printer...
Page 225 Test Print Examples (Continued) 8: YMCKRGB Solid Fills These seven prints show uniformity of fill. If colors are uneven or wrong, see "Color is Uneven or Color is Wrong" on page 5-8. Look for: 1. Even, uniform fills throughout each print. 2.
Page 226 There is no head-to-drum adjustment possible in this printer. If the gap is suspect, check that the printhead is correctly and completely installed. s8400-1 4 12: Manuf X-Axis (Scanner) This print is used by Manufacturing and Engineering. 5-30 Phaser 8400 Color Printer...
Page 227 Test Print Examples (Continued) 13-19: Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills This prints show uniformity of fill. Look for: 1. Even, uniform fills throughout the print. 2. There should be no wrinkling or deformity of the paper throughout the print. 3.
Page 228 Transfix Roller defects do not move in the X-direction; but, these defects repeat every 4.58 in. (11.63 cm) down the length of the page. Many Transfix Roller defects will be most visible on duplex solid fills. 5-32 Phaser 8400 Color Printer...
Page 229 Test Print Examples (Continued) 22: Manuf. Skew Margins This print consists of an image used by manufacturing to gauge skew and margin on 2- sided prints. Skew To measure skew: the measurement between the edge of the paper and the magenta frame should be within tolerance along the entire length of the top of the paper.
Page 230 A blank piece of paper is used to remove contamination from the drum, transfix roller, and paper path. 29: Oil Bar Chase This print is used by Manufacturing. 30: Purge Efficiency This print is used by Manufacturing and Engineering. 5-34 Phaser 8400 Color Printer...
Page 231 Test Print Examples (Continued) 31: Cleaning Page This page is automatically printed following a purge. It is used to flush the jet nozzles of any possible contamination or color mixed jets. It can also be printed on its own. s8400-162 Service Manual 5-35...
Page 232 5-36 Phaser 8400 Color Printer...
Page 233: Adjustments And Calibrations
Adjustments and Calibrations In this chapter... Printer Component Homing Positions and Indicators Printer Calibrations Jet Substitution Mode Resetting NVRAM Section...
Page 234: Adjustments
Remove the printer covers using the procedures that begin on page 8-4. Remove the left head maintenance drive gear (see the following figure) by removing the e-clip from the drive shaft. Left Idler Gear Left Drive Gear s8400-163 Phaser 8400 Color Printer...
Page 235 At the same time, rotate the left and right idler gears until the wiper is all the way to the bottom and the gears cannot be rotated further. Rotating the left and right gears together ensures that the wiper stays parallel and does not pop out of the belts.
Page 236: Printer Component Homing Positions And Indicators
When the wiper is homed, the wiper should be moved all the way to the bottom of the printer. When the wiper is at the bottom, you can easily remove the waste tray. See the "Wiper Alignment Procedure" on page 6-2. Phaser 8400 Color Printer...
Page 237: Homing The Head Tilt Gear
Homing the Head Tilt Gear The Printhead Is Not in the Printer If the printhead is not in the printer, move the tilt gear, located on the inside of the left frame, manually to its disengaged position. Drum Printhead in print position Tilt gear disengaged.
Page 238 If the printhead is engaged, manually assist the movement of the printhead. Note The hole on the drum maintenance camshaft drive gear should be at the 6:00 position after the rotation. Insert screwdriver and rotate clockwise. Drum maintenance camshaft gear s8400-187 Phaser 8400 Color Printer...
Page 239 Note When the tilt gear is disengaged, the two arrows on the left side of the printer are pointing at each other. Tilt gear disengaged Tilt gear engaged s8400-195 Service Manual...
Page 240: Homing The Process Gear Drive Train
The hole in the transfix camshaft gear align with the hole on the frame. Holes in process drive frame aligns with holes in gears Hole in gear aligns with Hole in gear arrow on aligns with frame arrow on frame s8400-194 Phaser 8400 Color Printer...
Page 241: Printer Calibrations
Printer Calibrations Wiper Alignment See the Wiper Alignment Procedure on page 6-2. Jet Substitution Mode The Jet Substitution Mode provides a temporary solution for print-quality problems when weak or missing jets cannot be recovered. Jet Substitution Mode reduces the maximum imaging speed by 50% or more and has other limitations that affect printer performance.
Page 242: Disabling Jet Substitution Mode
Press and hold the Up Arrow button, then press the Back button. Turn Jet Substitution Mode Off, then press the OK button. Scroll to Print the Eliminate Light Stripes test page to verify that Service Mode is disabled for all jets. 6-10 Phaser 8400 Color Printer...
Page 243: Resetting Nvram
Resetting NVRAM Resetting NVRAM returns all the Image Processor Board NVRAM-stored parameters to their factory default values. The print counts and the Adobe firmware serial number are not affected by this reset. You can reset the PostScript NVRAM using the Service Tools Menu or the Service Diagnostics Menu. Service Manual 6-11...
Page 244 6-12 Phaser 8400 Color Printer...
Page 245: Cleaning And Maintenance
Cleaning and Maintenance In this chapter... Maintenance Inspection Cleaning Section...
Page 246: Service Cleaning Maintenance Procedure
Persistent paper jams inside the printer or at the media tray if the rollers are visibly dirty. Wiggly vertical stripes caused by too much oil created by a dirty maintenance kit blade. Most print-quality problems can be corrected by running the cleaning procedures on the printer’s front panel menu. Phaser 8400 Color Printer...
Page 247: Cleaning
Cleaning Supplies Required 90% pure isopropyl alcohol Alcohol-moistened, lint-free wipes Foam swabs Clear packaging tape Caution Do not use rubbing alcohol because it can contain water and oils that leave undesirable residue on the printer parts. Never use water to clean the printer’s internal components.
Page 248: Pick Roller Cleaning Method
Trays 2-4. This cleaning method has been found to be extremely effective for removing debris. Isopropyl alcohol, while effective, tends to smear the debris, rather than remove it. Remove the tray with the paper-picking or paper jamming problem (Trays 2, 3, or Phaser 8400 Color Printer...
Page 249: Maintenance
Peel off a strip of tape. Stretch the tape across the table with the sticky side up. Fasten it to the table at both ends. Remove the roller. Roll the roller across the tape to remove the debris from the roller. Locate a clean section of the tape, rub it onto the surface of the pick pad for the paper tray, then remove it.
Page 250: Lubrication
The printer is lubricated during assembly at the factory and requires no periodic lubrication. Some parts require lubrication following replacement. These parts are identified in the replacement procedures. When lubricating during replacement, use the grease approved for the Phaser 8400 printer. The grease part number is 006-7997-00. Caution Plastic parts will deteriorate when unspecified grease and chemicals are used, such as WD-40®...
Page 251 Gears: Replace gears that show any signs of wear or breakage. Look for these problems: Thinned gear teeth Bent or missing gear teeth; check especially where a metal gear drives a plastic gear. Fractured or cracked gears (Oil or incorrect grease on a plastic gear can cause the gear to crack.) Belts: There are 3 rubber belts in the printer.
Page 252 Phaser 8400 Color Printer...
Page 253: Service Parts Disassembly
Service Parts Disassembly In this chapter... Overview General Notes on Disassembly Covers Imaging Paper Path Motors, Gears, Solenoids, Clutches, and Fans Electronics Section...
Page 254: Overview
When needed the orientation of the printer is called out in the procedure for locating printer parts. Refer to the printer orientation graphic for locating the right, left, front and back sides of the printer. Back Left Right Front s8400-001 Phaser 8400 Color Printer...
Page 255: General Notes On Disassembly
General Notes on Disassembly Caution Follow the steps of all disassembly procedures in the order given to avoid damaging printer components. Before servicing the printer, switch OFF the printer power, wait until the printer completely shuts down, and disconnect the power cord from the wall outlet. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards.
Page 256: Covers
Carefully remove the Front Door (Tray 1/MPT) assembly (PL1.3), by releasing the left hinge pin (PL1.4) from the printer frame and sliding the assembly to the right to remove it. s8400-184 Note Do not lose the hinge pins or stay retainers for the front door. Phaser 8400 Color Printer...
Page 257: Control Panel Cover
Control Panel Cover (PL 1.6) Open the Exit Cover. Open exit cover from Cleaning Kit S8400-185 Using either your fingers or a small flathead screwdriver, loosen the Front Panel Cover on the left side and then slide it forward and lift up to remove it from the printer.
Page 258: Left Side Cover
Lift the upper exit guide slightly, and engage the pins on the upper exit guide with the slots on the Exit Cover before inserting the cover hinge pins into the pivot points in the printer frame. Phaser 8400 Color Printer...
Page 259 s8400-107 1. Front Door, Tray 1 (MPT) 6. Exit Cover 2. Control Panel Cover 7. Ink Loader Assembly and Door 3. Control Panel 8. Interface Cover 4. Right Side Cover 9. Side Door 5. Left Side Cover Service Manual...
Page 260: Ink Loader Assembly And Door
Hooks on the bottom of the Ink Loader Assembly allow it to hang on the rear of the printer chassis while the connectors are removed. Disconnect the two Ink Loader harness connectors from the printer chassis and remove the Ink Loader, Assembly and Door as one unit s8400-112 Phaser 8400 Color Printer...
Page 261 Replacement Note: Note The grey cable must be routed between the Ink Loader and the printer side. The white cable must be routed towards the left side. The Exit Flag must be raised before reinstalling the Ink loader. Service Manual...
Page 262: Imaging
Remove the left side cover (see page 8-6). Relieve tension on the belt by pulling the end of the spring arm toward the front of the printer using your fingers. Slide the belt off the pulley. s8400-066 8-10 Phaser 8400 Color Printer...
Page 263 Using a spring hook or pliers, remove the Y-Axis tension spring from the chassis retainer and the spring arm. Brace the printer to keep it from moving during removal of the spring. Caution This is a strong spring that can cause damage if it slips during removal; use extreme caution when removing.
Page 264 Ensure the spring arm screws are in the right locations and that the arm floats freely. Note Torque the screws connecting the spring arm to the motor to 20 in.-lbs. Caution Ensure that the ground lug is replaced on the mounting screw (see figure above) during replacement. 8-12 Phaser 8400 Color Printer...
Page 265: Printhead Assembly, Right And Left Printhead Restraints
Restraints (PL 2.4) (PL 2.5 and 2.6) Videos are available with instructions for replacing the printhead assembly. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Warning The printhead is hot when the printer is operating. Turn off power to the printer and allow the printhead to cool for 30 minutes before starting removal procedure.
Page 266 While pulling back slightly on the printhead to keep it away from the drum surface, unlock (push down) the right and left printhead restraint arms, #3 above, then slowly allow the spring-loaded printhead to tilt forward. 8-14 Phaser 8400 Color Printer...
Page 267 On the left side of the printer, pull the X-Axis bias spring and hook out slightly and shift to the side (rotate down), see #1 and #2 of the following figure. Allow the spring hook to rest against the detentes in the printer frame. Bias spring hook Purge pump s8400-149...
Page 268 Remove left and right printhead restraints. First remove the screw, then pull inward towards the printhead, then lift up and slightly toward the rear of the printer to remove (see figure below). s8400-133 Note Adjust printhead position as required to remove the right restraint. 8-16 Phaser 8400 Color Printer...
Page 269 Remove the Roll Block on the left end of the printhead shaft. Caution The roll block may be hot if the printer was just shut down. Printhead shaft Roll block s8400-150 Disconnect the heater harness plug and free the harness (see the following figure) from its restraint.
Page 270 To avoid damage observe the following order when reinstalling the printhead: Ensure that the tilt gear is in the home position (see page 6-5). Rest the printhead on the cradle notches provided (see the previous illustration) while reconnecting the cable and ZIF connectors. 8-18 Phaser 8400 Color Printer...
Page 271 Insert the ribbon cables fully and squarely into the ZIF connectors. Caution Ensure that the flex cables are inserted into the ZIF connectors on the printhead fully and squarely. If the cables are inserted incorrectly, they can short out the Wave Amp. Connect the data cable connector and heater harness connector.
Page 272: X-Axis Bias Spring
Using your hands, a spring hook, or pliers, remove the X-Axis bias spring from inside the printer cavity. s8400-071 Replacement Note: Note Do not rotate the spring more than 1/4 turn. 8-20 Phaser 8400 Color Printer...
Page 273: Printhead Wiper
Printhead Wiper (PL 2.7) Videos are available with instructions for replacing the printhead wiper. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the printhead (see page 8-13). Caution Place several sheets of paper between the printhead and the drum to protect the drum from damage.
Page 274: Media Release Blade Carriage Assembly And Transfix Roller
Media Release Blade Carriage Assembly and Transfix Roller (PL 2.13) Videos are available with instructions for replacing the Transfix Roller. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the Right Side Cover (see page 8-5). Disconnect J250 from the I/O Board.
Page 275 Remove the Media Release Blade and Transfix Roller. s8400-113 Service Manual 8-23...
Page 276: Paper Preheater And Deskew Assembly
Slide the Preheater off the shelves and out of the printer as shown by (3). s8400-088 Replacement Note: Note The fingers on the Inner Simplex Guide, go over the segmented roller. First snap the left retainer into place, then the right. 8-24 Phaser 8400 Color Printer...
Page 277: Duplex Roller
Duplex Roller (PL 3.10) Open the Front Door. Remove the upper and lower duplex guides (see page 8-40). Remove the Duplex Roller by removing the left KL-clip on the shaft and sliding the left side bearing down the shaft toward the right (1). Then slide the shaft toward the left (2) to free the right end of the shaft.
Page 278: Transfix Load Module
Transfix Load Module (PL 3.9) Videos are available with instructions for replacing the Transfix Load Module. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the Front Door (MPT) assembly (see page 8-4). Remove the Ink Loader Assembly and Door (see page 8-8).
Page 279 Insert a T-20 Torxbit through the slotted hole in the Transfix Load Module, engage the hole on the back of the module, and lever the module’s spring cam toward the center of the printer to release/unhook the spring hooks from the Transfix Load Arms.
Page 280 Remove the Transfix Camshaft (see page 8-29) Remove the grounding springs from the Transfix Load Module. s8400-127 Remove two screws securing each end of the Transfix Load Module to the chassis. s8400-128 8-28 Phaser 8400 Color Printer...
Page 281: Transfix Camshaft Assembly
Remove the Transfix Load Module by rotating the bottom in and pulling it forward. Note The Transfix Load Module is a very tight fit, remove carefully. s8400-129 Replacement Notes: Note Place a small amount of Rheolube 768 grease (P/N 00679900) in the groove on the end of each Transfix Load Arm (see figure at Step 9) before reattaching the spring hooks.
Page 282 Slide the shaft to the right (1) and make sure the bearing slides over to the gear, move the shaft down and slightly to the right (2) and then up and to the left (3) to remove it from the printer chassis cavity. s8400-156 8-30 Phaser 8400 Color Printer...
Page 283: Drum Maintenance Camshaft Assembly
Drum Maintenance Camshaft Assembly (PL 2.11) Remove both the Drum Maintenance Pivot Plate Assembly (see page 8-32). Remove the Process Drive Gearbox assembly (see page 8-50). Slide the shaft to the right, free the bushing, and remove the shaft to the right. Carefully pry the bushing out of the right ground plane.
Page 284: Drum Maintenance Pivot Plate Assembly
Remove the Pivot Plate Shaft. Disconnect the connector from the I/O Board (black/white). Feed the cable into the printer while sliding the Drum Maintenance Pivot Plate out the drum maintenance drawer cavity. GREASE POINTS s8400-158 8-32 Phaser 8400 Color Printer...
Page 285 Replacement Note: Note Lightly grease the metal plates on which the cams ride, using a small quantity of Rheolube 768 grease (P/N 00679900). Also fill the pocket under the shaft ground with grease. Service Manual 8-33...
Page 286: Drum Assembly
Drum Assembly (PL 2.8) Videos are available with instructions for replacing the Drum Assembly. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the Front Door Assembly (see page 8-4). Remove Ink Loader Assembly (see page 8-8).
Page 287 Remove 3 screws and washers from the left side of the Drum Assembly. Remove the Drum Assembly from the chassis by lifting it straight up as shown in the following figure. No washer s8400-160a Caution Never rest the drum on its pulley. Let the pulley hang over the edge of a surface and place the drum on its feet.
Page 288 Connect the Drum Heater Cable to the Relay Board. Connect the Drum Encoder Cable to the Power Control Left Cable. Connect the Drum Thermistor Cable to the I/O Board. Connect the Exit Module Cable to the I/O Board. 8-36 Phaser 8400 Color Printer...
Page 289 Ensure that the Drum Heater Cable and Drum Encoder Cable are dressed correctly and secured by the retainer hook at the Process Gear Assembly. Reinstall the Drum Fan Assembly and secure it with 3 screws. Torque the top screw into the Labyrinth Seal to 20 in.-lbs. and the other two screws into the chassis to 12 in.-lbs.
Page 290: Purge Pressure Pump
Purge Pressure Pump (PL 2.14) Remove the left cover. Disconnect the air hose from the Purge Pressure Pump. Disconnect the wiring harness from the Purge Pressure Pump. Remove three screws and remove the Purge Pressure Pump. s8400-083 8-38 Phaser 8400 Color Printer...
Page 291: Paper Path
Paper Path Exit Module Assembly (PL 3.15) Remove the Exit Cover and both side covers (see page 8-6). Remove the three screws securing the media drive motor, and let the motor hang. Disconnect three connectors: two on the right (I/O Board J680 and J870) and one on the left.
Page 292: Paper Guides
Pry inward (toward the center of the printer) on the right upper retainer until it is free of the mounting boss and remove the guide. Outer Duplex Paper Guide With Sensors (Safety Interlocks) (PL 3.4) Remove the Control Panel (see page 8-5). Remove 4 screws and remove the guide. 8-40 Phaser 8400 Color Printer...
Page 293 Upper Duplex Guide with Solenoid (PL 3.5) Remove the Right Side Cover (see page 8-5). Remove the Outer Duplex Paper Guide as specified in the preceding paragraph. Disconnect the solenoid connector from the I/O board and extract the harness from the right side frame. Remove the Upper Duplex Guide from the printer.
Page 294 Replacement Notes: Note Route the solenoid harness through the right side frame when replacing the Upper Duplex Guide. 8-42 Phaser 8400 Color Printer...
Page 295 Note Verify that the solenoid lever engages the hole in the Paper Release Guide. s8400-207 1. Inner Simplex Guide 4. Upper Duplex Guide with Solenoid 2. Lower Exit-Guide Assembly with Strip Flag 5. Lower Inner Duplex (Green) (Green) 3. Outer Duplex Paper Guide With Sensors (Safety Interlocks) Service Manual 8-43...
Page 296: Take Away Roller
Note Pressure from the idler rollers makes it difficult to move the Take Away Roller shaft to the right during removal. s8400-153 8-44 Phaser 8400 Color Printer...
Page 297: Pick Assembly
Pick Assembly (PL 3.12) Remove Tray 2 from the printer. Reach into the tray cavity and release the green colored catch holding the Pick Roller in place. The catch is located on the ceiling of the tray cavity about 1/4 of the way across the unit from the right side and about 5 inches (12.5 cm.) back.
Page 298: Media Tray Lift Motor
From the rear of the printer, inside the cavity, remove the push nut (this is a press fit). Remove the gear from the shaft. Remove the two screws holding the Media Tray Lift Motor to the printer frame. 8-46 Phaser 8400 Color Printer...
Page 299 Remove the Media Tray Lift Motor from the outside of the printer. s8400-159 Replacement Note: Note Ensure that the two tabs of the bushing are seated in the chassis. Position the push nut so the fingers on the inside of the nut are pointed up toward the end of the shaft.
Page 300: Motors, Gears, Solenoids, Clutches, And Fans
Media Drive Gearbox with Two Clutches and Solenoid (PL 4.8) Videos are available with instructions for replacing the Media Drive Gearbox. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the Left side (page 8-6) and Exit cover (page 8-6).
Page 301: Tray 1 (Mpt) Pick Solenoid
Replacement Note: Note To replace the Media Drive Gearbox, first remove the paper tray. Rotate the Pick Roller Shaft until the clutch seats. Then work upwards, rotating the duplex feed rollers until the other shafts seat. Ensure that the Media Drive Gearbox is correctly positioned on the side frame.
Page 302: Process Drive Motor And Gearbox
Process Drive Motor and Gearbox (PL 4.9) Videos are available with instructions for replacing the Process Drive Motor and Gearbox. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Remove the right side cover (see page 8-5). Disconnect the drum heater wiring harness from the Relay Board to get it out of the way and free other wiring harnesses from the gearbox cable restraint.
Page 303 Remove three screws and remove the Process Drive Motor and Gearbox. s8400-100 Disconnect the wiring harness from the Process Drive Motor. Service Manual 8-51...
Page 304 Remove pins from the new gearbox after installation. Note Ensure that the drum heater harness, Y-Axis encoder harness, and the drum fan harness are replaced in the cable restraint on the gearbox. 8-52 Phaser 8400 Color Printer...
Page 305: X-Axis Motor Assembly
X-Axis Motor Assembly (PL 4.5) Remove the Right Side Cover from the printer (see page 8-5). Disconnect the wiring harness. Remove four screws securing the motor to the chassis and remove the motor. Fit in notch s8400-097 Replacement Note: Note When reinstalling the X-Axis motor, ensure that the fork, extending out from the side of the cone nut on the motor shaft, is engaged with the side rail.
Page 306: Head Tilt Compound Gear
On reassembly, the leaf spring on the back side of the chassis must be behind the gear to engage. Note On reassembly, lubricate the curved (cam) surfaces of the gear using a small quantity of Rheolube 768 grease (P/N 00679900). 8-54 Phaser 8400 Color Printer...
Page 307: Electronics
Electronics Electronics Module (PL 5.1) Videos are available with instructions for replacing the Electronics Module. Videos are located on the Phaser 8400 Customer Support training CD-ROM. Caution Touch the back of the Electronics Module before starting this procedure to discharge any electrostatic charge present on the case.
Page 308: Wave Amp Board
Wave Amp and printhead. If the cables are inserted incorrectly, they can damage the Wave Amp Board. Route the ribbon cables carefully through the slots. Ensure that the T-shaped strain relief on the cable is nearest the Wave Amp on installation. 8-56 Phaser 8400 Color Printer...
Page 309: I/O Board
I/O Board (PL 5.4) Remove the right side cover (see page 8-5). Disconnect the wires to the I/O Board. Remove the two screws attaching the I/O Board to the printer. Remove the I/O Board. s8400-102 Replacement Note: Note Ensure the corner of the board is behind the ground tab on reassembly. Service Manual 8-57...
Page 310: Drum Heater Relay Board
Warning Ensure that no wires are routed behind the Drum Heater Relay Board during reinstallation. Some of these wires carry AC line voltage and a short could result in AC being shorted to accessible locations. 8-58 Phaser 8400 Color Printer...
Page 311: Nvram Replacement
NVRAM Replacement (PL 5.8) Remove the back cover from the Electronics Module. Caution Some semiconductor components, such as the NVRAM chap, are vulnerable to damage by Electrostatic Discharge (ESD). Review the "Electrostatic Discharge (ESD) Precautions" on page 1-vi before continuing with this procedure.
Page 312 8-60 Phaser 8400 Color Printer...
Page 313: Parts Lists
Parts Lists In this chapter... Serial Number Format Using the Parts List Xerox Supplies Section...
Page 314: Serial Number Format
Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: Component's part number Product type or model number Serial number of the printer Serial numbering.
Page 315: Using The Parts List
Using the Parts List No.: The callout number from the exploded part diagram. Part Number: The material part number used to order specific parts. Qty: This number represents the parts per printer, not the number of parts supplied in the actual part order. Name/Description: Details the name of the part to be ordered and the number of parts supplied per order.
Page 316: Covers
Covers s8400-169 Phaser 8400 Color Printer...
Page 317 Parts List 1.0 Covers Name/Description Part Number Front Door (MPT) Assembly 200467880 Front Door Stay Retainer Clip 131714380 Front Door Stay with Spring 386740780 Hinge Pins, Front Door 131713880 Control Panel Cover 200467380 Control Panel with Bezel 657012880 Exit Cover Assembly 200469380 Ink Loader Door (part of PL 2.12) 200469880...
Page 318: Imaging
Imaging s8400-108 Phaser 8400 Color Printer...
Page 319 Parts List 2.0 Imaging Name/Description Part Number Ink Loader Assembly and Door 200469880 Printhead Assembly 650430300 Drum Assembly 105115080 Belt, Y-Axis Drum 214498780 Printhead Wiper 367053480 Belt, Wiper Drive 214501280 Purge Pressure Pump 119641180 Left Printhead Restraint 343167280 Right Printhead Restraint 343167180 Transfix Camshaft Assembly 384187480...
Page 320: Paper Path
Paper Path s8400-109 Phaser 8400 Color Printer...
Page 321 Parts List 3.0 Paper Path Name/Description Part Number Inner Simplex Guide (White) 351111480 Lower Inner Duplex Guide (Green) 351112080 Lower Exit Guide Assembly with Strip Flag (Green) 351112780 Outer Duplex Paper Guide with Sensors (Safety 351113680 Interlocks) Upper Duplex Paper Guide with Solenoid 351113280 Exit Roller 401091980...
Page 322: Motors, Gears, Solenoids, Clutches, And Fans
Motors, Gears, Solenoids, Clutches, and Fans s8400-170 9-10 Phaser 8400 Color Printer...
Page 323 Parts List 4.0 Motors, Gears, Solenoids, Clutches, and Fans Name/Description Part Number Drum Cooling Fan 119641780 Electronics Module System Fan 119642680 Paper Path Motor Cooling Fan 119650580 Motor, Y-Axis Drive 147101780 X-Axis Motor Assembly 650429400 Tray Lift Motor Kit and Gear 650429500 Compound Gear, Head Tilt 401097880...
Page 324: Circuit Boards
Circuit Boards s8400-111 9-12 Phaser 8400 Color Printer...
Page 325 Parts List 5.0 Circuit Boards Name/Description Part Number Electronics Module (no RAM, NVRAM, or Configuration 119649580 Card) Hard Drive Assembly 650432900 Hard Drive with Japanese Fonts 650433000 Wave Amp Assembly 671522380 I/O Board 671529180 Drum Heater Relay Board 650431700 Configuration Card-B, Programmed 650431200 Configuration Card-BD, Programmed 650431300...
Page 326: Sensors And Flags (Actuators)
Sensors and Flags (Actuators) s8400-106 9-14 Phaser 8400 Color Printer...
Page 327 Parts List 6.0 Sensors and Flags (Actuators) Name/Description Part Number Drum Temperature Sensor Assembly 119643080 Optical Sensor (Generic Snap-In) 119640580 Safety Interlock Switch (Mech) 119645580 Exit Module Sensor Assembly 119648180 Paper Present Flag 386731280 Exit Flag 386732680 Sensor Assembly, Paper Tray 441223780 Waste Tray Sensor 119648780...
Page 328: Xerox Supplies
161006610 Cable Power AUST 240 V, 96 L 161006611 Cable Assembly SWISS 220/240 V, 50 Hz 161015400 Cable Assembly PWR. DANISH, 250 V 161024000 Cable Assy PWR, PRC 161030400 Cable Power, 240 V, ARGENTINA 161030700 9-16 Phaser 8400 Color Printer...
Page 329 Description Part Number Standard-Capacity Maintenance Kit, 108R00602 Phaser 8400 Extended-Capacity Maintenance Kit, 108R00603 Phaser 8400 Genuine Xerox Solid Ink 8400 Black 108R00604 (3 sticks) Genuine Xerox Solid Ink 8400 Cyan 108R00605 (3 sticks) Genuine Xerox Solid Ink 8400 Magenta 108R00606...
Page 330 Consumables and Routine Maintenance Items Description Part Number Genuine Xerox Solid Ink 8400 Yellow 108R00607 (3 sticks) Genuine Xerox Solid Ink 8400 Black 108R00608 (6 sticks) Rainbow Pack 108R00612 (1 Cyan,1 Magenta,1 Yellow, 1 Black Software and Documentation Description Part Number...
Page 331 Phaser Color Printing Media (Continued) Description Part Number Phaser Professional Solid Ink Business 103R01041 Cards, Letter,10/sheet, 25 sheets Phaser Professional Solid Ink Business 103R01042 Cards, A4,10/sheet, 25 Sheets Phaser Color Printing Labels, Letter, 30/ 016181200 Sheet, 100 Sheets Phaser Color Printing Labels, Letter, 6/ 016181300 Sheet, 100 Sheets Phaser Color Printing Labels, A4, 14/Sheet,...
Page 332 9-20 Phaser 8400 Color Printer...
Page 333: Wiring Diagrams
Wiring Diagrams In this chapter... Main Wiring Diagram Right-Side Wiring Diagram Left-Side Wiring Diagram Inside Front Wiring Diagram Inside Top Wiring Diagram Inside Top - printhead Wiring Diagram Section...
Page 334: Main Wiring Diagram
Heat maintenance clutch generates: sense ECB J160 24 V PWM J820 Media Tray Width sense (3) switch Length sense (2) switch sense ECB Width sense (3) switch Length sense (2) switch Elevator plate motor s8400-181 10-2 Phaser 8400 Color Printer...
Page 335 Main Wiring Diagram (Continued) NOTE: All items connected with carry line voltage. Printhead 30 connector J620 J480 AC Resv. heaters (2) JDC1 Power Control AC Jetstack heaters (2) Power J3AC X- axis motor J820 Supply Drum Heater +/-50 V Drum fan J2AC Series/parallel heater +/-12 V unreg...
Page 336: Right-Side Wiring Diagram
It grounds end of pivot 37,006.4x plate shaft. Drum Heater 5,002.42 Add Paper Waste Tray 13,387.4 37,006.4x Dead Maint. Kit 37,006.4x 37,014.4x No Display 13,016.14x 37,006.4x 37,016.4x No Handfeed 13,067.14x 37,006.4x 37,020.4x s8400-179 10-4 Phaser 8400 Color Printer...
Page 337 Right-Side Wiring Diagram (Continued) The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the front panel. 13,387.4x J4AC Routes to 37,006.4x bottom of channel 37,027.4x X-Motor J800 DEAD Power Signal cable is on the top of the channel.
Page 338: Left-Side Wiring Diagram
37,062.4x 37,022.4x 37,023.4x 37,023.4x Purge Valve 37,022.4x Purge Motor 37,013.4x Elec Fan J280 37,032.4x Y-Motor J790 37,062.4x Head VSS 37,021.4x J390 37,034.4x MT Elevator MP Motor s8400-177 Ensure ground strap is clipped to the channel. 10-6 Phaser 8400 Color Printer...
Page 339 Left-Side Wiring Diagram (Continued) The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the front panel. 37,015.4x 37,034.4x Ensure the wiring is retained by restraint. 37,017.4x 37,015.4x 37,018.4x MP Fan 37,019.4x 37,034.4x MP Motor...
Page 340: Inside Front Wiring Diagram
The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the front panel. 37,008.4x Preheat Pwr. J860 13,131.41 Paper Jam Open Front 37,036.4x Cover Process Motor Load Paper Jam FC 37,036.4x Load Paper 13,131.41 37,008.4x s8400-175 10-8 Phaser 8400 Color Printer...
Page 341: Inside Top Wiring Diagram
Inside Top Wiring Diagram The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the front panel. 37,010.4x Ink 1 Heater J180 34,062.4x J1AC 37,009.4x Ink Load Pwr. J2AC 37,002.4x JSL Heater 34,062.4x 37,002.4x Ensure ink loader heater...
Page 342: Inside Top - Printhead Wiring Diagram
J110 37,062.4x J140 37,063.4x Head VSS Head VPP J180 34,062.4x Out of Ink Out of Ink 34,062.4x 37,062.4x Ensure the printhead heater s8400-176 37,063.4x wiring is retained by restraint. 10-10 Phaser 8400 Color Printer...
Page 343: Appendix
Appendix Contents... Menu Map Media Margin Specification Table Paper Weight Equivalence Table On-site Printhead Troubleshooting Checklist Appendix...
Page 344 USB Port CentreWare IS Wait Timeout NetWare Page Description Language Requires: Job Pipelining* IPX Frame Type Network Configuration Duplex Configuration Optional Lower Tray(s) Page 1 of 2 **** Hard Drive ***** 8400DX only with stored jobs present Phaser 8400 Color Printer...
Page 345 Paper Source 2-Sided Printing** Tray 1 Setup PostScript Error Info Font Number Tray 2 Paper Type Print-Quality Mode Pitch Tray 3 Paper Type*** TekColor Correction Point Size Printer Setup Tray 4 Paper Type*** Image Smoothing Symbol Set (continued) Load Paper Timeout Reset PostScript Setup Orientation Cleaning Page Source...
Page 346 82.075 135.1 #5-1/2 Baronial 111.125 101.125 112.9 3 x 5 Card 76.2 66.2 6 x 9 Envelope 152.4 228.6 142.4 188.6 Custom 76.2 - 127 - 12.5 12.5 51.2 - 102 - 215.9 355.6 190.9 330.6 Phaser 8400 Color Printer...
Page 347 Paper Weight Equivalence Table US Bond US Text US Index US Tag Metric Postcard Weight Book Cover Bristol Weight Weight Weight Thickness (lbs.) Weight Weight Weight (lb.) (lb.) (g/m (mm) (lb.) (lb.) (lb.) 0.18 0.20 0.23 Service Manual...
Page 348: On-Site Printhead Troubleshooting Checklist
(For Xerox personnel only: Record ink information in Non-Xerox Ink section of the STS app.) Note: If you answered YES to any of the above, be sure to document the use of non-Xerox ink in the Comments section of this document. Xerox U.S. personnel please record non-Xerox ink use in the FIST system as well as in this document.
Page 349 3c. Select Eliminate Light Stripes from the printer front panel up to 3 times as needed to recover a weak or missing jet. If the problem persists, continue to the Wiper/Purge Checklist. Xerox Phaser 8400 Printhead Checklist - Version 1.0 075-0882-00 Page 2...
Page 350 Is purge mass noticeable less than what is pictured? Go to # 6 If YES, inspect the purge hoses for splits or tears. Continued on next page… (continued) Xerox Phaser 8400 Printhead Checklist - Version 1.0 075-0882-00 Page 3 Phaser 8400 Color Printer...
Page 351 6. Print Service Test 2: Weak and Missing Jets. Are there weak or missing jet(s)? If NO weak or missing jets and generic ink is used, document the brand of non-Xerox ink and lot codes in the Comments section below.
Page 352 071-0865-01 B...

Xerox Phaser 8400 Service Manual

1 General Information

2 Theory of Operation

3 Error Messages and Codes

4 General Troubleshooting

5 Print-Quality Troubleshooting

6 Adjustments and Calibrations

7 Cleaning and Maintenance

8 Service Parts Disassembly

9 Parts Lists

10 Wiring Diagrams

Appendix

Quick Links

Troubleshooting

Related Manuals for Xerox Phaser 8400

Summary of Contents for Xerox Phaser 8400