Download  Print this page

Xerox PHASER 8500 Service Manual

Xerox printer user manual
Hide thumbs

Advertisement

Service Manual
701P27910
Phaser
8400/8500/8550/8560
®
Color Printer

Advertisement

Table of Contents
loading

  Also See for Xerox PHASER 8500

  Related Manuals for Xerox PHASER 8500

  Summary of Contents for Xerox PHASER 8500

  • Page 1 Service Manual 701P27910 Phaser 8400/8500/8550/8560 ® Color Printer...
  • Page 3 Service Manual 701P27910 Phaser 8400/8500/8550/8560 ® Color Printer Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.
  • Page 4 Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied or otherwise reproduced without prior written consent from Xerox Corporation.
  • Page 5: Service Terms

    Service Terms Manual Terms Common Acronyms: Product Terms Phaser 8400/8500/8550/8560 Color Printer Service Manual Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read Note, Caution, and Warning statements.
  • Page 6: Symbols Marked On The Product

    Symbols Marked on the Product Power Safety Precautions Power Source Disconnecting Power Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place. Use caution (or draws attention to a particular component).
  • Page 7: Electrostatic Discharge (Esd) Precautions

    Electrostatic Discharge (ESD) Precautions Phaser 8400/8500/8550/8560 Color Printer Service Manual Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components.
  • Page 8: Service Safety Summary

    Service Safety Summary General Guidelines Warning Labels Safety Interlocks Servicing Electrical Components For qualified service personnel only: Precautions. Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.
  • Page 9: Servicing Mechanical Components

    Servicing Mechanical Components Servicing Heated Components Phaser 8400/8500/8550/8560 Color Printer Service Manual When servicing mechanical components within the printer, manually rotate drive assemblies, rollers, and gears. Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
  • Page 10: Regulatory Specifications

    ■ Consult the dealer or an experienced radio/television technician for help. Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.
  • Page 11 European Union Phaser 8400/8500/8550/8560 Color Printer Service Manual The CE mark applied to this product symbolizes Xerox’s declaration of conformity with the following applicable Directives of the European Union as of the dates indicated: ■ January 1, 1995: Low Voltage Directive 73/23/EEC as amended by 93/68/EEC ■...
  • Page 12: Manual Organization

    Manual Organization The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the print engine and attached options.
  • Page 13: Table Of Contents

    Service Terms ................iii Symbols Marked on the Product .
  • Page 14 Printer Self-Maintenance ..............2-33 Printhead Maintenance Cycle (Eliminate Light Stripes) .
  • Page 15 Jam Codes ................. 3-48 Jam Code Definition Table.
  • Page 16 5 Print-Quality Troubleshooting Print-Quality Problems Overview ..............5-2 Random Light Stripes .
  • Page 17 7 Cleaning and Maintenance Service Cleaning Maintenance Procedure ............7-2 Cleaning .
  • Page 18 Xerox Supplies........
  • Page 19: General Information

    General Information In this chapter... ■ Printer Introduction and Overview ■ Printer Configurations ■ Control Panel Configuration ■ Parts of the Printer ■ Routine Maintenance Items and Consumables ■ Printer Specifications Chapter...
  • Page 20: Printer Introduction And Overview

    Printer Introduction and Overview The Phaser 8400/8500/8550/8560 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure understanding of this product, complete the Phaser 8400/8500/ 8550/8560 Service Training and self-study guide. Left Front Phaser 8400/8500/8550/8560 Color Printer Service Manual Back...
  • Page 21: Printer Configurations

    Printer Configurations Phaser 8400/8500/8550/8560 Color Printer Service Manual The Configuration Card holds configuration information that enables or disables built-in features as described in the following tables. Features 8400B Maximum Print Speed Memory 128 MB Hard Drive PostScript Fonts PCL Fonts Japanese Fonts* Job Pipelining Automatic 2-Sided...
  • Page 22 525-Sheet Feeder Tray 4 USB Connection Standard Ethernet Connection * The following features are included with the Phaser 8500/8550 printers with a hard drive: proof print, saved print, secure print, personal print, and font storage. Phaser 8560 Printer Configurations Phaser Features...
  • Page 23: Control Panel Configuration

    Control Panel Configuration LED Indicators Control Panel Feature Descriptions Phaser 8400/8500/8550/8560 Color Printer Service Manual The Control Panel consists of one tricolor LED, a display window, and six functional buttons. These buttons navigate the menu system, perform functions, and select modes of operation for the printer. Green = Ready to Print Flashing Green = Receiving, Processing Data, ■...
  • Page 24: Menu Maps

    Ready) temperatures to reach the proper operating values. On power- up, when the Xerox splash screen displays, press and release the Up Arrow button, then press the Down Arrow button. If the printer detects ink on the drum, the display indicates a warming-up status.
  • Page 25: Parts Of The Printer

    Parts of the Printer Front View Right Side View with Printer Interfaces Phaser 8400/8500/8550/8560 Color Printer Service Manual This section shows the main external components of the printer, including interfaces, the electronics module, and the internal sensors. s8500-005 1. Optional 525-Sheet Feeder Tray 4 2.
  • Page 26: Rear View

    Rear View The rear view consists of the printer’s main electronics and power supply, which are enclosed in a metal case called the Electronics Module. The rear panel allows access to the Electronics Module, RAM, and NVRAM. The printer’s Hard Drive is also mounted on the rear panel. When installing a new electronic module in the printer, the following components need to be transferred from the old board.
  • Page 27: Routine Maintenance Items And Consumables

    10,000 prints regardless of the colors used. Extended-capacity Drum Maintenance Kits for 8400 and 8550/ 8560 models produce 30,000 pages up to 20% coverage and 20,000 pages when coverage exceeds 20%. Phaser 8500 models do not support the 8550/ 8560 extended-capacity kit Routine Maintenance:...
  • Page 28: Printer Specifications

    Printer Specifications Physical Dimensions and Clearances 1-10 Print Engine Only Value Width: 422 mm (16.6 in.) Depth: 514 mm (20.24 in.) Height: 368 mm (14.48 in.) Weight: 26.8 kg (59 lb.) Optional 525-Sheet Feeder Value Width: 422 mm (16.6 in.) Depth: 514 mm (20.24 in.) Height:...
  • Page 29 Phaser 8400/8500/8550/8560 Color Printer Service Manual Print Engine Only 10 cm (4 in.) 56 cm (22 in.) 60 cm (24 in.) Note Check that the printer is on a stable, non-vibrating suface. Advise the customer to use care not to shake the printer excessively when loading media or closing the Front Door.
  • Page 30: Functional Specifications

    Functional Specifications Electrical Specifications Environmental Specifications 1-12 Characteristic Specification Printing Process Solid-ink Color Medium Yellow, cyan, magenta, and black ink sticks, each shape- coded. The printer uses the subtractive color system to produce the colors red, green, and blue. Operating Modes and (8400) Resolutions Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced...
  • Page 31: Media And Tray Specifications

    Media and Tray Specifications Phaser 8400/8500/8550/8560 Color Printer Service Manual Paper Size Paper Type Paper Weight/Media Type Letter (8.5 x Plain Paper 60–120 g/m 11 in.) or 121–220 g/m A4 (210 x Letterhead 297 mm) Transparency Phaser Professional Solid Ink Transparencies Card Stock 100–120 g/m...
  • Page 32 1-14 Paper Size Paper Type Paper Weight/Media Type Custom NOTE Print custom size media from Tray 1 only. Maximum: 216 mm wide x 355 mm long (8.5 in. wide x 14 in. long) Minimum: 75 mm wide x 127 mm long (3 in.
  • Page 33: Theory Of Operation

    Theory of Operation In this chapter... ■ Main Printer Subsystems ■ Print Process ■ Printer Self-Maintenance ■ Configuration Card Personality Parameters Chapter...
  • Page 34: Main Printer Subsystems

    Main Printer Subsystems Printer Subsystem Overview Transfix System Drum Preheater Drum Maintenance Kit Wiper Assembly The printer is made up of eight major subsystems, which are described in this section: ■ Process Drive ■ Media Drive ■ Ink Loader ■ Printhead ■...
  • Page 35 Theory of Operation The Ink Loader: Stores and melts the ink. The melted ink drops into the Printhead ink reservoirs underneath the ink loader. The Printhead: Delivers ink onto the drum surface to create an image. The Printhead includes 1236 interleaved jets (309 of each primary color) to provide the ability to electronically turn off a weak or missing jet to restore image quality.
  • Page 36: Process Drive

    Process Drive A small DC servomotor powers the Process Drive gearbox to rotate the gears to specific positions during the printing process. The Process Drive is able to actuate each camshaft system independently through the use of the swing arm in the gear train. The rotational direction of the motor controls the operation of the transfix and drum maintenance system.
  • Page 37: Media Drive

    Media Drive Phaser 8400/8500/8550/8560 Color Printer Service Manual The Media Drive assembly drives each roller in the media transport path. A gear train located behind the motor connects it to the Exit Rollers, which are built into the Exit Module. Gear trains located within the Media Drive, along with two clutches and a solenoid, allow the motor to control the Pick, Take Away, Duplex, and Deskew rollers.
  • Page 38: Ink Loader

    Theory of Operation Ink Loader The Ink Loader consists of four parallel channels with an ink melting element at the end of each channel. Coil springs exert pressure on four ink sticks to load one unique color in each channel. When the Printhead requires ink, the melting element of the appropriate color melts the end of the ink stick.
  • Page 39: Printhead

    Theory of Operation Printhead The Printhead is the heart of the printer, spanning nearly the length of the drum. Using its 1236 jet nozzles (309 jets for each primary color), with a horizontal motion of slightly less than 5 mm (0.2 inches), the Printhead can print the entire image on the rotating drum.
  • Page 40 Theory of Operation Printhead Ink Loader Black Yellow Funnel Filter Level Sense Probe Purge Valve Cyan Magenta s8500-013 The Printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the jet array. Channels formed by the stacked plates route ink past the 1236 individual, piezo-electric crystal-driven diaphragms, which force the ink in droplets out the 1236 corresponding nozzles.
  • Page 41 Phaser 8400/8500/8550/8560 Color Printer Service Manual X-Axis Hook X-Axis Shaft Tension Spring Drum X-Axis or lateral movement of the Printhead is accomplished using a stepper motor driving a fine-thread screw system. The Printhead, mounted to the X- Axis shaft, moves laterally across the surface of the drum. To find the Printhead home position, the X-Axis system drives the Printhead in an open-loop.
  • Page 42: Printhead Tilt

    Printhead Tilt 2-10 The Printhead is able to rotate into four basic positions: Printhead lock / ship position (19.5 degrees): The Printhead restraint pins are resting against the right and left locks. In this position, the Printhead tilt arm/follower is free of the tilt cam, and the head is secured for shipping.
  • Page 43 Printhead is in print position. When the arrows on the latching mechanism and frame align, the Printhead is in the print position and the tilt gear disengages from the Process Drive. Phaser 8500/8550/8560 printers have a solenoid (Head Tilt Solenoid) that is actuated and deactuated when the tilt cam gear rotates to the respective engaged and disengaged positions.
  • Page 44 Theory of Operation As viewed from the left side of the printer, when the arrows are not aligned, the tilt gear is engaged. Head Tilt Compond Gear Tilt Drive Gear Tilt Gear Engaged s8500-133 To accommodate Printhead maintenance, the Printhead is tilted back away from the Drum.
  • Page 45: Drum Maintenance Kit

    Drum Maintenance Kit Phaser 8400/8500/8550/8560 Color Printer Service Manual The Drum Maintenance Kit creates a thin layer of silicone oil on the surface of the Drum prior to printing. The oil keeps the ink from sticking to the Drum’s surface and facilitates image transfer to the media. The oil is contained in porous foam rollers made from rolled paper/fiber material.
  • Page 46: Purge System

    Theory of Operation Purge System Proper Printhead operation is dependant on the correct operation of the purge system. The purge system uses air pressure and a Wiper Blade to purge any debris or air bubbles that may be obstructing the Printhead nozzles. The waste ink that is expelled during the purge is funneled into the Waste Tray.
  • Page 47 Theory of Operation Warning When servicing the printer be careful of the purge system as it passes the Printhead. If a damaged Wiper Blade catches on the Printhead, it could propel hot liquid ink upward into your face. 30 Sec Printhead Purge Tube Solenoid Valve...
  • Page 48: Drum Assembly And Transfix System

    Drum Assembly And Transfix System 2-16 The Drum Assembly and Transfix Module form the key portion of the printer where imaging takes place. The Drum Assembly and Transfix Module are separate, yet interrelated. This section discusses the Drum. The next section provides more detail on the Transfix Module.
  • Page 49 Phaser 8400/8500/8550/8560 Color Printer Service Manual Single Reduction Belt Drive Pulley Y-Axis Motor Tension Spring Warning Always keep your fingers away from the drum drive system; it uses a closed-loop servo drive system, which is inherently dangerous. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured.
  • Page 50 Theory of Operation Transfix System The Transfix Roller applies pressure to the back side of the media as it moves between the Transfix Roller and Drum. This pressure transfers the image from the drum to the paper. A set of springs in the Transfix Load Module determines how much pressure the Transfix Roller applies to the Drum.
  • Page 51: Electronics Module

    Electronics Module Main Board Configuration Card Phaser 8400/8500/8550/8560 Color Printer Service Manual The Electronics Module includes the main board, the power control board, and the power supply. The Electronics Module is a Field Replaceable Unit (FRU). The main board performs the image processing functions. Communication ports on the board receive the print job image data and convert it to drive signals for the Printhead.
  • Page 52 Power Control Board Power Supply 2-20 Information stored on the Configuration Card includes the feature value, ethernet address, and personality parameters. The card reads a combination of feature values and the printer hardware capabilities; this will determine the printer model configuration.You can migrate the Configuration Card from one printer to another to transfer the printer configuration.
  • Page 53 Phaser 8400/8500/8550/8560 Color Printer Service Manual The DC power supply generates + 3.3 V, +/- 15 V, and +/- 50 V. These voltages provide direct or regulated voltage values to various circuits in the printer. The power control board regulates +/- 15 V to +/- 12 and other voltages.
  • Page 54: I/O Board

    I/O Board Sensors 2-22 All sensor and switch readings are input into the I/O Board. The I/O Board translates these states into encoded information that it sends over a serial data bus (I/O Board data cable) to the Electronics Module. The Electronics Module has no direct connection to sensors, switches, or solenoids.
  • Page 55: Print Process

    Print Process Drum Preparation Phaser 8400/8500/8550/8560 Color Printer Service Manual Once the printer processes an image and creates a printing bitmap, the print cycle begins. Sensors maintain correct operating temperatures for the Printhead and Drum. Sensors also monitor ink levels in the reservoirs. If necessary, the ink loader adds ink.
  • Page 56: Printing

    Theory of Operation Printing To print, the Drum rotates at a speed dependent upon print resolution. As the Drum reaches the correct speed, the jets begin to fire to deposit the image on the oiled portion of the Drum. As the jets fire, the Printhead moves from right to left to complete the image on the drum.
  • Page 57: Paper Pick For Tray 1

    Paper Pick for Tray 1 Phaser 8400/8500/8550/8560 Color Printer Service Manual To pick a sheet of paper, the Tray 1 solenoid actuates, and the drive gear rotates slightly to engage with the drive train. A bias force from the lift plate against a rotating cam causes the roller to rotate enough so the missing tooth gear engages the drive train.
  • Page 58: Paper Pick For Trays 2 - 4

    Theory of Operation Paper Pick for Trays 2 - 4 Note Trays 3 and 4 are 525-Sheet Feeders. For Trays 2 through 4, the paper pick process is different than the pick process used by Tray 1. To pick a sheet of paper, the Media Path Drive starts, and the pick clutch engages, which turns the Pick Roller and the Nudger Roller.
  • Page 59: Transfixing And Exiting

    Transfixing and Exiting Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfixing and exiting consists of four major functions: Staging the paper for rendezvous with the image on the drum and transfix roller nip. Loading the transfix roller and engaging the drum stripper blade assembly.
  • Page 60 2-28 Transfix Load Arm Transfix Load Module Transfix Load Spring Transfix Drum Transfix Roller Gear Transfix Cam Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfer Roller Process Drive Swing Arm Gear s8500-026...
  • Page 61 Theory of Operation Release Blade Strip Solenoid Exit Sensor Transfix Roller Preheat Sensor Strip Sensor Paper Preheater s8500-027 Phaser 8400/8500/8550/8560 Color Printer Service Manual 2-29...
  • Page 62: Duplex Printing

    From this point on, the print is processed through the Preheater and transfix system to the Output Tray in the same manner as a single-sided print. Phaser 8500/8550/8560 models include a Preheater Lift Solenoid, mounted to the Transfix Load Module, that increases the physical spacing between the Preheater plates when printing the second side of duplex prints.
  • Page 63: Transfix And Print Speeds

    Transfix and Print Speeds Phaser 8400/8500/8550/8560 Color Printer Service Manual Transfix Speeds Characteristic Fast Color Peak Transfix Speed, 20 ips (8400) Simplex tray feed 25 ips (8500/ 8550/8560) Peak Transfix Speed, 5 ips (8400) Duplex 10 ips (8500/ 8550/8560) Peak Transfix Speed, 20 ips Legal Peak Transfix Speed,...
  • Page 64 2-32 Approximate Print Speeds (8500/8550/8560) Tray (Source) / Simplex, A4 Paper Resolution Tray 1 Fast Color (225 x 400 dpi) 12 pages per minute Standard (300 x 450 dpi) Enhanced (525 x 450 dpi) High Res/Photo (525 x 2400 dpi) PCL 600 x 300 Mode PCL 600 x 600 Mode Trays 2 - 4...
  • Page 65: Printer Self-Maintenance

    Printer Self-Maintenance Printhead Maintenance Cycle (Eliminate Light Stripes) Phaser 8400/8500/8550/8560 Color Printer Service Manual The printer has several automatic or semi-automatic maintenance functions. These functions may be started automatically after a certain number of prints or during printer startup, or they may be started by the customer if a print- quality defect is noted.
  • Page 66: Paper Preheater Cleaning (Remove Print Smears)

    Paper Preheater Cleaning (Remove Print Smears) Transfix Roller Oiling Drum Cleaning - Chase Page 2-34 This customer-initiated cleaning procedure is selected by choosing Print Smears on the Control Panel’s procedure cleans ink out of the Preheater that may have been deposited there.
  • Page 67: Configuration Card Personality Parameters

    Configuration Card Personality Parameters Phaser 8400/8500/8550/8560 Color Printer Service Manual Configuration Card “Shadowed” Personality Parameters Attribute Parameter N/A “version” not version (of the layout of parameter personality parameters) NEST Base Printer Name NEST SysAdmin Contact NEST Printer Location NEST Asset Identifier Host Name Domain Name Network Mask...
  • Page 68 2-36 Configuration Card “Shadowed” Personality Parameters (Continued) Attribute Parameter HTTP KeyUser_Username HTTP Admin_HostAccessList HTTP KeyUser_HostAccessList Notify Authentication Scheme IPP user name IPP password Login Password Security Print Hosts AppSocket AppSocket Enabled Enabled Enabled Enabled MIME MIME Enabled EtherTalk EtherTalk Enabled PSERVER PSERVER Enabled...
  • Page 69: Error Messages And Codes

    Error Messages and Codes In this chapter... ■ Introduction ■ Power-Up Error Messages and LED Codes ■ BIST Error Reporting ■ POST Error Reporting ■ PEST Error Reporting ■ Fault Code Error Message Troubleshooting ■ Jam Codes Chapter...
  • Page 70: Introduction

    Introduction This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running Service Diagnostics test functions to verify that a specific printer component is operating correctly. For information on Service Diagnostics and all internal printer test functions see “Service Diagnostics Mode Menu”...
  • Page 71: Power-Up Error Messages And Led Codes

    Power-Up Error Messages and LED Codes BIST Error Reporting Phaser 8400/8500/8550/8560 Color Printer Service Manual The printer has three sets of tests that are run when first powered on: ■ Built-In Self Tests (BIST) ■ Power On Self Tests (POST) ■...
  • Page 72: Post Error Reporting

    POST Error Reporting 8400 Error Code 01.01 02.01 02.02 03.01 03.02 03.03 03.04 04.01 04.02 04.03 04.04 05.01 05.02 POST checks the communication paths within the Electronics Module and to other various printer components. POST testing initializes the Control Panel, and in most cases if an error occurs, a text message is displayed on the Control Panel along with an LED blink code flashing on all three LEDs (Control Panel LED, PS LED and PE LED).
  • Page 73 8400 Error Code 6.08 07.01 07.02 08.01 09.01 10.01 10.02 11.01 11.02 11.03 11.04 12.xx 13.01 13.02 14.xx 15.01 15.02 15.03 Phaser 8400/8500/8550/8560 Color Printer Service Manual POST Error Reporting Blink Pattern Definition Table (Continued) PS, PE and Control POST Panel LEDs (for Error 8400)
  • Page 74: Pest Error Reporting

    8400 Error Code 15.04 15.05 15.06 15.07 15.08 15.09 15.10 15.11 16.01 16.02 16.03 16.04 17.01 18.01 18.02 18.03 18.04 19.01 PEST Error Reporting POST Error Reporting Blink Pattern Definition Table (Continued) PS, PE and Control POST Panel LEDs (for Error 8400) Type...
  • Page 75: Fault Code Error Message Troubleshooting

    Fault Code Error Message Troubleshooting Fault Code Error Reporting Interpreting Fault Codes Phaser 8400/8500/8550/8560 Color Printer Service Manual Fault codes are saved to NVRAM and can be retrieved from the printer’s fault history. All procedures that ask for a test to be run are referencing tests from within the “hidden”...
  • Page 76: 1,000.4X Errors - 525-Sheet Feeder Faults

    1,000.4x Errors - 525-Sheet Feeder Faults 1,0XX.6x Errors - 525-Sheet Feeder Program Faults 1,001.46: The upper 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted. 1,002.47: The lower 525-sheet feeder had an overcurrent condition. The lift motor or clutch may be shorted.
  • Page 77: 2,0Xx.4X Errors - I/O Circuit Board Fault

    2,0XX.4x Errors - I/O Circuit Board Fault 2,0XX.6x Errors - I/O Board Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 2,001.47: The print engine cannot detect the presence of the I/O Board. Troubleshooting Procedure for I/O Board Step Questions or Actions Are all I/O Board connections properly seated? Reseat the connections and power On the...
  • Page 78: 3,0Xx.6X Errors - Ipc Program Faults

    3,0XX.6x Errors - IPC Program Faults 4,0XX.4x Errors - Process Control System Fault 3-10 There is a communication problem between the engine and PostScript regions. Reset NVRAM, and then retest. Replace the EEPROM chip. 4,017.47: This fault code indicates a problem with the process control system. The ambient temperature is considered too cold to warm up the printer (less than 10 4,018.48:...
  • Page 79 Phaser 8400/8500/8550/8560 Color Printer Service Manual 4,024.42: This fault code indicates a problem with the wiper. The wiper is not aligned properly and engaged the headtilt while in the waste lock position. Troubleshooting Procedure for 4,024 Error Code Step Questions and Actions Ensure the Process Drive is correctly homed as described in “Homing the Process Drive Train”...
  • Page 80: 4,0Xx.6X Errors - Process Control Software Fault

    4,0XX.6x Errors - Process Control Software Fault 3-12 Troubleshooting Procedure for 4,025 Error Code (Continued) Step Questions and Actions Remove the Waste Tray and Printhead and look for ink build-up. Is there ink build-up anywhere in the printer? 1. Check the Process Drive for damage. 2.
  • Page 81: 5,0Xx.4X Errors - Y-Axis Sub-System Fault

    5,0XX.4x Errors - Y-Axis Sub-System Fault 5,0XX.6x Errors - Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 5,001.41: The Drum turned one full revolution without seeing the Drum home sensor activate. 5,002.42: The Y-Axis encoder is not working properly or the Drum has stalled. 5,003.43: There is a general problem with the Y-Axis sub-system.
  • Page 82: 6,0Xx.4X Errors - X-Axis Fault

    6,0XX.4x Errors - X-Axis Fault 6,0XX.6x Errors - Program Faults 3-14 6,000.41: An X-Axis Motor current error occurred. Troubleshooting Procedure for X-Axis Motor Step Questions and Actions 1. Inspect the Printhead power cable and heater wiring. 2. Verify the Printhead travels smoothly from left to right.
  • Page 83: 7,0Xx.4X Errors - Process Motor Gearbox Faults

    7,0XX.4x Errors - Process Motor Gearbox Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,002.44: There is a problem with the process motor sub-system. The process motor stalled during operation. Troubleshooting Procedure for 7,002 Error Code Step Questions and Actions Verify the Process Drive system is properly homed, see “Homing the Process Drive Train”...
  • Page 84: 7,0Xx.4X Errors- Printhead Tilt Faults

    7,0XX.4x Errors- Printhead Tilt Faults 3-16 Troubleshooting Procedure for 7,006 Error Code (Continued) Step Questions and Actions Review instructions for 7,008.xx and 7,010.xx fault codes. The 7,007.49, 7,008.41, 7009.42, and 7,010.43 errors indicate that the Printhead was unable to tilt normally on its axis. Possible causes include: ■...
  • Page 85 Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,007.49: The process motor stalled while tilting the head. Troubleshooting Procedure for 7,007 Error Code Step Questions and Actions 1. Check the Printhead wire routing. 2. Remove the Printhead and inspect the Printhead tilt and drive gears for ink spills.
  • Page 86 3-18 Troubleshooting Procedure for 7,008 Error Code (Continued) Step Questions and Actions Perform the Wiper Alignment procedure (see “Wiper Alignment Procedure” on page 6-2). Did this correct the problem? Use Service Diagnostics to run the Wiper Drive test. Did the test fail? 7,009.42: The Printhead is tilted back but not properly restrained in the park arms.
  • Page 87 Phaser 8400/8500/8550/8560 Color Printer Service Manual 7,010.43: The Printhead is stuck in the tilted position, or is not able to tilt forward to the print position, due to problems. 7,011.44: This is a soft fault and will not halt the printer. 7,012.45: The Drum transfix is not in home position, after the return home motion has been completed.
  • Page 88: 7,0Xx.6X Errors - Program Faults

    7,0XX.6x Errors - Program Faults 3-20 Troubleshooting Procedure for 7,010 to 7,015 Error Code (Continued) Step Questions and Actions Use Service Diagnostics to run the Head Maintenance Wiper Clutch test. Did the test fail? 1. Align the Wiper Assembly (page 6-2). 2.
  • Page 89: 8,0Xx.xx Errors - Wiper/Media Drive Faults

    8,0XX.xx Errors - Wiper/Media Drive Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 8,005.48: The Media Drive stalled while moving the Wiper to home position. 8,006.49: The Wiper cannot verify the home position. 8,007.41: The Wiper stalled finding home. 8,008.42: The Wiper stalled while trying to move away from home position. 8,009.43: The Media Drive stalled while moving without the Head Maintenance Clutch engaged.
  • Page 90: 8,0Xx.6X Errors - Program Faults

    8,0XX.6x Errors - Program Faults 3-22 Troubleshooting Procedure for Wiper/Media Gearbox (Continued) Step Questions and Actions Run the Wiper Alignment test (see “Wiper Alignment Procedure” on page 6-2). Did the test pass? 1. Inspect the wiper system for improper operation, obstructions, or damage (broken gear or belt).
  • Page 91: 9,0Xx.xx Errors - Ink Loader Faults

    5 for cyan, 6 for magenta, 7 for yellow, and 8 for black. Features on the bottom of genuine Xerox ink sticks actuate the Ink Out Sensor located at the forward end of each ink channel of the Ink Loader. The sensor indicates the passage of ink to provide a count of ink consumption.
  • Page 92: 9,009.44 And 9,00X.6X Errors - Program Faults

    3 = Magenta 4 = Black Did the test pass? Note Xerox is not financially responsible for the incorrect operation of its products caused by the use of non- Xerox ink. 9,009.44: This fault indicates a device failure attempting to access NVRAM.
  • Page 93 Phaser 8400/8500/8550/8560 Color Printer Service Manual 11,006.43: Printhead broken serial link detected. 11,006.45: Printhead broken serial link detected. 11,007.44: PCI error detected. 11,008.45: The DMA hardware is not responding. 11,009.46: Communication timeout failure detected. 11,010.47: Hardware version mismatch. 11,010.48: Hardware version mismatch. 11,011.48: Software version mismatch.
  • Page 94: 11,100.60 Errors - Temperature Error

    11,100.60 Errors - Temperature Error 12,000.60 Errors - Program Faults 13,0XX.xx Errors - Thermal Faults 3-26 The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Check that the room temperature does not exceed specifications and the fans run correctly. If OK, then replace the Electronics Module.
  • Page 95 Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,008 to 13,010 Error Code (Drum Heater) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12). Is the room too cold or too hot? Ensure ground integrity (see “Ensuring Ground Integrity”...
  • Page 96 3-28 13,067.43: The Drum Temperature Sensor circuit is open. 13,069.45: The Drum Temperature Sensor circuit is shorted. 13,071.47: The Drum Temperature Sensor returned a bad reading, or the reading was corrupted by ESD (Electrostatic Discharge). Troubleshooting Procedure for 13,067 to 13,071 Error Code (Drum Thermistor) Step Questions and Actions Using Service Diagnostics, run the Drum...
  • Page 97 Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,136 to 13,199 Error Code (Printhead) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12). Is the room too cold or too hot? Ensure ground integrity (see “Ensuring Ground Integrity”...
  • Page 98 3-30 13,327.42: The Printhead reservoir thermistor returned a bad reading, or the reading was corrupted by ESD. Troubleshooting Procedure for 13,264 to 13,327 Error Code (Printhead) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications”...
  • Page 99: 13,000.6X Errors - Program Faults

    13,000.6x Errors - Program Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for 13,326 to 13,583 Error Code (Ink Loader) Step Questions and Actions Check that the ambient room temperature is within specifications (see “Environmental Specifications” on page 1-12). Is the room too cold or too hot? Ensure ground integrity (see “Ensuring Ground Integrity”...
  • Page 100: 19,0Xx.xx Errors - Printhead Calibration Faults

    19,0XX.xx Errors - Printhead Calibration faults. 3-32 19,001.46: HFD server failed due to NVRAM operation. This fault only occurs when the printer is set in manufacturing mode. Program fault. 19,002.47: Attempted to perform a Printhead operation without the Printhead NVRAM data being loaded. 19,003.48: Scale and offset error is too large.
  • Page 101: 19,0Xx.6X Errors - Waveform Program Faults

    19,0XX.6x Errors - Waveform Program Faults 21,000.69 Errors - Diagnostic Code Version Mismatch 22,0XX.6x Errors - Jam Codes 23,0XX.6x Errors - NVRAM Fault 26,0XX.6x Errors - Printing Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual 19,005.63: Wave Amplifier overcurrent. This error can occur in too-low humidity environments.
  • Page 102: 26,962.6X Errors - "Fall Out" Code

    26,962.6x Errors - “Fall Out” Code 27,0XX.6x Errors - Profile Library 29,0XX.6x Errors - Jam Manager 31,0XX.4x Errors - Mechanical Initialization Jam 3-34 Check the previous error in the fault history and troubleshoot that code. Ensure the ground integrity of the printer (see “Ensuring Ground Integrity” on page 4-65).
  • Page 103: 31,0Xx.6X Errors - Program Faults

    31,0XX.6x Errors - Program Faults 33,0XX.xx Errors - Tray Manager Device Faults 34,0XX.xx Errors - Printhead NVRAM Faults Phaser 8400/8500/8550/8560 Color Printer Service Manual Reset NVRAM, and then retest. Ensure ground integrity for the printer (see “Ensuring Ground Integrity” on page 4-65).
  • Page 104: 36,000.40 Errors - Drum Maintenance Faults

    36,000.40 Errors - Drum Maintenance Faults 36,001.67 Errors - Drum Maintenance Fault 36,002.44 Errors - Drum Maintenance Program Fault 37,0XX.xx Errors - PEST Faults 3-36 Troubleshooting Procedure for Drum Maintenance Step Questions and Actions Ensure ground integrity (see “Ensuring Ground Integrity” on page 4-65). Did this correct the problem? Ensure the Process Drive system is correctly homed as described in “Homing...
  • Page 105 Phaser 8400/8500/8550/8560 Color Printer Service Manual ■ Reservoir heater, 37,004.40 or 37,005.41 ■ Drum heater error 37,006.42 ■ Preheater error 37,008.44 ■ Ink melters errors 37,009.45 thru 37,013.40 The printer includes several heaters powered by AC. The printer itself can power up despite insufficient or irregular AC voltage but it may fail its AC heater tests.
  • Page 106 3-38 8400 PEST Description Inkmelt 3 (Black) disconnect. 37,012.48: The inkmelt heater is not drawing the expected power from the supply. 37,013.40: Troubleshooting Procedure for Heaters Step Questions and Actions Check the wiring running from the problem component to the Printhead. Is the wiring damaged? Run the appropriate diagnostic test: 37,002.47 = Left Jetstack Heater...
  • Page 107 Phaser 8400/8500/8550/8560 Color Printer Service Manual 8400 PEST Description Drum Fan disconnect. The 37,014.41: Drum Fan is not drawing the expected power. 37,015.42: Troubleshooting Procedure for Fans Step Questions and Actions Run the appropriate diagnostic test: 37,013.40 = (8400) Electronics Fan 37,014.40 = (8500/8550/8560) Electronics Fan 37,014.41 = (8400) Drum Fan...
  • Page 108 3-40 50V Power Supply Fault Troubleshooting Procedure Step Questions and Actions Check for a short in the Electronics Module. NOTE Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge. NOTE It is possible that the power supply is not shorted, but instead is out of spec and can lead to an error condition.
  • Page 109 Phaser 8400/8500/8550/8560 Color Printer Service Manual 50V Power Supply Fault Troubleshooting Procedure (Continued) Step Questions and Actions To isolate the problem to the I/O Board or its related cabling, unplug these I/O Board connectors. Umbilical Right J1 ■ Waste Tray Sense J110 ■...
  • Page 110 3-42 8400 PEST Description 37,022.40: 37,023.41: Solenoid or Clutch Troubleshooting Procedure Step Questions and Actions Run the appropriate diagnostic test: 37,017.44 = Head Maintenance Clutch ■ 37,018.45 = Deskew Clutch ■ 37,019.46 = (8500/8550/8560) Main tray ■ pick Clutch 37,019.46 =(8400) Pick Solenoid ■...
  • Page 111 Phaser 8400/8500/8550/8560 Color Printer Service Manual 8500/8550/ 8400 8560 8400 PEST Description 37,022.40: 37,025.43: Pressure pump motor disconnect. The Purge Pump is not drawing the expected power. Troubleshooting Procedure for Purge Pump Step Questions and Actions Run the Pressure Pump Motor test. Did the test pass? Check the Purge Pump wiring.
  • Page 112 3-44 Troubleshooting Procedures for Drum Heater Relay Board Step Questions and Actions Run the Drum Heater Relay test. Did the test pass? Check the wiring for damage. 8500/8550/ 8400 8560/8560 PEST Description 37,027.45: 37,030.48: X-Axis Motor disconnect. The X-Axis motor is not drawing the expected power.
  • Page 113 Phaser 8400/8500/8550/8560 Color Printer Service Manual Troubleshooting Procedure for Y-Axis Motor Step Questions and Actions 1. Remove any obstructions interfering with Drum rotation. 2. Inspect the Drum and ensure the Drum rotates smoothly, if not replace the Drum Assembly and retest. Did this correct the problem? Disconnect the Y-Axis Belt.
  • Page 114 3-46 Troubleshooting Procedure for Process Drive Step Questions and Actions Do the Process Drive gears, Transfix Camshaft, and Drum Maintenance Camshaft rotate freely? Run the Process Motor test. Did the test pass? Check the wiring for damage. 8400 PEST Description The power supply did not reset 37,038.47: properly.
  • Page 115 Phaser 8400/8500/8550/8560 Color Printer Service Manual 8400 PEST Description Power supply -50 volt under limit. 37,056.47: 37,057.48: Power supply +15 volt over limit. Power supply +15 volt under limit. Power supply +15 volt under 37,058.40: 37,059.41: Power supply -15 volt over limit. Power supply -15 volt under limit.
  • Page 116: Jam Codes

    Jam History and press OK to display the most recent jam list. Phaser 8500/8550/8560 models have improved jam reporting. When the printer is in a jam condition (in Customer Mode), pressing HELP displays the jam code. The jam code contains 4-digits compared to the 3-digit codes produced by 8400 models.
  • Page 117: Jam Code Definition Table

    Note The following table only shows the 3-digit jam code. For Phaser 8500/ 8550/8560, a 4th digit represents the tray number (5 represents a chase page and 6 represents duplex). Numbers following the 4th digit represent...
  • Page 118 3-50 Jam Code Troubleshooting Procedures (Continued) Deskew sensor in unexpected state at ready. 1. Ensure ground integrity, see page 4-65. 2. Replace Tray 1 Pick Solenoid. Deskew Sensor in unexpected state. 1. Ensure ground integrity of the printer, see page 4-65. 2.
  • Page 119 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Deskew Sensor time-out during movement from Exit Roller to deskew roller when duplexing print. 1. \Ensure the media is appropriate for two-sided printing. Not too short, not too smooth. Check printer specifications. 2.
  • Page 120 3-52 Jam Code Troubleshooting Procedures (Continued) Strip flag unexpected event during fault. Strip flag unexpected event during transfix roller oiling. The strip flag actuated unexpectedly when paper picked from Tray 2. The strip flag actuated unexpectedly when paper picked from Tray 3. The strip flag actuated unexpectedly when paper picked from Tray 4.
  • Page 121 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Print pulled back into transfix nip during exit. 1. Ensure the media is not too thick and that it is supported by the printer. 2. Use a less glossy media. 3.
  • Page 122 3-54 Jam Code Troubleshooting Procedures (Continued) Tray 1 width sensor during Tray 1 pick. 1. Examine the Tray 1 width guides for proper movement and ensure the side guides are not being adjusted while printing. 2. Ensure the Front Door is closed and the wiring is connected and seated. 3.
  • Page 123 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Media Drive stalled while the printer was in standby mode. M4M Media Drive stalled while the printer picked from Tray 2. Media Drive stalled while the printer picked from Tray 3. Media Drive stalled while the printer picked from Tray 4.
  • Page 124 3-56 Jam Code Troubleshooting Procedures (Continued) Y-Axis Motor stalled while the print exited the printer. 1. Check the media, generally label, trifold or envelopes cause this error. 2. Try running fewer sheets through the tray. 3. Ensure the Process Drive is correctly aligned, refer to “Homing the Process Drive Train”...
  • Page 125 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Process motor stalled while the printer performed an auto Drum maintenance cycle. Process motor stalled while the printer performed Printhead maintenance. Process motor stalled while the printer performed Printhead purge. Process motor stalled while the printer performed an oil transfix roller cycle.
  • Page 126 3-58 Jam Code Troubleshooting Procedures (Continued) The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 2. The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 3. The Exit Cover open flag unexpectedly tripped when the printer picked from Tray 4.
  • Page 127 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Tray 2 media size sensor unexpectedly activated while exiting print. 1. Ensure ground integrity of the printer, see page 4-65. 2. Ensure the Tray 2 paper guides are correctly set. 3.
  • Page 128 3-60 Jam Code Troubleshooting Procedures (Continued) Tray 3 pick flag triggered unexpectedly while printer was in a fault state. Tray 3 pick flag triggered unexpectedly while printer in standby. Tray 3 pick flag triggered unexpectedly while picking from Tray 2. Tray 3 pick flag triggered unexpectedly while picking from Tray 3.
  • Page 129 Phaser 8400/8500/8550/8560 Color Printer Service Manual Jam Code Troubleshooting Procedures (Continued) Tray 3 pick flag sensor timed out while exiting print. 1. Verify the paper loaded in Tray 3 is supported media. 2. Reduce the amount of media in the tray and reposition the guides to fit firmly against the media.
  • Page 130 3-62 Jam Code Troubleshooting Procedures (Continued) Tray 4 pick flag triggered unexpectedly while pick from Tray 2. Tray 4 pick flag triggered unexpectedly while pick from Tray 4. Tray 4 pick flag triggered unexpectedly while pick from Tray 4. Tray 4 pick flag triggered unexpectedly while pick from Tray 1. Tray 4 pick flag triggered unexpectedly while duplexing.
  • Page 131: 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 Chapter...
  • Page 132: Introduction

    Introduction Hidden Service Menu This chapter covers the general start-up, Power On Self Test (POST), and power supply operations of the printer to aid in troubleshooting problems not associated with a Control Panel error message or error code. For troubleshooting problems associated with an error code or Control Panel error message, notes on how to use the troubleshooting procedure tables, and how to use service diagnostics, see Chapter 3 “Error Messages and Codes”...
  • Page 133 Phaser 8400/8500/8550/8560 Color Printer Service Manual Menu Item Description Reset NVRAM Provides access to reset the printer back to its factory-default settings and erase all network settings. If possible, print the Configuration Page before resetting NVRAM. Power Saver Timeout Selects the Power Saver Timeout, the amount of time the printer must be idle before changing to Power Saver low-energy consumption mode, per ENERGY STAR\256 guidelines.
  • Page 134: Service Diagnostics

    30 seconds until the Control Panel indicates Turn the printer power On. Wait for the Xerox logo to begin moving across the display. Before the logo is centered on the display (stops moving), press and hold the Back and Help buttons on the Control Panel.
  • Page 135: Service Diagnostics Mode Menu

    Service Diagnostic Control Panel Button Descriptions Service Diagnostics Mode Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual Button Function Back Returns to the prior higher level menu structure, if available. Cancels the display of test results on the Control Panel. If help text is displayed on the Control Panel, pressing BACK will restore the current menu item and remove the help text.
  • Page 136: Service Diagnostics Menu Map

    Service Diagnostics Menu Map Service Diagnostics Menu Map Menu Main Menu Displays general help text describing the general operation of the Control Panel/menu system. Development Menu A temporary submenu containing some development functions and access to tests still under development. Return to Customer Exits service diagnostics and runs through POST to Ready.
  • Page 137 Phaser 8400/8500/8550/8560 Color Printer Service Manual Service Diagnostics Menu Map (Continued) Menu Exercise Menu Functions for causing mechanical actions which may then be observed. Press a Control Panel button to stop the test Activators Menu Exercise All Tray 1 Pick Solenoid Cycles the activator repeatedly. Tray 2 Pick Clutch Tray 3 Pick Clutch Tray 4 Pick Clutch...
  • Page 138 Service Diagnostics Menu Map (Continued) Menu Drum Maintenance Cam Shaft Deskew Shaft Wiper Shaft Tray 1 Pick Shaft Tray 2 Pick Shaft Tray 2 Lift Motor Tray 3 Pick Shaft Tray 4 Pick Shaft Tray 3 Lift Motor Tray 3 Motor & Shafts Tray 4 Pick Shaft Tray 4 Lift Motor...
  • Page 139 Phaser 8400/8500/8550/8560 Color Printer Service Manual Service Diagnostics Menu Map (Continued) Menu Function Menu Functions for commanding more complex actions by portions of the printer mechanism. Initialize Mechanism Print DMU Blot Display Fault History Access PE NVRAM Parameters Clear Fault History Clear ISC Fault Clear PS NVRAM Clear PE NVRAM...
  • Page 140: Check Menu Definition Tables

    Check Menu Definition Tables Check / Activators Menu 4-10 A submenu containing a set of extensive tests that return measured mechanism parameters for comparison against stated limits. Refer to the table associated with each test for their normal operating ranges. In cases where insufficient baseline data is available, the Typical Values have been left blank.
  • Page 141 Phaser 8400/8500/8550/8560 Color Printer Service Manual The Deskew Clutch test gathers data on the performance of the Deskew Clutch coil. Deskew Clutch Typical Value Definition (8400) Peak Power (watts) 2.5 to 5.3 3.0 to 5.8 Average Power 2.2 to 5.3 1.5 to 3.0 (watts) Gathers data on the performance of the Tray 1 Pick Solenoid coil and flapper.
  • Page 142 4-12 Gathers data on the performance of the stripper solenoid coil and plunger. Strip Solenoid Typical Value Definition (8400) Peak Power (watts) 8.0 to 15 Average Power 8.0 to 15 (watts) Gathers data on the performance of the purge vent solenoid coil. Purge Vent Solenoid Typical Value...
  • Page 143: Check Shafts Menu

    Check Shafts Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual Drum Heater Relay (Continued) Typical Value Definition (8400) 110 V Coil Average Power (watts) 110 V Coil Min Power (watts) 110 V Coil Peak Power Time (sec) 110 V Coil Initial Average Power (watts) Runs the Media Path Drive train and engages the Deskew Clutch on the fly...
  • Page 144 4-14 Deskew Shaft (Continued) Typical Value R# Definition (8400) CCW On average fe. 250 to 600 1.0 to 2.5 CCW On fe ripple. 115 to 360 0 to 2.0 CCW Off fe settling 0.010 to time (sec). 0.20 Time to CW On 0.010 to peak fe (sec).
  • Page 145 Phaser 8400/8500/8550/8560 Color Printer Service Manual Deskew Shaft (Continued) Typical Value R# Definition (8400) CW On fe settling 0.010 to time (sec). 0.20 CW On average fe. -610 to -220 10 CW On fe ripple. 110 to 400 -2.25 to 11 CW Off fe settling 0.010 to time (sec).
  • Page 146: Check Paper Path Menu

    Check Paper Path Menu 4-16 Runs the Media Path Drive train and engages the Head Maintenance Clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc.
  • Page 147 Phaser 8400/8500/8550/8560 Color Printer Service Manual Wiper Shaft (Continued) Typical Value R# Definition (8400) CCW On fe ripple. 25 to 100 CCW Off fe setting 0.004 to time (sec). 0.15 Time to CW On 0.005 to peak fe (sec). 0.20 CW On peak fe.
  • Page 148 4-18 Wiper Shaft (Continued) Typical Value R# Definition (8400) CW On average fe. -50 to 15 10 CW On fe ripple. 20 to 75 11 CW Off fe settling -5 to .01 time (sec). Runs the Media Path Drive train and engages the Tray 1 Pick SAolenoid on the fly.
  • Page 149 Phaser 8400/8500/8550/8560 Color Printer Service Manual Tray 1 Pick Shaft (Continued) Typical Value (8400) R# Definition On response time. -1.5 to 0.95 (sec). Initial average MP -1 to 1400 fe. (mpts). Transition MP fe 750 to 1800 min. (mpts). Typical Value (8500/ 8550/8560) Actions...
  • Page 150 4-20 Tray 1 Pick Shaft (Continued) Typical Value (8400) R# Definition Contact average fe. 120 to 2000 Pushdown MP fe 750 to 2000 max. Final average MP 900 to 1500 fe. (mpts). Test is the same for each pick shaft although for Tray 2 the Media Path Drive motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used.
  • Page 151 Phaser 8400/8500/8550/8560 Color Printer Service Manual Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Typical Value (8400) R# Definition On fe settling time (sec). On average fe. On fe ripple. Off fe settling time (sec). Time to lift plate up (sec).
  • Page 152 4-22 Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Typical Value (8400) R# Definition Plate lifted average Test picks paper from selected tray (test currently supports picking from Tray 2 only) and moves it through either the simplex or duplex paper path to determine paper path power requirements.
  • Page 153 Phaser 8400/8500/8550/8560 Color Printer Service Manual Paper Lead Edge Times (Continued) Typical Value R# Definition (8400) Tray 4 Pick Tray 4 Pick Interval (us) Tray 4 Transport Interval (us) Tray 3 Transport Interval (us) Tray 3 Pick Unused Tray 3 Pick Interval (us) Tray 3 Transport Interval (us)
  • Page 154 4-24 Paper Lead Edge Times (Continued) Typical Value R# Definition (8400) Common Stage Interval (us) Transfix Interval (us) Exit Interval (us) Simplex Path Exited Interval (us) 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.
  • Page 155 Phaser 8400/8500/8550/8560 Color Printer Service Manual Paper Trail Edge Times (Continued) Typical Value R# Definition (8400) Tray 4 Pick Tray 4 Pick Trailing Edge Interval (us) Tray 3 Pick Tray 3 Pick Trailing Edge Interval (us) Tray 2 Pick Unused Unused Tray 1 Pick Unused...
  • Page 156 4-26 Paper Trail Edge Times (Continued) Typical Value R# Definition (8400) Simplex Path Exit Trailing Edge Interval (us) 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.
  • Page 157 Phaser 8400/8500/8550/8560 Color Printer Service Manual Paper Sensor Bounce Times (Continued) Typical Value R# Definition (8400) Preheat Bounce Interval (us) Strip Bounce Interval (us) Exit Bounce Interval (us) Test picks paper from selected tray (test currently supports picking from Tray 2 only) and moves it through either the simplex or duplex paper path to determine paper path power requirements.
  • Page 158 4-28 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.
  • Page 159 Phaser 8400/8500/8550/8560 Color Printer Service Manual 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.
  • Page 160 4-30 Paper is picked and moved through either the duplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected.
  • Page 161: Check Drive Menu

    Check Drive Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual This test moves the wiper drive mechanism through the complete range of its motion in each direction and does an “on the fly” reversal to verify operability. Wiper Drive Typical Value R# Definition (8400) Up Motion Drive...
  • Page 162 4-32 Wiper Drive (Continued) Typical Value R# Definition (8400) 11 Bottom Encounter -2500 to Distance (uin) -1800 12 Turnaround 0.001 to Recovery time 0.250 (sec) 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.
  • Page 163 Phaser 8400/8500/8550/8560 Color Printer Service Manual This test drives the X-Axis Motor in each direction until the Printhead stalls into the stops. Next, the test moves the Printhead into the clear and performs an on the fly reversal. X-Axis Drive Typical Value R# Definition...
  • Page 164 4-34 With the drum turning at a constant velocity, the transfix roller is loaded against the drum, held for one revolution, then raised. The velocity with which the transfix roller is moved differs for the two tests. Transfix Drive Slow and Transfix Drive Fast Typical Value R# Definition...
  • Page 165 Phaser 8400/8500/8550/8560 Color Printer Service Manual Drum Maintenance Drive (Continued) Typical Value R# Definition (8400) Roller Average 50 to 1600 -.05 to .05 Period (sec) Roller Revs 3 to 40 Roller Disengaged -0.001 to Time (sec) 0.05 Blade loaded -160 to average Y-Axis following error (mpts)
  • Page 166 4-36 Tilt Drive (Continued) Typical Value R# Definition (8400) Pre Standby peak -5100 to Magnitude (pm -500 ticks) Post Wipe Peak 1400 to Location () 4150 Post Wipe peak -4000 to Magnitude (pm ticks) This test raises the lift plate to verify motion and sensor operation. If the test is requested for a tray not installed, an “Option Not Detected”...
  • Page 167: Check Drum Menu

    Check Drum Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual Uses the sine and cosine sum data to determine the characteristics of the encoder disk and encoder sensors. Y-Axis Encoder Typical Value R# Definition (8400) Sin Sum Data 150000 to Offset (sin sum 800000 units) Sin Sum Data...
  • Page 168 4-38 Rotates the drum at a constant velocity and samples the Y-Axis position. Uses the data to determine Y-Axis motor and drum vibration and the most significant other vibrational frequencies. Y-Axis Geometry Typical Value R# Definition (8400) Drum Normalized FFT Power (none) Drum Frequency (hz) Motor FFT Power...
  • Page 169 Phaser 8400/8500/8550/8560 Color Printer Service Manual This procedure performs a “4 corner” test using the minimum and maximum velocity and acceleration used during printing and minimum and maximum load for a total of eight test cycles. Measures servo response parameters under various conditions.
  • Page 170 4-40 This test does a chase using a special sheet of preprinted media and records the y-axis following error. Y-Axis Belt Slip Typical Value R# Definition (8400) Initial Peak Y-Axis 0 to 12000 1200 to 8000 Reports the amplitude of the FE (mpts) Max Following 0 to 11000 1100 to 7500 Reports the amplitude of the...
  • Page 171 Phaser 8400/8500/8550/8560 Color Printer Service Manual 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. Stripper Contact Typical Value R# Definition...
  • Page 172 4-42 Stripper Contact (Continued) Typical Value R# Definition (8400) Release -0.75 to Displacement (mpts) Release Time (sec) 0 to 0.09 Releasing Period 0 to .001 (sec) Releasing -45 to 0 Amplitude (mpts) This test uses the drum servo error signal to indicate when the drum is contacted by the roller blade.
  • Page 173: Check Motors Menu

    Check Motors Menu Phaser 8400/8500/8550/8560 Color Printer Service Manual This test turns on the Y-Axis motor and runs it very slowly for one revolution. Y-Axis Motor Typical Value R# Definition (8400) Motor fe ripple 0.08 to 0.60 .07 to .7 (ticks) Motor fe average 0.5 to 0.7...
  • Page 174 4-44 This test turns on the process motor and runs it very slowly for one revolution. Process Motor Typical Value R# Definition (8400) Motor fe ripple 2.8 to 6.0 (ticks) Motor fe average -4 to 3.0 (ticks) Motor drive voltage 5 to 11 ripple (volts) Motor drive voltage...
  • Page 175 Phaser 8400/8500/8550/8560 Color Printer Service Manual This test turns on the specified motor and runs it at constant velocity for approximately 20 revolutions while recording drive data. The test is the same for each motor. Requesting a test for tray not installed generates an “Option Not Detected”...
  • Page 176: Check Misc Menu

    Check Misc Menu 4-46 This test looks at the paper path sensors to identify if anything would prevent a page from printing. The Control Panel will display messages indicating if anything unexpected is found for: R0 = upper paper path; R1 = tray 1; R2 = tray 2;...
  • Page 177 Phaser 8400/8500/8550/8560 Color Printer Service Manual 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. Temperature Status Typical Value R# Definition...
  • Page 178 4-48 Purge Pump (Continued) Typical Value R# Definition (8400) Initial Pumping Power (watts) Max Pressure Pumping Power Pumping Time To Max (sec) No Pressure Pumping Power (watts) Pressure Decay Time (sec) Phaser 8400/8500/8550/8560 Color Printer Service Manual Typical Value (8500/ 8550/8560) Actions Reports minimum pumping...
  • Page 179 Phaser 8400/8500/8550/8560 Color Printer Service Manual This test determines averaged readings for key system voltages. Voltages Typical Value R# Definition (8400) Main Board Voltages 5 Volts (volts) 1.8 Volts (volts) ~1.8V 2.5 Volts (volts) ~2.5V 3.3 Volts (volts) +/-2.5% unregulated12 +/- 20% Volts (volts) 2.5 Volts (volts)
  • Page 180 4-50 This test drives the process motor a short distance in each direction to verify that the dmfix drive unit was in its home position. Drum Maint/Transfix Home Typical Value R# Definition (8400) DM Initial FE Peak (pm motor counts) DM Initial FE Peak Time (sec) TF Initial FE Peak...
  • Page 181: Electronics Troubleshooting

    Control Panel displays status messages as each sub-test is performed. This test takes about 8 seconds. All LEDs are off during the test. If POST diagnostics pass, the Control Panel displays the Xerox logo and turns on the green LED.
  • Page 182 Mechanical Initialization 8400 (1/2) Start the Thermals 13,xxx Unbind Media Path Motor and Home the MPT 31,000 Wait for the Head to read OK_TO_WIPE Temperatures 13.xxx Home XA 6000 Move XA to HEAD TILT POSITION 6000 4-52 Start Mechanical Recovery Set FIRMWARE states: CapState = UNKNOWN Head Tilt State = UNKNOWN...
  • Page 183 Mechanical Initialization 8400 (2/2) _head Parked On? Last Power Down? Move Cap/Wiper to the Park ARMS- and restrain head again. 8035,7009 Device Fault Codes 80xx - Wiper 7002 - PM stalled 70xx - Headtilt 7014 - Head Not Restrained 31001 - Media Path 5001 - YA Home Timer...
  • Page 184 Mechanical Initialization (8500/8550/8560) 4-54 MECHANICAL RECOVERY Start Mechanical Start the Set FIRMWARE states: thermals. CapState = UNKNOWN 13,xxx HeadTiltState = UNKNOWN DmfixState = UNKNOWN YaState = HOMELESS Close preheater Unbind Media Path Motor and HOME the MPT 31,001 Home the Y-Axis 5001, 5004 Wait for head to read OK_TO_WIPE...
  • Page 185 Unplanned Shutdown Temperature Below Purge Threshold Phaser 8400/8500/8550/8560 Color Printer Service Manual If the printer was not shutdown by the power switch the last time it was turned off or it was shutdown with ink on the drum: As soon as the printer has warmed up, the media path motor moves the wiper to the bottom of its travel and the process motor moves the printhead to the print position a chase page is sent through the paper path to clean ink from the drum.
  • Page 186: Miscellaneous Electrical Troubleshooting

    Miscellaneous Electrical Troubleshooting Error Message Displayed on Control Panel LCD Blank Display and the PS and PE LEDs Are Flashing an Error Code Printer Fails Power-Up: PS, PE and 3.3 V LEDs Do Not Illuminate 4-56 The Electronics Module contains the power supply, image processor board and the power control board.
  • Page 187 Phaser 8400/8500/8550/8560 Color Printer Service Manual Unplug power cord and remove printer's covers. Caution Use caution around motors, pulleys and live AC connections when working with the printer covers off. Unplug the following Electronics Module connections. This step removes all other circuits so the Electronics Module can be tested alone.
  • Page 188 4-58 ■ Inkload Signal J910 ■ DMU Sense J860 ■ Drum Thermistor J870 ■ Exit Module J680 ■ Heater Relay Control J950 Retest the resistance of the I/O board. If the resistance is still less than 1K ohm, replace the I/O board, reinstall all cables and retest printer.
  • Page 189 Printer Prints and the Display is Frozen With No Errors Phaser 8400/8500/8550/8560 Color Printer Service Manual If the PE and PS indicators do not flash momentarily, the short is on the printhead. Replace the printhead and retest the printer. Skip the rest of this section if the PE and PS indicators flash because the problem is elsewhere in the printer.
  • Page 190 RAM can cause erratic printer behavior. Internal fault Record any error codes and report to Xerox Office Group. If the printer detects an error, the printer will attempt to reboot and re initialize (up to three times) to correct the problem. After the third cycle of rebooting, an error code displays on the LCD and flashes on the PS and PE indicators.
  • Page 191 Printer Reports Missing Drum Maintenance Kit Printer Reports Missing Waste Tray Optional Features Not Available 525-Sheet Feeder Does Not Function Phaser 8400/8500/8550/8560 Color Printer Service Manual Plug in all cables removed during service. Trace through all service steps performed to reattach any cables that were unplugged during debugging.
  • Page 192 Printer Does Not Print, LEDs are On and the Display is Frozen With No Errors 4-62 Turn off printer and wait 30 seconds for power supply capacitors to discharge. Replace 525-Sheet Feeder. Perform full test of printer. Nonspecific electronics failure. Double check PS and PE indicators for any error code information.
  • Page 193 Verifying Print Engine Operation by Printing Stored Pages Phaser 8400/8500/8550/8560 Color Printer Service Manual If the Electronics Module, I/O Board and Control Panel are working, the error code 34,001.43 should appear on the display to indicate the Printhead is disconnected. If the correct error code is displayed, continue with the next steps of the procedure.
  • Page 194: Verifying Power Supply Operation

    Verifying Power Supply Operation Measuring AC Power Supply Voltages 4-64 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 195: Measuring Dc Power Supply Voltages

    Detecting condition of Fuse F2 and F3 Measuring DC Power Supply Voltages Ensuring Ground Integrity Phaser 8400/8500/8550/8560 Color Printer Service Manual The Drum and Preheater connect to F3. The Printhead and Ink Loader connect to F2. Turn the power switch Off and wait for the printer to shut down. Unplug the Power Cord.
  • Page 196 General Troubleshooting Key Ground Connections The following illustration shows the grounding points in the printer. DM Ground I/O Board X-Axis Motor Transfix Roller Clip Ground Ground Springs X-Axis Return Y-Axis Motor Media Path Drive Spring Ground Ground Ground s8500-032 4-66 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 197: Testing Motor And Solenoid Resistances

    Testing Motor and Solenoid Resistances Phaser 8400/8500/8550/8560 Color Printer Service Manual 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.
  • Page 198: Paper Path And Media-Based Problems

    Paper Path and Media-Based Problems Media-Based Problems Pick Errors - Trays 2, 3, and 4 4-68 For paper path and media-based problems, first check the displayed error codes using the Error Code Definition Table beginning on page 3-7 to help determine where the error is occurring.
  • Page 199: Paper-Pick Errors - Tray 1

    Paper-Pick Errors - Tray 1 Preheater and Transfix Jams Checking the Process and Media Path Drive Phaser 8400/8500/8550/8560 Color Printer Service Manual 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 200: Media Skews Passing Through The Paper Path

    Media Skews Passing Through the Paper Path 4-70 Inspect the gears and mating cam gears for stripped or damaged gear teeth. Replace the Process Drive Gearbox. Replace the media path drive gearbox. Ensure the media is supported. Ensure that the side guides are properly adjusted. Do not overfill the tray, especially with envelopes.
  • Page 201: Operating System And Application Problems

    Print an internal test print from the printer’s Control Panel to ensure the problem is not printer related. There is additional help available at www.xerox.com/office/support. You can access PhaserSMART Technical Support, Technical Support via email, driver downloads, and much more.
  • Page 202 Ethernet Port Verification for Default Assigned IP Address 169.254.xxx.xxx USB Port Verification 4-72 An alternate method is required to test the Ethernet port when the PC’s IP address falls within the range 169.254.xxx.xxx. PCs that have not been configured for a specific network default to a “LOCAL LINK” value within the 169.254.xxx.xxx range.
  • Page 203: Network Problems

    Scroll and select Network Log Pages Highlight the appropriate menu item from the list and select OK. Note Phaser 8500/8550/8560 printers include diagnostic tools for network connections. Use the menu path Problems>Network >Diagnostics. To troubleshoot network problems, select the standard Network Log Pages or Network Diagnostics. Network...
  • Page 204: Obtaining A Back Channel Trace With Usb To Serial Adapter

    P/N F5U109 and Windows XP. Other USB-to-Serial adapters are available. However, software installation procedures may vary by brand. Xerox is not responsible for any changes made to your Laptop or PC setup to make the adapter software function properly. Load the software from the CD and reboot the PC. Follow the instructions included with your adapter to install the necessary software.
  • Page 205 Phaser 8400/8500/8550/8560 Color Printer Service Manual Name the new connection with the model number of the printer. Configure the new connection using the COM port configured in step 3, then click OK. Set “Bits per second” to 19200, and set “Flow control” to Hardware, then click [OK].
  • Page 206 General Troubleshooting 4-76 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 207: Print-Quality Troubleshooting

    Print-Quality Troubleshooting In this chapter... ■ Print-Quality Problems Overview ■ Analyzing Service Test Prints Chapter...
  • Page 208: 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...
  • Page 209: Random Light Stripes

    Random Light Stripes Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual One or more color bars are missing on the test page. This is likely caused by a weak or clogged Printhead jet. ■ Run the Eliminate Light Stripes routine from the Control Panel. ■...
  • Page 210: Predominate Light Stripes

    Predominate Light Stripes Initial Actions Random Light Stripes Troubleshooting Procedure (Continued) Step Questions and Actions Remove the Drum Maintenance Kit and clean the wiper blade with a lint-free cloth or replace the maintenance kit. Did this correct the problem? For the 8400: Download the latest Jet Fix snippet from the Customer Support Site and follow the readme instructions.
  • Page 211: Smudges Or Smears

    Smudges or Smears Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Predominate Light Stripes Troubleshooting Procedure Step Questions and Actions Clean the exit path and Stripper Blade with a lint-free cloth. Did this correct the problem? Remove the Drum Maintenance Kit and wipe the clear plastic wiper blade with a lint-free cloth.
  • Page 212 Smudges or Smears Troubleshooting Procedure Step Questions and Actions Clean the exit path, including the Stripper Blade with a lint-free cloth. Did this correct the problem? 1. On the Control Panel, select -> Troubleshooting --> Print Quality Problems. 2. Select Remove Print Smears, and then press the Enter button.
  • Page 213: Print Too Light Or Too Dark

    Print Too Light or Too Dark Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual The overall image density is too light or dark. ■ Check the media used is supported by this printer. ■ Check the media settings are correct at the Control Panel. Troubleshooting Reference Applicable Parts Ink Sticks...
  • Page 214: Blank Prints

    Blank Prints Initial Actions 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. ■ Check the media used is supported by this printer. ■...
  • Page 215: Color Is Uneven Or Wrong

    Phaser 8400/8500/8550/8560 Color Printer Service Manual This may be due to incorrect colors in the ink loader, old ink in the Printhead, color mixing at the faceplate, or Drum thermal problems. Using non-Xerox ink may cause unpredictable color results. ■...
  • Page 216 5-10 Color is Uneven or Wrong Troubleshooting Procedure (Continued) Step Questions and Actions Check thermal regulation of the Drum. Run the Service Diagnostics Drum Thermal Check test, see “Temperature Status” on page 4-47. Are the Drum thermal values out of the appropriate range? Check the Drum Fan for correct installation and operation.
  • Page 217: Streaks Or Lines Down The Print

    Streaks or Lines Down the Print Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual There are several possible causes of streaks running the length of a print. ■ Check the media used is supported by this printer. ■ Check that the exit path is clear of debris. Troubleshooting Reference Applicable Parts Stripper Blade...
  • Page 218 5-12 Streaks or Lines Down the Print Troubleshooting Procedure (Continued) Step Questions and Actions If there are streaks on the front side only of a 2-sided print, the Preheater may be scraping ink off the print. 1. Look for ink shavings along the streaks on the printed paper.
  • Page 219: Scratches Or Marks Parallel To The Long Axis Of Printing, Particularly With Film

    Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Film Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Scratches or marks are usually caused by debris in the paper path. The scratch or mark may extend into non-printed areas or be more pronounced on the lower portion of the image.
  • Page 220 5-14 Scratches or Marks Troubleshooting Procedure Step Questions and Actions 1. Check the Drum Maintenance Kit. If the defect is a thin line that is glossier than the surrounding area, it may be due to a defect on the maintenance kit wiper blade. 2.
  • Page 221: Ink On White Portion Of Print

    Ink on White Portion of Print Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Color on the print where no color should be printed is often called a latent image. A latent image remains on the Drum when it should have been transferred to its sheet of paper.
  • Page 222 5-16 Ink on White Portion of Print Troubleshooting Procedure (Continued) Step Questions and Actions 1. Clean the Stripper Blade, it may be contaminated with ink. 2. Run Remove Print Smears. Did this correct the problem? 1. Check for ink on the Transfix Roller. 2.
  • Page 223: Fuzzy Text

    Fuzzy Text Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Text appears indistinct and difficult to read. There are three typical reasons for fuzzy text, as called out in this illustration. Top left image displays a Y-axis Drum rotation problem. Lower left image displays the wrong Drum temperature problem.
  • Page 224: Poor Primary Color Fills

    Poor Primary Color Fills Initial Actions 5-18 Fuzzy Text Troubleshooting Procedure Step Questions and Actions 1. Test the Drum Temperature Sensor with Service Diagnostics. 2. Check that the Drum Termperature Sensor is clean and properly positioned. Did this correct the problem? 1.
  • Page 225 Phaser 8400/8500/8550/8560 Color Printer Service Manual Poor Primary Fills Troubleshooting Procedure Step Questions and Actions Banded and inconsistent primary fills may indicate a missing, weak, or discolored jet. 1. Print the Weak/Missing Jet test print. 2. If there are discolored jets, print the Solid Fill test print in the affected color.
  • Page 226: Ghosting

    Ghosting Initial Actions 5-20 The image from a previous print is on the current print. This problem can occur from prints being stacked in the output tray, causing the pressure of the stack and the heat of the printer to cause “blocking” which has the appearance of ghosting.
  • Page 227 Phaser 8400/8500/8550/8560 Color Printer Service Manual Ghosting Troubleshooting Procedure (Continued) Step Questions and Actions Inspect and clean the Drum Maintenance Kit wiper blade. If necessary, replace the kit. Did this correct the problem? Test Drum maintenance operation. 1. Run service diagnostics to verify the Drum maintenance system is operating correctly.
  • Page 228: Poor Small Text Resolution

    Poor Small Text Resolution Initial Actions 5-22 Small characters appear heavy and “plug up.” ■ Check the media used is supported by this printer. ■ Check that the paper path is clean and clear of debris. Troubleshooting Reference Applicable Parts Drum Temperature Sensor ■...
  • Page 229: Vertical Lines Appear Wavy

    Vertical Lines Appear Wavy Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Straight vertical lines appear to be wavy and ill-formed. This problem is likely caused by too much oil on the Drum. ■ Check the media used is supported by this printer. ■...
  • Page 230: Oil Streaks On Print

    Oil Streaks on Print Initial Actions 5-24 Wavy Vertical Lines Troubleshooting Procedure Step Questions and Actions Test Drum maintenance operation. 1. Run service diagnostics to verify the Drum maintenance system is operating correctly. 2. Check, and if necesary, replace these parts;...
  • Page 231 Phaser 8400/8500/8550/8560 Color Printer Service Manual Oil Streaks on Print Troubleshooting Procedure (Continued) Step Questions and Actions Check the Drum Maintenance Kit ground. Inspect the back of the Drum Maintenance Kit to Drum Maintenance Camshaft to Drum Fan ground clip. Did this correct the problem? Remove Print Smears.
  • Page 232: Incomplete Image Transfer To Paper

    Incomplete Image Transfer to Paper Initial Actions 5-26 All of the image does not transfer to the paper. Media that is not smooth enough or too light can cause this problem. This problem can also occur on watermarked paper or when poor Drum oiling causes an incomplete image on one side of the page.
  • Page 233 Phaser 8400/8500/8550/8560 Color Printer Service Manual Incomplete Image Transfer Troubleshooting Procedure (Continued) Step Questions and Actions Check and clean the Drum Maintenance Kit wiper blade. Replace the kit if necessary. Did this correct the problem? 1. Test the Drum Temperature Sensor with Service Diagnostics.
  • Page 234: Ink Smears On First Printed Side Of Auto-Duplex Print

    Ink Smears on First Printed Side of Auto-Duplex Print Initial Actions 5-28 Preheater temperature is too high. Note For 8500/8550/8560 models only. If the customer is manually duplexing, check that the customer is selecting the second side in the print driver. ■...
  • Page 235: Repeating Defects On Print

    Repeating Defects on Print Initial Actions Phaser 8400/8500/8550/8560 Color Printer Service Manual Ink Smears on First Printed Side of Duplex Print Troubleshooting Procedure Step Questions and Actions Test the Preheater temperature. Does the Preheater operate within the normal operating range? Replace the Preheater if necessary.
  • Page 236: White Stripes (Pinstripes)

    White Stripes (Pinstripes) Initial Actions 5-30 Repeating Defects Troubleshooting Procedure Step Questions and Actions A single repeating defect that has a different Y position on each page, but the same X position on each page is probably due to a defect on the Drum.
  • Page 237: Wrinkling

    Wrinkling Phaser 8400/8500/8550/8560 Color Printer Service Manual White Stripes Troubleshooting Procedure Step Questions and Actions Print the Solid Fills test print to reveal an X- axis problem. See “Primary Solid Fills 10x” on page 5-40 for more information. Are the pinstripes apparent on the prints? Check X-Axis motion and verify there is nothing interfering such as a poorly dressed cable or screw.
  • Page 238 Initial Actions 5-32 ■ Check the media used is supported by this printer. ■ Check that the paper path is clean and clear of debris. Troubleshooting Reference Applicable Parts Preheater ■ Drum Maintenance Kit ■ Transfix Components ■ Wrinkling Troubleshooting Procedure Step Questions and Actions Try a higher quality or heavier media type...
  • Page 239: 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 240: Analyzing Service Test Prints

    6 hours (or overnight, if practical). Then perform a clean/purge cycle again. There may be a problem in the Purge Pump or the Wiper Assembly. Verify that Xerox ink is being used. Follow the instructions on the “Printhead Troubleshooting Checklist”.
  • Page 241: X-Axis Motion (8400 Only)

    For X-Axis Motion problems, see “Analyzing Service Test Prints” on page 5-34 (solid fill prints). This print is used by Engineering and Manufacturing. The print must be printed on Xerox Photo Paper. Using a lower grade paper will result in inaccurate measurements. This is a text print...
  • Page 242: Color Bands, Rgbk Dither

    Print-Quality Troubleshooting Color Bands, RGBK Dither The large, secondary colored areas in this print reveal banding and weak jets. Look for: Vertical “bars” or bands of much lighter color or a different hue running in-line in one or more of the solid fills. Causes: A weak jet can cause banding;...
  • Page 243: Reverse Text

    Reverse Text Phaser 8400/8500/8550/8560 Color Printer Service Manual The print indicates if the Printhead is producing properly-sized drops of ink and that the Drum temperature is not too high. Note This print should be made with the printer covers closed and in place. The heat loss without the covers can hide the “too-hot”...
  • Page 244: Big Bands Ohp

    Print-Quality Troubleshooting Big Bands OHP This print allows you to evaluate transparency printing. It prints two transparencies from Tray 1, one with primary color fills and one with secondary color fills and a band of 50% blue, as this is a popular background color for overhead transparencies.
  • Page 245: Gray Fill, Dot Size Uniformity

    Gray Fill, Dot Size Uniformity Phaser 8400/8500/8550/8560 Color Printer Service Manual This print consists of a 66% black fill. It reveals thermal variations, transfix roller pressure variations, or Drum oiling variations. Look for: Large area of differences in the density across the width of the page. (A slight variation is normal.) Look for a lighter vertical band, about 1/3 the width of the page, running the length of the page.
  • Page 246: Ymckrgb Solid Fills

    YMCKRGB Solid Fills Primary Solid Fills 10x 5-40 These seven prints show uniformity of fill. If colors are uneven or wrong, see “Color is Uneven or Wrong” on page 5-9. Look for: Even, uniform fills throughout each print. Wrinkles or deformity of the paper itself caused by the print process show up in duplexed solid fill prints at Standard or Enhanced resolutions.
  • Page 247: Head-To-Drum Gap (8400 Only)

    Head-to-Drum Gap (8400 Only) Phaser 8400/8500/8550/8560 Color Printer Service Manual These prints indicate if the gap between the Printhead and the Drum is correct. EFGHIJKLMNOPQ EFGHIJKLMNOP FGHIJKLMNOPQ EFGHIJKLMNOPQ EFGHIJKLMNOP EFGHIJKLMNOP Lines: The horizontal lines of the print are made up of long and short dashes. Inspect the first and last 1/2 in.
  • Page 248: Black, Red, Green, Blue, Cyan, Magenta, And Yellow Solid Fills

    Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills 5-42 These prints show uniformity of fill. Check for the following: Even, uniform fills throughout the print. There should be no wrinkling or deformity of the paper throughout the print. Poor transfer on one side.
  • Page 249: Manuf. Skew Margins

    Manuf. Skew Margins Phaser 8400/8500/8550/8560 Color Printer Service Manual This print consists of an image used by manufacturing to gauge skew and margin on 2 sided prints. s8400-145 To measure skew, measure 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 250: Cleaning Page

    Cleaning Page Other Test and Specialty Prints 5-44 If you have skew on duplex prints, check for a worn duplex roller an verify that the front door is completely closed and latched on both the left and right sides.If the lead-edge margins are outside of tolerance, check the preheater flag.
  • Page 251: Adjustments And Calibrations

    Adjustments and Calibrations In this chapter... ■ Printer Component Homing Positions and Indicators ■ Jet Substitution Mode ■ Jet Substitution Mode Chapter...
  • Page 252: Adjustments

    Adjustments Wiper Alignment Procedure Remove the printer covers using the procedures that begin on page 8-4. Remove the left head maintenance drive gear by removing the e-clip from the drive shaft. Left Idler Gear Left Drive Gear Phaser 84000/8500/8550/8560 Color Printer Service Manual s8500-059...
  • Page 253 Phaser 84000/8500/8550/8560 Color Printer Service Manual 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 254: Printer Component Homing Positions And Indicators

    Printer Component Homing Positions and Indicators Wiper Assembly Positions After servicing the printer, manually set the following assemblies to their home position before powering on the printer. If the assemblies are not home, gears in the Process Drive can grind or the printer can generate errors. ■...
  • Page 255: Homing The Head Tilt Gear

    Adjustments and Calibrations Homing the Head Tilt Gear The Printhead Is Not in the Printer If the Printhead is removed, manually rotate the Head Tilt Gear, located on the inside of the left frame, to its disengaged position. Drum Printhead Tilt gear (disengaged) DM Cam Gear Tilt Gear...
  • Page 256 The Printhead Is in the Printer Remove the Drum Maintenance Kit. Caution Center the Printhead on its X Axis before continuing with Step 2. Check that the Printhead is clear of the frame to prevent the Printhead from binding against the frame. Insert a flat blade screwdriver into the end of Drum Maintenance Camshaft and rotate clockwise one revolution.
  • Page 257 Adjustments and Calibrations Note When the tilt gear is disengaged, the two arrows on the left side of the printer are pointing at each other. Tilt Gear Disengaged Tilt Gear Engaged s8500-063 Phaser 84000/8500/8550/8560 Color Printer Service Manual...
  • Page 258: Homing The Process Drive Train

    Homing the Process Drive Train Examine the Process Drive gears for the following: ■ The holes is the Process Drive frame must align with the holes in the gear. ■ The hole in the Drum Maintenance Camshaft gear must align with the arrow on the frame.
  • Page 259: Timing The Drum Maintenance Camshaft

    Timing the Drum Maintenance Camshaft Phaser 84000/8500/8550/8560 Color Printer Service Manual Caution Use either the pins that come with replacement Process Drives, or a paper clip, bent into a U shape to hold the gears in their proper position during removal and replacement. If the Process Drive is incorrectly installed, the printer could be damaged.
  • Page 260 6-10 Apply pressure in the direction indicated by the arrow to the Drum Maintenance Kit and Drum Maintenance Pivot Plate to force these components against the Drum Maintenance Camshaft. This forces the cam to home position. Home position is indicated by the hole in the camshaft end gear aligning with the arrow embossed on the frame.
  • Page 261 Phaser 84000/8500/8550/8560 Color Printer Service Manual Check that the hole in camshaft gear is aligned with the arrow embossed on the ground plane. The hole in the upper mating gear should align with the adjacent hole in the frame. Hole in gear aligns with arrow on frame...
  • Page 262: Jet Substitution Mode

    Stripes menu. Although it does not slow down the imaging speed as it does on 8400 models, it still provides an end solution to eliminating light stripes. Phaser 8500/8550/8560 printers feature a Jet Substitution mode that is similar to Phaser 8400 printers, but with two important differences: ■...
  • Page 263: Enabling Jet Substitution Mode (8500/8550/8560)

    Enabling Jet Substitution Mode (8500/8550/8560) Disabling Jet Substitution Mode (8400) Phaser 84000/8500/8550/8560 Color Printer Service Manual To correct print-quality problems, refer to the Eliminate Light Stripes test page to determine which jets are weak or missing. Select Jet Substitution Mode, and then press the OK button. Select Select, and then press the OK button.
  • Page 264: Disabling Jet Substitution Mode (8500/8550/8560)

    Disabling Jet Substitution Mode (8500/8550/8560) Resetting NVRAM 6-14 After the Printhead is replaced, disable Jet Substitution Mode to restore normal operation. To deselect Jet Substitution Mode: On the Control Panel, scroll to button. Select Print Quality Problems, and then press the OK button. Select Eliminate Light Stripes, and then press the OK button.
  • Page 265: Cleaning And Maintenance

    Cleaning and Maintenance In this chapter... ■ Maintenance ■ Inspection ■ Cleaning Chapter...
  • Page 266: Service Cleaning Maintenance Procedure

    Appropriate cleaning procedures, as listed in the following tables, should be performed when specific print-quality or paper transport problems occur. All cleaning procedures are detailed in the printer’s Phaser 8400 Reference Guide or the Phaser 8500/8550 User’s Guide. Light Stripes or Missing Colors Problem type...
  • Page 267: Pick Roller Cleaning Method

    Pick Roller Cleaning Method Tray 1 Phaser 8400/8500/8550/8560 Color Printer Service Manual Ink Smears, Oil Spots, or Random Ink Streaks Problem type Solution Ink smears on the front, Select the automated procedure back, or edges of a page. Smears Check the maintenance kit for ink and paper-dust build-up on the wiper blade.
  • Page 268: Maintenance

    Trays 2~4 Drum Temperature Sensor Maintenance Drum Maintenance Kit Use off-the-shelf clear packaging tape and follow the procedures listed below to clean the pick roller and pick pad for Trays 2~4. This cleaning method has been found to be extremely effective for removing debris. Isopropyl alcohol, while effective, tends to smear the debris, rather than remove it.
  • Page 269: Waste Tray

    ■ 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.) www.xerox.com/office/...
  • Page 270 Belts: There are 3 rubber belts in the printer. Inspect the belts for wear. Look for these problems: ■ Loose rubber particles below the belts indicate a worn belt. ■ Missing teeth in the belts ■ Cracking or moderate fraying; a small amount of fraying is inevitable, so look for other signs of wear before replacing the belt.
  • Page 271: 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 Chapter...
  • Page 272: Overview

    Overview Standard Orientation of the Printer This section contains the removal procedures for selected printer parts listed in the Field Replaceable Units (Service Parts) Parts List. In general, replacement procedures are not given because re-installing a part is usually simply a reversal of the disassembly. Replacement procedures are included where this is not the case and special steps are required.
  • Page 273: General Notes On Disassembly

    General Notes on Disassembly Special Notes Regarding Screws Used in This Equipment. Notations in the Disassembly Text Phaser 8400/8500/8550/8560 Color Printer Service Manual 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.
  • Page 274: Covers

    Covers Front Door/Tray 1 Assembly (PL1.0.1) Open the Front Door by pulling out on the handle to the right side of the door. Remove the right and left stay retainers from the Front Door. Open the plug cover and disconnect the plug from the right side of Front Door.
  • Page 275: Control Panel Cover (Pl1.0.5)

    Control Panel Cover (PL1.0.5) Control Panel (PL1.0.6) Right Side Cover (PL1.0.10) Phaser 8400/8500/8550/8560 Color Printer Service Manual Open the Exit Cover. Exit Cover Control Panel Cover Control Panel Front Door Using either your fingers or a small flathead screwdriver, loosen the Control Panel Cover on the left side, and then slide it forward while lifting up to remove it from the printer.
  • Page 276: Left Side Cover (Pl1.0.9)

    Left Side Cover (PL1.0.9) Exit Cover (PL1.0.7) Remove the Control Panel Cover (page 8-5). Open the Exit Cover and Front Door. Remove the rear screw. Release the latching tabs and remove the Left Side Cover. Remove the Right Side Cover (page 8-5). Remove the Left Side Cover (page 8-6).
  • Page 277: Ink Loader (Pl1.0.8)

    Ink Loader (PL1.0.8) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Right Side Cover (page 8-5). Remove the Left Side Cover (page 8-6). Remove the Exit Cover (page 8-6). Lift the Ink Loader clear of the chassis and hold it in position against the rear of the chassis to allow access to the connectors.
  • Page 278: Imaging

    Imaging Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor (PL 2.0.4) (PL 2.0.14) (PL 4.0.4) Warning The use of safety glasses is recommended for this procedure. Remove the Left Side Cover (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.
  • Page 279 Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove 3 screws (3 coarse thread and 1 fine thread) from the spring arm. The 3 screws securing the arm to the motor remain in place. Y-Axis Motor Assembly If replacing the motor, remove 3 motor screws to separate the motor from the arm and remove the spring arm.
  • Page 280: Printhead, Right And Left Printhead Restraints

    Printhead, Right and Left Printhead Restraints 8-10 (PL 2.0.4) (PL 2.0.5 and 2.0.6) Warning Allow components adaquate time to cool before servicing the printer. Caution Perform the steps in the order given to prevent damage to the printer. Remove the Ink Loader (page 8-7). Caution Place several sheets of paper between the faceplate of the Printhead and the Drum to protect the Drum from damage.
  • Page 281 Phaser 8400/8500/8550/8560 Color Printer Service Manual On the left side, pull the X-Axis Bias Spring Hook out slightly and shift to the side (rotate down). Allow the hook to rest against the detents in the frame. Purge Pump Disconnect the air hose from the Purge Pump. Bias Spring Hook s8500-074 8-11...
  • Page 282 8-12 Remove Left and Right Printhead Restraints. First remove the screw, then pull inward towards the Printhead, then lift up and slightly toward the rear to remove. Printhead Restraint Note Adjust Printhead position as required to remove the right restraint. Remove the Roll Block on the left end of the Printhead shaft.
  • Page 283 Heater Cable Phaser 8400/8500/8550/8560 Color Printer Service Manual Disconnect the heater harness and free the harness from its restraint. Finger Holes Cable Restraint Flex Cable (8400 Only) EMI Tape Heater Harness Plug (8500/8550/8560) Ground Strap (8500/8550/8560 Only) Lift the Printhead out of its mounting position and place the shaft ends in the cradle notches near the top of the chassis frame.
  • Page 284 Replacement 8-14 Disconnect the flex cable from the Printhead (Phaser 8400 printers have two cables). Caution Do not pinch or tear the air hose while removing the Printhead as this will damage the printer. Lift the Printhead free of the printer chassis. The following replacement steps are basically the reverse of the disassembly steps and provide important precautions.
  • Page 285: Head Tilt Solenoid (Pl4.0.12)

    Head Tilt Solenoid (PL4.0.12) Phaser 8400/8500/8550/8560 Color Printer Service Manual After completing the installation, print the Light Stripes Page and check for jets in service mode. If necessary, use the Control Panel to reset the jet substitution mode. Note Be careful not to lose the restraining spring from the unit. Remove the Printhead (page 8-10).
  • Page 286: X-Axis Bias Spring (Pl2.0.19)

    X-Axis Bias Spring (PL2.0.19) 8-16 Caution The spring is in close proximity to the Drum. Use care not to damage the Drum with the removal tools or the spring. Remove the Printhead (page 8-10). Using your hands, a spring hook, or pliers, remove the X-Axis Bias Spring from inside the printer cavity.
  • Page 287: Wiper Assembly (Pl2.0.17)

    Wiper Assembly (PL2.0.17) Phaser 8400/8500/8550/8560 Color Printer Service Manual Caution Place several sheets of paper between the Printhead and the Drum to protect the Drum from damage. Remove the Printhead (page 8-10). Using the gears, position the Wiper Blade all the way up. On the left side, remove the KL clip and gear as shown below.
  • Page 288 Replacement 8-18 Position the Wiper so both ends are all the way down following reassembly (see “Wiper Alignment Procedure” on page 6-2). When reinstalling the belt into the wiper clip in 8500/8550/8560 models, place the belt partly on the clip, and then press the center of the clip with a small needle-nose plier until the belt is secured in the clip.
  • Page 289: Stripper Carriage (Pl2.0.12) And Transfix Roller (Pl2.0.13)

    Stripper Carriage (PL2.0.12) and Transfix Roller (PL2.0.13) Phaser 8400/8500/8550/8560 Color Printer Service Manual Caution Hold the Transfix Roller and Stripper Carriage with one hand during removal of the Transfix Roller shaft to prevent the Transfix Roller from falling and damaging the printer. Also, do not use the Transfix Roller Shaft Restraint as a lever to pry the shaft.
  • Page 290: Preheater (Pl2.0.17)

    Preheater (PL2.0.17) 8-20 Open the Front Door. Remove the Lower Inner Duplex Guide (page 8-33). Remove the Inner Simplex Guide (page 8-33). Unplug the AC and sensor flag connectors from the bottom of the Preheater. Note Release the lock on the back of the AC connector. Slide the latches in and forward to latch in their slots.
  • Page 291: Duplex Roller (Pl3.0.8)

    Duplex Roller (PL3.0.8) Phaser 8400/8500/8550/8560 Color Printer Service Manual Latches Slide the Preheater off the shelves and out of the printer. Replacement Note The fingers on the Inner Simplex Guide, go over the segmented roller. First snap the left retainer into place, then the right. Open the Front Door.
  • Page 292: Transfix Load Module (Pl2.0.15)

    Transfix Load Module (PL2.0.15) 8-22 Remove the Front Door (page 8-4). Remove the Ink Loader (page 8-7). Remove the Preheater (page 8-20). Remove the Media Drive (page 8-40). Remove 4 screws, disconnect 2 connectors, and remove the Exit Module (page 8-32). Remove the Upper and Lower Duplex Guides (page 8-33).
  • Page 293 Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the clevis pins securing the Transfix Load Arms to the chassis, and remove the Transfix Load Arms and Transfix Roller. Clevis Pin Remove the Transfix Camshaft (page 8-25) Remove the grounding springs from the Transfix Load Module. Grounding Springs Transfix Load Arm Add Grease...
  • Page 294 8-24 Remove two screws securing each end of the Transfix Load Module to the chassis. Transfix Load Module 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. Transfix Load Module Replacement Note Place a small amount of Rheolube 768 grease (P/N 070E00890) in...
  • Page 295: Transfix Camshaft (Pl2.0.10)

    Transfix Camshaft (PL2.0.10) Drum Maintenance Camshaft (PL2.0.11) Phaser 8400/8500/8550/8560 Color Printer Service Manual Perform Steps 1 through 7 (remove Transfix Load Arms) of the Transfix Load Module removal procedure (page 8-22). Remove the Process Drive (page 8-43). Slide the shaft to the right and make sure the bearing slides over to the gear.
  • Page 296: Drum Maintenance Pivot Plate (Pl2.0.16)

    Drum Maintenance Pivot Plate (PL2.0.16) 8-26 Remove the Drum Maintenance Kit. Remove the Right Side Cover (page 8-5). Remove the Left Side Cover (page 8-5). Remove the grounding clip on the right end of the Pivot Plate Shaft. Remove the KL-clip on the right end of the Pivot Plate Shaft. Remove the Pivot Plate Shaft.
  • Page 297: Drum Assembly (Pl2.0.3)

    Drum Assembly (PL2.0.3) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Front Door (page 8-4). Remove the Right Side Cover (page 8-5). Remove the Left Side Cover (page 8-5). Remove the Exit Cover (page 8-6). Remove the Ink Loader (page 8-7). Remove the Lower Inner Duplex Guide (page 8-33).
  • Page 298 8-28 Remove the Exit Module (page 8-32). Exit Module Assembly Media Release Blade Assembly Transfix Load Arm 110 Connector (J250) to Control Panel Cable (Not Shown) Drum Heater Relay Board Power Control Left Cable Caution The Drum Temperature Sensor harness is routed through the Exit Module.
  • Page 299 Replacement Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Drum Assembly from the chassis by lifting it straight up as shown in the following figure. Note You will need to temporarily remove 3 screws of the Media Drive motor (PL 4.8) and pull the motor out of the way before you can lift the Drum and pulley from the chassis.
  • Page 300 8-30 Align the clevis on the Transfix Load Arms with the holes in the mounting ears on the Drum. The Transfix Load Arms point in the opposite direction from the Drum Thermistor. Ensure that the cam followers on the Transfix Load Arms are under the Transfix Cams.
  • Page 301: Purge Pump (Pl2.0.7)

    Purge Pump (PL2.0.7) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Left Side Cover (page 8-6). Disconnect the air hose from the Purge Pump. Disconnect the harness from the Purge Pump. Remove 3 screws to remove the Purge Pump. Replacement Note Screws in plastic are torqued to 12 in.
  • Page 302: Paper Path

    Paper Path Exit Module (PL3.0.13) 8-32 Caution The Drum Temperature Sensor harness is routed through the Exit Module. Use care during removal to avoid damaging the sensor. Remove the Exit Cover (page 8-6). Remove 3 screws securing the Media Drive, and let the motor hang. Disconnect 3 connectors: two on the right (I/O Board J680 and J870) and one on the left.
  • Page 303: Inner Simplex Guide (Pl3.0.1)

    Inner Simplex Guide (PL3.0.1) Lower Inner Duplex Guide (PL3.0.2) Lower Exit-Guide Assembly with Strip Flag (PL3.0.3) Phaser 8400/8500/8550/8560 Color Printer Service Manual Open the Front Door to access the guide. Using a small flatblade screwdriver, pry inward on one retainer to remove it from the mounting post then remove the other retainer.
  • Page 304: Outer Duplex Guide With Safety Interlocks (Pl3.0.4)

    Outer Duplex Guide With Safety Interlocks (PL3.0.4) Upper Duplex Guide with Solenoid (PL3.0.5) 8-34 Remove the Control Panel (page 8-5). Remove 4 screws and remove the guide. Outer Duplex Guide Lower Inner Duplex Guide Inner Simplex Guide Lower Exit Guide Assembly Replacement Note Seat the guide on the chassis.
  • Page 305 Service Parts Disassembly Solenoid Lever Upper Duplex Guide Hole for Solenoid Lever s8500-099 Replacement Note Route the Stripper Solenoid harness through the right side frame when replacing the Upper Duplex Guide. Also, verify that the solenoid lever engages the hole in the Stripper Carriage. Phaser 8400/8500/8550/8560 Color Printer Service Manual 8-35...
  • Page 306: Take Away Roller (Pl3.0.7)

    Take Away Roller (PL3.0.7) 8-36 Remove the Right Side Cover (page 8-5). Remove the Left Side Cover (page 8-5). Remove the Media Drive (page 8-40). Remove the Lower Simplex Guide (page 8-33). Remove the KL-clip from the right end of the shaft. Remove the KL-clip and bushing from the left end of the shaft.
  • Page 307: Pick Assembly (Pl3.0.10)

    Pick Assembly (PL3.0.10) Phaser 8400/8500/8550/8560 Color Printer Service Manual Note Replace the Retard Roller at the same time you replace the Pick Assembly. Remove Tray 2 from the printer. Reach into the tray cavity and release the orange colored catch holding the Pick Roller in place.
  • Page 308 Service Parts Disassembly s8500-102 Retard Roller Repalcement s8500-103 8-38 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 309: Tray Lift Motor And Gear (Pl4.0.6)

    Tray Lift Motor and Gear (PL4.0.6) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Electronics Module (page 8-46). Remove Tray 2. Disconnect the harness from the Tray Lift Motor. From the rear of the printer, inside the cavity, remove the push nut (this is a press fit).
  • Page 310: Motors, Gears, Solenoids, Clutches, And Fans

    Motors, Gears, Solenoids, Clutches, and Fans Media Drive with Two Clutches and Solenoid (PL4.0.5) 8-40 Remove the Left Side Cover (page 8-6). Remove the Exit Cover (page 8-6). Disconnect the fan, Media Drive motor, deskew clutch, pick clutch, and Tray 1 Pick Solenoid harnesses. Remove the 6 screws securing the Media Drive..
  • Page 311: Tray 1 Pick Solenoid (Pl4.0.3)

    Tray 1 Pick Solenoid (PL4.0.3) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Left Side Cover (page 8-6). Disconnect the solenoid harness. Remove 1 screw from the solenoid, and remove the solenoid. Tray 1 Pick Solenoid Replacement Note Align the hole on the solenoid with the boss on the Media Drive. Install and torque the screw to 12 in.
  • Page 312: Preheater Lift Solenoid (Pl4.0.1)

    Preheater Lift Solenoid (PL4.0.1) 8-42 Open the Front Door. Remove the Control Panel and cover (page 8-5). Remove 4 screws, disconnect 2 connectors, and remove the Exit Module (page 8-32). Remove the Outer and Upper Duplex Guides (page 8-34). The Preheater Lift Solenoid is now visible on the top of the Transfix Load Module.
  • Page 313: Process Drive (Pl4.0.14)

    Process Drive (PL4.0.14) Phaser 8400/8500/8550/8560 Color Printer Service Manual Caution Replacement drives come with two pins to hold the gears in position. Use either the pins that come with replacement drives, or a paper clip, bent into a U shape to hold the gears in their proper position during removal and replacement.
  • Page 314: X-Axis Motor (Pl4.0.12)

    X-Axis Motor (PL4.0.12) 8-44 Replacement Note After replacing the Process Drive, Drum Maintenance Pivot Plate or the Drum Maintenance Camshaft (or any component requiring removal of the Process Drive), the printer may experience Front Cover jams from Tray 2. The jam occurs with paper in the Preheater and C3T jam errors (strip flag timeout during transfix) recorded in Jam History.
  • Page 315: Head Tilt Gear (Pl4.0.9)

    Head Tilt Gear (PL4.0.9) Phaser 8400/8500/8550/8560 Color Printer Service Manual Remove the Printhead (page 8-10). At the left side, remove the KL-clip. Remove the Waste Tray Cover, without disconnecting the Waste Tray Detect Sensor harness. Reach in to the Waste Tray cavity and remove the Head Tilt Gear. Head Tilt Compound Gear Replacement Note On reassembly, the leaf spring on the back side of the chassis must...
  • Page 316: Electronics

    Electronics Electronics Module (PL5.0.5) 8-46 Caution Touch the back of the Electronics Module before starting this procedure to discharge any electrostatic charge present on the case. Also, do not completely remove EMI tape, if added to a connector. Note Do not fully remove EMI tape, if included with any connector. Disconnect the Power Cord and all connections to the Electronics Module.
  • Page 317: Wave Amplifier (Pl5.0.4)

    Wave Amplifier (PL5.0.4) Phaser 8400/8500/8550/8560 Color Printer Service Manual Note Do not fully remove EMI tape, if included with any connector. Remove the Electronics Module (page 8-46). Remove the Printhead (page 8-10). Remove 3 screws. Caution Route the ribbon cables carefully through the slots. Remove the Wave Amp through the back of the printer Replacement Note Insert the ribbon cables fully and squarely into the flex connectors on...
  • Page 318: I/O Board (Pl5.0.13)

    I/O Board (PL5.0.13) 8-48 Remove the Right Side Cover (page 8-5). Disconnect all connections to the I/O Board. Remove 2 screws to remove the board. I/O Board Ground Tab Replacement Note Locate the corner of the board behind the ground tab on reassembly. Install and torque the 2 screws to 12 in.
  • Page 319: Drum Heater Relay Board (Pl5.0.17)

    Drum Heater Relay Board (PL5.0.17) Phaser 8400/8500/8550/8560 Color Printer Service Manual Warning This board is supplied with 120 VAC, shut off printer power and disconnect the power cord before starting this procedure. Remove the Right Side Cover (page 8-5). Disconnect all connections to the board. Remove 2 screws securing the board to the chassis.
  • Page 320: Nvram (Pl5.0.9)

    NVRAM (PL5.0.9) 8-50 Caution Some semiconductor components, such as the NVRAM chip, are vulnerable to damage by Electrostatic Discharge (ESD). Note Observe the orientation of the NVRAM chip before removing it. Remove the Back Cover from the Electronics Module. Note On 8400 models, the NVRAM chip is located at U850.
  • Page 321: Dimm Memory (Pl5.0.8)

    DIMM Memory (PL5.0.8) Phaser 8400/8500/8550/8560 Color Printer Service Manual Caution Some semiconductor components, such as memory, are vulnerable to damage by Electrostatic Discharge (ESD). Review the “Electrostatic Discharge (ESD) Precautions” on page 1-v before continuing with this procedure. Note Observe the orientation of the memory devices before removing them. Notice that the DIMM boards are inverted to each other.
  • Page 322: Hard Drive (Pl5.0.7)

    Hard Drive (PL5.0.7) 8-52 Caution Some semiconductor components, such as the NVRAM chip, are vulnerable to damage by Electrostatic Discharge (ESD). Remove the Back Cover from the Electronics Module. Disconnect the 2 connectors from inside the Electronics Module. Pull out and replace the entire unit, including chassis holder, hard drive, and board.
  • Page 323: Parts Lists

    Parts Lists In this chapter... ■ Serial Number Format ■ Using the Parts List ■ Xerox Supplies Chapter...
  • Page 324: Serial Number Format

    Serial Number Format The serial number is coded as follows: Serial Number Example: 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 ■...
  • Page 325: Using The Parts List

    Using the Parts List Phaser 8400/8500/8550/8560 Color Printer Service Manual 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.
  • Page 326: Pl 1.0 Covers

    Parts Lists PL 1.0 Covers s8500-117 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 327 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 1.0 Covers No. Name/Description Front Door (MPT) Assembly Front Door Stay Retainer Clip Front Door Stay with Spring Hinge Pins, Front Door Control Panel Cover Control Panel with Bezel Exit Cover Assembly Exit Cover with Badge Ink Loader Door (part of PL 2.1) Left Side Cover...
  • Page 328: Pl 2.0 Imaging

    PL 2.0 Imaging Phaser 8400/8500/8550/8560 Color Printer Service Manual 8500 118...
  • Page 329 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 2.0 Imaging No. Name/Description Ink Loader Assembly and Door Printhead Drum Assembly, includes Encoder Belt, Y-Axis Drum Printhead Wiper Belt, Wiper Drive Purge Pressure Pump Left Printhead Restraint Right Printhead Restraint Transfix Camshaft Assembly Drum Maintenance Camshaft Assembly Stripper Carriage Assembly...
  • Page 330: Pl 3.0 Paper Path

    Parts Lists PL 3.0 Paper Path s8500-119 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 331 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 3.0 Paper Path No. Name/Description Inner Simplex Guide Lower Inner Duplex Guide Lower Exit Guide Assembly with Strip Flag Outer Duplex Paper Guide with Sensors (Safety Interlocks) Upper Duplex Guide with Solenoid Exit Roller Take Away Roller Duplex Roller...
  • Page 332: Pl 4.0 Motors, Gears, Solenoids, Clutches, And Fans

    Parts Lists PL 4.0 Motors, Gears, Solenoids, Clutches, and Fans s8500-120 9-10 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 333 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 4.0 Motors, Gears, Solenoids, Clutches, and Fans No. Name/Description Preheater Lift Solenoid Motor, Y-Axis Drive Pick Solenoid, Tray 1 Head Tilt Solenoid Gearbox, Media Drive with 2 Clutches, Solenoid Tray Lift Motor Kit and Gear (plus item 10) Paper Path Cooling fan Electronics Module System Fan Compound Gear, Head Tilt...
  • Page 334: Pl 5.0 Circuit Boards

    Parts Lists PL 5.0 Circuit Boards s8500-121 9-12 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 335 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 5.0 Circuit Boards and Cables No. Name/Description Cable, Y-Axis Motor Ground Wiring Harness, Left Side Power Control Cable, Wave Amp Signal Wave Amp Electronics Module (no RAM, NVRAM, or Configuration Card) Cable, Printhead Interface Hard Drive Hard Drive with Japanese Fonts 128 MB SDRAM...
  • Page 336: Pl 6.0 Sensors And Flags (Actuators)

    Parts Lists PL 6.0 Sensors and Flags (Actuators) s8500-122 9-14 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 337 Phaser 8400/8500/8550/8560 Color Printer Service Manual Parts List 6.0 Sensors and Flags (Actuators) No. Name/Description Drum Temperature Sensor Optical Sensor (Generic Snap-In) Safety Interlock Switch (Mech) Exit Module Sensor Assembly Paper Present Flag Exit Flag Sensor Assembly, Paper Tray Waste Tray Detect Sensor Qty Part Number 130K75210 130E11530...
  • Page 338: Xerox Supplies

    Xerox Supplies 9-16 Kits Description Mechanical Kit (Hardware) Nut Plate - 2 ea. ■ 6 mm press nut - 2 ea. ■ #8 SAE washer - 5 ea. ■ Thumbscrews - 2 ea. ■ M4 x 12 delta pt/ hexhead - 5 ea.
  • Page 339 Mechanical Parts Kit Flashlight Grease Serial Cable Adapter Consumables and Routine Maintenance Items Description Standard-Capacity Maintenance Kit Extended-Capacity Maintenance Kit Genuine Xerox Solid Ink Black (3 sticks) Genuine Xerox Solid Ink Cyan (3 sticks) Part Number ZMD128 ZMD256 097S03380 097S03381 097S03381...
  • Page 340 Genuine Xerox Metered Solid Ink Cyan (6 sticks) Genuine Xerox Metered Solid Ink Magenta (6 sticks) Genuine Xerox Metered Solid Ink Yellow (6 sticks) 108R00709 (8550) Genuine Xerox Metered Solid Ink Black (6 sticks) Genuine Xerox Solid Ink Cyan (1 stick)
  • Page 341 Phaser 8400/8500/8550/8560 Color Printer Service Manual Phaser Color Printing Media (Continued) Description Phaser Premium Cover Paper, Letter, 100 Sheets Phaser Premium Cover Paper, A4, 100 Sheets Phaser Professional Solid Ink Transparency, Letter, 50 Sheets 103R01039 Phaser Professional Solid Ink Transparency, A4, 50 Sheets Phaser Professional Solid Ink Business Cards, Letter,10/ sheet, 25 sheets Phaser Professional Solid Ink Business Cards, A4,10/sheet,...
  • Page 342 Parts Lists 9-20 Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 343: 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 Chapter...
  • Page 344: Main Wiring Diagram

    Main Wiring Diagram Printhead Driver JET0 + /- JET1 + /- JET2 + /- CLK + /- ADCTX + /- ADCRX + /- + /-12 V regulated +3.3 V Gnd (9) Spares (Vss & Vpp) J210 (8400 Only) J240 J630 (8400 Only) Wave Amp ECB VssD VppD...
  • Page 345: Main Wiring Diagram (Continued)

    Main Wiring Diagram (Continued) J620 Power Control J820 +/-12 V unreg J790 generates +/- 12 V reg. J390 (Left Side) Printer ambient temperature J800 (Right Side) Serial Data J870 J250 I/O ECB J860 J680 J600 Phaser 8400/8500/8550/8560 Color Printer Service Manual 30 connector J480 X- axis motor...
  • Page 346: Right-Side Wiring Diagram

    Right-Side Wiring Diagram 10-4 The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. Wiring Harness Pass-Through J250 37020.4x Strip Solenoid J910 13387.4 J400 Drum Heater J110 Waste Tray Ground Clip J600 Add Paper Tray J610 No Handfeed...
  • Page 347: Right-Side Wiring Diagram (Continued)

    Right-Side Wiring Diagram (Continued) Phaser 8400/8500/8550/8560 Color Printer Service Manual The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. Routes to Top of Channel 13387.4x 37027.4x X-Motor Ribbon Cable (Routed in Middle of Channel) J4AC 37006.4x...
  • Page 348: Left-Side Wiring Diagram

    Left-Side Wiring Diagram 10-6 The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. 37022.4x Purge Motor J280 37032.4x Y-Motor J790 37062.4x Head VSS J390 37034.4x MP Motor 37013.4x Electric Fan Phaser 8400/8500/8550/8560 Color Printer Service Manual 37023.4x Purge Valve...
  • Page 349: Left-Side Wiring Diagram (Continued)

    Left-Side Wiring Diagram (Continued) Phaser 8400/8500/8550/8560 Color Printer Service Manual The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. 37034.3x MP Motor 37015.4x MP Fan (8400 Only) Ground Clip 37018.4x Pick Clutch 37019.4x Pick Solenoid...
  • Page 350: Inside Front Wiring Diagram

    Inside Front Wiring Diagram 10-8 The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. 37008.4x Preheat Power (AC Connector) Paper Jam (Open Front Cover) Phaser 8400/8500/8550/8560 Color Printer Service Manual 37036.4x Process Motor Load Paper J860 13131.41 Sensor Flag...
  • Page 351: Inside Top Wiring Diagram

    Inside Top Wiring Diagram Phaser 8400/8500/8550/8560 Color Printer Service Manual The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. 8400 37010.4x Ink 1 Heater J2AC 37002.4x JSL Heater 8500/8550 37010.4x Ink 1 Heater...
  • Page 352: Inside Top - Printhead Wiring Diagram

    Inside Top - Printhead Wiring Diagram 10-10 The arrows indicate which connectors you should look at for the PEST codes. The PEST codes are displayed on the Control Panel. Cable Restraint J180 32064.4x Out of Ink Heater Cable Phaser 8400/8500/8550/8560 Color Printer Service Manual (8400 Only) J140 37063.4x Head VPP s8500-131...
  • Page 353: Reference

    Reference Contents... ■ Menu Map (8400) ■ Menu Map (8500/8550/8560) ■ Paper Weight Equivalence Table ■ On-site Printhead Troubleshooting Checklist (8400) ■ On-site Printhead Troubleshooting Checklist (8500/8550/8560) Appendix...
  • Page 354 Menu Map (8400) Main Menu: READY TO PRINT. READY TO PRINT. Information Information Walk-Up Walk-Up Printer Setup Printer Setup Troubleshooting Troubleshooting Shut Down Shut Down Model Printer Name Print Server* Information IP Address* Serial # Menu Map Activation Date Printer Identification Information Pages Sample Pages Supplies Info...
  • Page 355 Printer Setup (continued) Paper Handling Setup PostScript Setup PCL Setup Front Panel Setup Printer Controls Troubleshooting Help Guide Paper Jams Print Quality Problems Network Log Pages* Service Tools Shutdown Power Saver (Recommended) Restart Printer Power Down Requires: Network Configuration Duplex Configuration Optional Lower Tray(s) **** 8400DX only with stored jobs present...
  • Page 356: Menu Map (8400

    Menu Map (8500/8550/8560) Main Menu: Ready To Print Ready To Print Walk-Up Features Walk-Up Features Information Information Paper Tray Setup Paper Tray Setup Printer Setup Printer Setup Troubleshooting Troubleshooting Walk-Up Features* Personal Print Jobs Secure Print Jobs Displays when print jobs are stored on the hard drive.*** Proof Print Jobs Saved Print Jobs Prints jobs using the Walk-Up printer driver.
  • Page 357 Printer Setup Configuration Page Connection Setup Network Setup* USB Setup Reset Connection Setup PostScript Error Info Print-Quality Mode TekColor Correction Image Smoothing User Defined Screens Reset PostScript Setup PostScript Setup PCL Setup Control Panel Setup Printer Controls File Security*** Overwrite Removals Remove Job Files Daily Removal Remove At HH:MM...
  • Page 358: Media Margin Specification Table

    Media Margin Specification Table Width Length Media Size (mm) (mm) Legal 215.9 355.6 Folio 215.9 330.2 215.9 279.4 Executive 187.15 266.7 B5 JIS B5 ISO #10 Envelope 104.775 241.3 Choukei 3 Gou C5 Envelope DL Envelope Statement 139.7 215.9 Choukei 4 Gou Monarch 98.425 190.5...
  • Page 359: Paper Weight Equivalence Table

    Paper Weight Equivalence Table Phaser 8400/8500/8550/8560 Color Printer Service Manual US Bond US Text Postcard Weight Book Cover Thicknes (lb.) Weight Weight s (mm) (lb.) (lb.) 0.18 0.20 0.23 US Tag Metric Bristol Index Weight Weight Weight Weight (lb.) (g/m (lb.) (lb.)
  • Page 360: On-Site Printhead Troubleshooting Checklist (8400

    On-site Printhead Troubleshooting Checklist (8400) For the latest policy information on Non-Xerox Supplies, visit the Xerox Service Partners Web Site: https://www.office.xerox.com/smart/sso index.cfm?fuseaction=sso.partnerLogin PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8400/WorkCentre C2424 IMPORTANT! This checklist outlines proper printhead troubleshooting procedures. All Xerox service employees and any other service personnel on any job involving a printhead replacement should perform it.
  • Page 361 If Line 636 IDU lists any values, record the numbers here: Xerox U.S. personnel please record these dates in the FIST system as well as in this document If YES please write down the error code. _______________ 3a. If error code 13,264.4x is present in the Fault History replace the...
  • Page 362 Step Is the Wiper Assembly correctly aligned? Step Print Service Test Print 1: Weak and Missing Jets. Is severe color mixing apparent? Visually check Step the printhead faceplate. Is the faceplate contaminated? Step Visually check the Wiper Assembly blade. Is it OK? Check the Step purge...
  • Page 363 ____________________________________________________________________________ A completed checklist and sample prints must be returned with each printhead. Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed troubleshooting checklist and a sample print with each returned printhead. Please return the following items with the defective printhead:...
  • Page 364: Ink Failure Checklist

    Ink Failure Checklist For the latest policy information on Non-Xerox Supplies, visit the Xerox Service Partners Web Site: https://www.office.xerox.com/smart/sso index.cfm?fuseaction=sso.partnerLogin GENERIC INK FAILURE CHECKLIST PERFORM THIS CHECKLIST ONLY IF YOU SUSPECT Print Test Print 1 (Weak/Missing Jets). CAREFULLY examine it.
  • Page 365: On-Site Printhead Troubleshooting Checklist (8500/8550/8560

    On-site Printhead Troubleshooting Checklist (8500/8550/8560) PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8500/8550/8560/8560MFP IMPORTANT! This checklist outlines proper printhead troubleshooting procedures. All Xerox service employees and any other service personnel on any job involving a printhead replacement should perform it. Service person name...
  • Page 366 30-99 _____________ 100+: ______________ Xerox U.S. personnel please record these dates in the FIST system as well as in this document If YES please write down the error code. _______________ 3a. If error code 13,264.4x is present in the Fault History replace the electronics module (continue to 3b.
  • Page 367 Is the Step Cap/Wipe/ Purge assembly correctly Circle aligned? Print Service Step Test Print 2: Weak and Missing Jets. Circle Is severe color mixing apparent? Step Visually check the printhead faceplate. Is the faceplate contaminated? Circle Step Visually check the Wiper Assembly blade.
  • Page 368 ____________________________________________________________________________ A completed checklist and sample prints must be returned with each printhead. Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed troubleshooting checklist and a sample print with each returned printhead. Please return the following items with the defective printhead:...
  • Page 369 Numerics 525-sheet feeder, parts list 9-13 8-pin NVRAM, parts list AC power 2-20 adjust x-axis scale, service menu back button basic positions, printhead 2-10 basic printhead cleaning cycle 2-33 belts drive, single reduction 2-16 drum 2-17 parts for wiper drive parts for y-axis printer removing from drum assembly...
  • Page 370 cleaning cycle 2-33 cleaning page 2-14 2-33 5-44 cleaning procedures Clear ISC Fault clevis pins 8-23 8-28 8-30 communication ports 2-19 4-71 configuration card 8400 series 8500 series theory 2-19 view configuration, control panel consumables 9-17 diagram life counters control panel LED indicators menu map covers...
  • Page 371 envelopes, printing on 1-14 environmental specifications 1-12 error codes 525-sheet feeder faults code version 3-33 electronics module 3-24 I/O board program I/O circuit board ink loader 3-23 IPC program 3-10 mechanical initialization 3-34 printhead calibration 3-32 process control system 3-10 process motor gearbox 3-15 thermal faults...
  • Page 372 media drive assembly parts 9-11 function gearbox removal 8-40 theory media path drive media path faults 3-34 miscellaneous error codes 3-33 NVRAM 2-19 NVRAM, reset 6-14 oil streaks 5-24 2-34 oiling cycle outer duplex guide illustration 8-34 paper path part removal 8-34 paper...
  • Page 373 1-12 functional 1-12 media and tray 1-13 physical dimensions 1-10 1-10 specifications, printer status indicator LED 5-11 streaks supplies, Xerox 9-16 test prints 5-34 tilt cam 2-10 2-11 tilt gear 2-12 Phaser 8400/8500/8550/8560 Color Printer Service Manual transfix roller 2-16...
  • Page 374 Index Notes Reference Description Phaser 8400/8500/8550/8560 Color Printer Service Manual...
  • Page 376 701P27910...