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Xerox Phaser 840 Service Manual

With phaser 8200 color printer addendum
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840/850/860
P h a s e r
®
C o l o r P r i n t e r
Service
Manual
With Phaser
8200 Color Printer Addendum
®
Download Free Service Manual at http://printer1.blogspot.com

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  Summary of Contents for Xerox Phaser 840

  • Page 1 840/850/860 P h a s e r ® C o l o r P r i n t e r Service Manual With Phaser 8200 Color Printer Addendum ® Download Free Service Manual at http://printer1.blogspot.com...
  • Page 3 P H A S E R ® 8 4 0 / 8 5 0 / 8 6 0 N E T W O R K C O L O R P R I N T E R S e r v i c e M a n u a l w i t h t h e P h a s e r 8 2 0 0 C o l o r P r i n t e r A d d e n d u m Warning...
  • Page 4 Other marks are trademarks or registered trademarks of the companies with which they are associated. ® PANTONE Colors generated by the Phaser 840 / 850 / 860 / 8200 Color Printers are four- and/or three-color process simulations and may not match PANTONE-identified solid color standards. Use current PANTONE Color Reference Manuals for accurate colors.
  • Page 5: User Safety Summary

    User safety summary Terms in manual CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury or loss of life. Power source: For 110 VAC printers, do not apply more than 130 volts RMS between the supply conductors or between either supply conductor and ground.
  • Page 6: Service Safety Summary

    DANGER high voltage: Protective ground (earth) terminal: Use caution. Refer to the manual(s) for information: WARNING: If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can cause an electrical shock. Electrical product may be hazardous if misused.
  • Page 7: Table Of Contents

    Regulatory Specifications................1 - 35 Error Codes and Messages 2 - 37 Phaser 840/850 Rear Panel PS and PE LED Codes ..........2 - 37 Phaser 860 Power-Up Error Messages and LED Codes........2 - 40 The BIST (Built-In Self Test)...............2 - 40 POST (Power On Self Test) .................2 - 41...
  • Page 8 Image never prints ..................3 - 115 Image is rotated 90 degrees ............... 3 - 115 Image prints in black-and-white ..............3 - 115 Printer isn’t in the Chooser ................ 3 - 116 Windows printing problems................3 - 117 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 9 Process belt tension adjustment ..............4 - 139 Exit roller drive belt tension adjustment.............4 - 140 Y-axis belt tension adjustment (Phaser 840 printer)........4 - 142 Y-axis belts tension adjustment (Phaser 850/860 printer)......4 - 144 Printhead-to-drum spacing adjustment (Phaser 840 Printer Only).....4 - 146 X-axis scale adjustment ................4 - 149...
  • Page 10 Upper feed roller assembly ................ 7 - 185 Paper/drum heater ..................7 - 187 Drum/transfix assembly................7 - 188 Drum position sensor assembly (Phaser 840 printer) ........ 7 - 192 Drum position sensor assembly (Phaser 850/860)........7 - 194 Printhead ....................7 - 196 X-axis motor and drive assembly ..............
  • Page 11 Appendix A - 243 On-site Printhead Troubleshooting Checklist Phaser 340/350/360/380/840/850 ..............A - 244 On-site Electronics Troubleshooting Checklist Phaser 840/850 ....A - 250 Z840/z850 Electronics Troubleshooting Guide.........A - 253 On-site Printhead Troubleshooting Checklist Phaser 860/8200..................A - 261 On-site Electronics Troubleshooting Checklist Phaser 860 ......A - 266...
  • Page 12 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 13: List Of Tables

    Rear panel DIP switch settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-28 Summary of differences between Phaser 840/850/860 - - - - - - - - - - - - - - - - - 1-29...
  • Page 14 Supplies and accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-227 viii Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 15: List Of Figures

    Front Panel - Phaser 860 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-24 Phaser 840 printer rear panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25...
  • Page 16 Removing the x-axis motor and drive assembly - - - - - - - - - - - - - - - - - - - 7-199 Removing the Y-axis belt drive assembly (Phaser 840 printer) - - - - - - - - - - - - 7-200...
  • Page 17: General Information

    General Information This service guide contains information used to verify operation, troubleshoot, repair, adjust, and maintain the Xerox Phaser® 840, Phaser® 850 and Phaser® 860 Color Printers. This guide includes a Field Replacement Unit Parts list. Topics such as printer theory of operation, detailed removal/replacement procedures, configuration page details, and verifying printer operation are located on the companion Color Printer Service &...
  • Page 18: Phaser 840 Printer Overview

    Phaser 840 Printer Overview The Phaser 840 Color Printer is an Adobe PostScript® Level 3 (Version 3010) color, solid-ink printer. It also supports color PCL 5c at 600 x 600 dots-per-inch resolution. The Phaser 840 printer prints at a number of resolutions: A 10 page-per-minute (ppm) Fast Color Mode, a standard 5.7 ppm mode, an Enhanced mode of 491 x 982 dpi at 3.3 ppm...
  • Page 19 A 133-MHz PowerPC processor oversees print engine operations and PostScript image processing. The printer features an integral bi-directional parallel port (IEEE 1284C with ECP mode) and a 10BaseT Ethernet port (with support for EtherTalk, Novell NetWare/NDS, TCP/IP, DHCP and Windows Peer-to-Peer). A USB high-speed serial port is also provided.
  • Page 20: Phaser 850 Printer Overview

    RAM. It also includes a High-Capacity Paper Tray and an internal IDE hard drive. Like the Phaser 840 printer, all printers support four available paper trays. They also support the optional 500-sheet High-Capacity Paper Tray Assembly. The printer can also print seven sizes of hand-fed envelopes.
  • Page 21: Phaser 860 Printer Overview

    Phaser 860 Printer Overview The Phaser 860 Color Printer is an Adobe PostScript Level 3 (Version 3010) color, solid-ink printer. It also supports color PCL 5c at 600 x 600 dots-per-inch resolution. The printer can print at the following resolutions: Fast Color mode, 16 page-per-minute (ppm) Standard mode, 10 ppm mode at 355 x 464 dpi Enhanced mode, 6 ppm at 464 x 928 dpi...
  • Page 22: Solid Inks

    The inks solidify almost instantly after being jetted onto the printer’s drum. Because Xerox proprietary solid inks bleed much less than ordinary liquid inks, they allow the printer to print brilliant colors on plain paper.
  • Page 23: Phaser 840/850 Ram And Printer Capabilities

    Phaser 840/850 RAM and Printer Capabilities The Phaser 840 printer features two DIMM connectors which accept both 32- or 64-Mbytes RAM DIMMs (16-Mbyte RAM DIMMs work but are not offered). The Phaser 850 printer features two DIMM connectors which will accept both 64- or 128-Mbytes RAM DIMMs.
  • Page 24: Memory Considerations Phaser 840/850

    (which gives greater printing throughput). The printer’s capabilities can be increase as detailed in the following table. For the Phaser 840 printer, adding RAM memory, and installing the SCSI daughter card enables the Plus and Extended configurations features.
  • Page 25 Installed RAM: 64 Mbytes Mem slot 1: SDRAM/parity/64 MB/KMM366S823BTL-G0 Mem slot 2: Empty This is a list of SDRAM DIMMs that are branded for use by Xerox in this printer at the time this guide was published: Table 1-2 Acceptible SDRAM DIMMs...
  • Page 26: Phaser 860 Ram And Printer Capabilities

    Print the Configuration Page and check the item “Installed RAM” to see what type of RAM is installed. This is a list of SODIMMs that are branded for use by Xerox in this printer at the time this guide was published:...
  • Page 27: Memory Considerations Phaser 860

    Memory Considerations Phaser 860 With more memory, the printer dual-frame buffers for printing one image while processing a second image (which gives greater printing throughput). The printer’s capabilities can be increase as detailed in the following table. For the Phaser 860 printer, installing the DP Option code ROM module and adding RAM enables these features.
  • Page 28: Print Engine Assemblies 840/850/860

    Cap/wipe/purge assembly Printhead assembly Drum Transfix roller Process motor Paper/ drum heater X-axis drive Y-axis and motor motor Paper feed motor 0388-0 Fig 1-3 Internal features of the print engine 1 - 12 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 29: Circuit Boards

    The printhead drive board, a part of the printhead, manages the signals and voltages of the printhead’s printing elements and sensors. The optional network card (Phaser 840 and 850 only) and internal hard drive could be considered eight and ninth circuit boards.
  • Page 30 Power Control Board I/O Board left Main Board Drum Maintenance Counter EEPROM Power Supply Internal Hard Drive P860-004 Fig 1-6 Circuit Boards of the print engine (right rear view Phaser 860) 1 - 14 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 31: The Printer's I C Bus

    The printer’s I C bus An internal data bus, called the I C bus, connects all I/O boards to the main board. Through this single bus, the main board can “poll” the I/O boards for the state of the printer’s sensors as well as actuate the printer’s solenoids. This data bus greatly simplifies the wiring that would otherwise be required for monitoring numerous sensors and solenoids.
  • Page 32: Printhead Maintenance System

    The system consists of a vacuum pump assembly, the cap/wipe/purge assembly and the cap/wipe/purge carriage drive. Cap/wipe/purge carriage drive Vacuum pump assembly Cap/wipe/purge assembly 0388-06 Fig 1-8 Printhead maintenance system of the print engine 1 - 16 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 33: Sensor Maps

    The printer monitors the positions of some of the movable assemblies, such as the drum, as well as the temperature of many other assemblies, such as the printhead, paper preheater and the drum. Unlike the Phaser 840 printer, the Phaser 850 /860 printer does Note not have a separate drum-home position sensor.
  • Page 34 Transfix roller Preheater exit sensor Preheater located on inside wall of drum/transfix frame Drum 0388-34 Fig 1-10 Switches and Sensors on the left side of the print engine 1 - 18 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 35 The actual position of some printer assemblies, such as the Caution printhead or the cap/wipe/purge assembly, cannot be ascertained at all times. The printer records, in NVRAM, where it last positioned such assemblies each time it moves them. If, after power-down or a power interruption, the assemblies are manually repositioned, the printer erroneously assumes that the assemblies are in the position it last left them.
  • Page 36: Combination Sensors And Their Meanings

    Open Open Closed Closed Open switch The slide switch actuators on the media trays will open a switch in the forward position and close a switch in the rear position. 1 - 20 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 37: The Main Board

    Network connection is provided through a built-in 10BaseT port in the Phaser 840 printer and a 10/100BaseT port for the Phaser 850/860 printer (not enabled in the Phaser 860B). For the Phaser 840 printer, a plug-in SCSI interface adapter board provides a SCSI port for an external hard drive or scanner.
  • Page 38: Features Of The Phaser 860 Main Board

    Fig 1-13 Features of the Phaser 850 printer main board ROM Upgrade Factory Code ROM Code DIMM EEPROM Printer ID RAM SODIMMs Hard Drive P860-002 Fig 1-14 Features of the Phaser 860 Main Board 1 - 22 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 39: Front Panel - Phaser 840/850 Printers

    Front Panel - Phaser 840/850 Printers These front panel features are found on the printer: 128 x 64 pixel backlighted graphic display Two push buttons and four arrow buttons Two LEDs The backlighted LCD serves two purposes: displaying current image processor LCD.
  • Page 40: Front Panel - Phaser 860

    The topic "Resetting NVRAM", on page 4-156 explains how to use the front panel buttons to reset the NVRAM to its factory-default values. P h a s e r 8 6 0 0726-42 Fig 1-16 Front Panel - Phaser 860 1 - 24 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 41: Rear Panel Connections

    Rear Panel Connections Phaser 840 printer connectors The rear panel of the Phaser 840 printer features the host interface connectors to the printer: Standard parallel (high-density connector), IEEE 1284C. Twisted Pair (10BaseT) Ethernet connector. A Universal Serial Bus port. Optional SCSI high-density connector (hard disk drive or Tektronix-approved scanner).
  • Page 42: Phaser 850 Printer Rear Panel

    IDE hard drive Optional Token Ring card PostScript Engine health health light light Ethernet 10/100BaseT Parallel Service switches RS-232 0388-77 Fig 1-18 Phaser 850 printer rear panel 1 - 26 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 43: Phaser 860 Printer Rear Panel

    Phaser 860 printer connectors The rear panel of the Phaser 860 printer features the host interface connectors to the printer: Standard parallel (high-density connector), IEEE 1284C. For the Phaser 860 printer, it can also be used to connect a parallel-interface scanner Twisted Pair (10/100BaseT) Ethernet connector.
  • Page 44: Rear Panel Status Leds

    Recovery mode (engineering use DOWN DOWN only) * Recommended DIP switch postion. ** If DIP switch 4 is left in the down position the printer will not turn off. 1 - 28 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 45: Phaser 840, 850 And 860 Printer Differences

    There are additional part differences not detailed in this table. Note Please refer to "FRU Parts List", on page 8-207 for a complete listing of parts and part numbers. Table 1-7 Summary of differences between Phaser 840/850/860 Phaser 840 Part 840 to 850 Difference 850 to 860 Difference...
  • Page 46 Table 1-7 Summary of differences between Phaser 840/850/860 Phaser 840 Part 840 to 850 Difference 850 to 860 Difference Description Left I/O board A new left I/O board. Right I/O board New board to support the new front panel. Y-axis drum...
  • Page 47: Specifications

    Specifications Table 1-8 Physical dimensions Dimensions Value Height: 38.7 cm. (15.25 ins.) 51.4 cm (20.25 ins.) with one High-Capacity Paper Tray Assembly 64.1 cm (25.25 ins.) with two High-Capacity Paper Tray Assemblies Width: 40 cm (17.25 ins.) Depth: 57.8 cm (22.75 ins.) Weight: Approximately 36 kgs (79 lbs.) Print engine weight only;...
  • Page 48 Addressability Phaser 840 printer: Selectable 273 x 300, 409 x 409, 491 x 982 or 600 x 1200 dots-per-inch (horizontal and vertical). Phaser 850 printer: Selectable 177 x 409, 355 x 464, 450 x 818 or 600 x 1200 dots-per-inch (horizontal and vertical).
  • Page 49 Labels : A/A4 laser quality sheet stock only, Recommended Avery® white laser labels: Phaser 840/850/860 use: Tek-branded labels. The Phaser 840 also supports: U.S.: 5160, 5960 and Metric: L7162. The Phaser 840/850/860 also support: Glossy, Photo, Cover stock and Transparencies...
  • Page 50 The printer may have any corner raised and dropped 6 cm (2.4 in.) while idle without subsequent impairment of operation. 1 - 34 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 51: Regulatory Specifications

    Regulatory Specifications The printers are in conformance with the following regulatory standards: FCC Part 15 Class B (for 115 VAC equipment) EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B EN61000-3-2 Flicker on AC Mains Susceptibility The packaged product meets National Safe Transit Committee Test Procedures Listed: UL 1950 Information Technology Equipment Certified to:...
  • Page 52 1 - 36 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 53: Error Codes And Messages

    Error Codes and Messages Phaser 840/850 Rear Panel PS and PE LED Codes The rear panel LEDs are located on each side of the rear panel DIP switches. The left LED represents the operation of the PostScript firmware. The right LED represents operation of the main board’s print engine firmware.
  • Page 54 Script operation returns wrong exit code. DMA transfer spills outside buffer. DMA transfer data mismatch. none IDE hard drive This test verifies that the main board is able to communicate with the IDE drive. 2 - 38 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 55 2L+1S=11 none 10baseT This test verifies the functionality of the Ethernet LAN (Phaser 840 Controller chip. Any test failures with this component are only) treated as non-fatal errors with the error information written to the start page. If a failure is detected, the message “Ethernet:”...
  • Page 56: Phaser 860 Power-Up Error Messages And Led Codes

    Code ROM, if it is socketed and not soldered down, and then replacing the main board. Rapid System hangs during code initialization. Reseat the main board blinking and all of its components. Replace the main board. 2 - 40 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 57: Post (Power On Self Test)

    POST (Power On Self Test) When these tests begin the front panel has been initialized. In most cases, if an error occurs, a text message is displayed on the front panel along with an LED blink code flashing on all three LEDs (front panel LED, PS LED and PE LED). The LED blink codes are setup similarily to the 840 and 850: Short Blink = 1, Long Blink = 5.
  • Page 58 Reseat main board, then replace the printhead. 21.05 Printhead reservoir thermistor is above range. Ensure the thermistor cable is plugged in. Reseat main board, then replace the printhead. 2 - 42 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 59 Table 2-3 POST (Power On Self Test) Error Messages (cont'd.) PS, PE and Front Description Front Panel Panel LEDs Error Code 21.06 Left printhead jetstack thermistor is out of range. Replace the printhead. 21.07 Right printhead jetstack thermistor is out of range. Replace the printhead.
  • Page 60: Fault Codes

    Board, other errors or unusual conditions during the execution of instructions. A CPU exception can either be caused by hardware or firmware error. Refer to infoSMART for descriptions of the most common faults. 2 - 44 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 61: Front Panel & Fault History Log Error Codes And Messages

    Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 2,000: SYSTEM FAULT I/O BOARD... 2,001.40: The engine cannot detect the presence of the right I/O board. SY_DEV_FAULT_IO_ Ensure the connections are sound. RIGHT 2,002.40: The engine cannot detect the presence of the left I/O board.
  • Page 62 C/W/P assembly, poorly locking pin? tension installed ink loader Measure the resistance of the x-axis motor Resistance Replace the x-axis approximately motor 12.5 Ohms? Replace the power control board 0388-82 2 - 46 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 63: Front Panel & Fault History Log Error Codes And Messages

    Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 4,014.44 Calibration Failure: Defined but not used. PC_DEV_FAULT_6x6DPI_ 4,015.45 The engine spent over 20 minutes in the printhead adjust-state. PC_DEV_FAULT_HEAD_A The engine declares a device fault and shuts down, rather than DJUST_TIMEOUT leave a hot heater against a cold drum for an indefinite period.
  • Page 64 Changing the printer defaults may also help, turn off 2-sided printing, turn on the Startup Page, etc. If these work-arounds are unsuccessful, replace the printhead. 2 - 48 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 65 Drum-home sensor failure. The drum has turned a full revolution without seeing the drum-home sensor activate. Check the Y-axis encoder and I/O Left board. Note: The Phaser 840 has a separate drum-home sensor. The Phaser 850 printer’s home sensor is part of the drum-position sensor.
  • Page 66 Verify that COMPOUND_ compound gear sensor is not physically broken and is plugged in GEAR_SENSOR_BAD to the left I/O board. Run diagnostics to verify operation or change the sensor. 2 - 50 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 67 Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 07,004.46: The Drum Maintenance home sensor did not actuate or change PM_FAULT_DM_CAM_ state as expected. Run diagnostics to verify clutch and sensor State_Error operation. Also verify that the shaft is properly assembled. ***see SF165 &...
  • Page 68 Bad message ID in pm_update_dmc_status(). The ITC message PM_PROG_FAULT_ received and passed to pm_update_dmc status() did not match FUNCS(20) any DMC status message that the Process Motor task was expecting. 2 - 52 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 69: Error Code

    Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 8,000: CAP TASK PROGRAM FAULT CODES 08,001.44: The cap-home sensor did not see the sensor’s flag when CAP_FAULT_HOME_ expected. The home sensor may be faulty, or the paper- feed SENSOR motor may not be operating.
  • Page 70 IL_FAULT_Y_JAM An ink stick jam will be reported three times before an ink-melter fault is declared. Replace the ink loader. If the problem persists, replace the power supply. ***see SF157*** 2 - 54 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 71 Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 9,008.43 and The black ink-melt heater is on, but ink does not seem to be 9,101:43 dripping. Check that the ink stick is able to advance in the chute. IL_FAULT_K_JAM An ink stick jam will be reported three times before an ink-melter fault is declared.
  • Page 72 Ensure the printer is not located next to an air-conditioning duct. Check that the printhead-to-drum gap is not too close (the drum can act as a heatsink). Inspect the printer wiring. Replace the printhead. 2 - 56 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 73 Table 2-4 Front Panel & Fault History Log Error Codes and Messages Error code Definition 13,011.66 Bad TCH message in fault state. While in the divice fault state, tc_bomb(this, 11) the reervoir thermal manager received an unexpected message, not a turn off or a regulate command. The device fault state is entered whenever the engine firmware detects a device fault (x,xxx.4x).
  • Page 74 15,004.45: Most likely cause is a failed drum heater. The head to drum gap TCD_THERMISTOR_ should only be checked or adjusted on the Phaser 840. The SLOW Phaser 850 and 860 have a pre-adjusted head. 16,000: PREHEATER THERMALS. Preheater thermal faults are determined by a thermistor in contact with the preheater.
  • Page 75 Refer to the fault history when troubleshooting media jams, this offers the quickest and easiest method of troubleshooting. For the Phaser 840 printer: 1. Pull the paper tray out about 1 inch (2.5 cms.). This activates all three tray sensors.
  • Page 76 Get a different batch of clamping the media in the tray media (usually there will be black marks on the media) 2 - 60 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 77 Table 2-6 22,000 Fault Codes and Actions Error code Additional clues Probable cause Action 2. Leading edge jam (right a. Media is low in tray a. Add more media b. Media has natural curvature b. Flip over media or replace corner fold) c.
  • Page 78 Media is not pushed far a. Feed paper in until the enough into the handfeed printer grabs slot b. Use a ruler to verify exact b. Media is not the expected media dimensions size 2 - 62 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 79 Table 2-6 22,000 Fault Codes and Actions Error code Additional clues Probable cause Action 22,500.00 Command stop event with media in front door area *** See SF144 & SB460*** a. Inspect the maintenance drawer for worn lift pins, replace if needed 1.
  • Page 80 Use long grain media c. Label stock curling c. Empty the exit tray often d. Extreme environment d. Do not leave media out of wrapper for extended periods of time in extreme environments 2 - 64 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 81 Front panel error and replace if needed d. Power supply problem b. Replace the DM Clutch, this is a solution for the Phaser 840 only c. Try again, cycle power, or NVRAM reset d. Replace front panel assembly e. Replace power supply 22,601.02 Unexpected Lower-tray-present-sensor event in Lower Feeder 2 with media in the...
  • Page 82 Replace printer if chassis warped 3. More than one sheet in a. Media was pulled from exit a. Empty exit tray into duplex while printing duplex path 2 - 66 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 83 Table 2-6 22,000 Fault Codes and Actions Error code Additional clues Probable cause Action 4. Excess skew a. Last sheet in tray a. Refill tray(s) b. First sheet in tray b. Make sure tray(s) is c. Failure of deskew system loaded properly and d.
  • Page 84 Remove media, inspect b. Hole or tear in media and reload damaged in media tray b. Remove media, inspect and reload 3. Media perfectly straight a. Unknown (static?) a. Try again 2 - 68 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 85 Table 2-6 22,000 Fault Codes and Actions Error code Additional clues Probable cause Action 22,707.00 Y-axis declared media is too long. Typically caused by a multipick or stuck A4 sensor 1. None a. Verify that the lower tray is properly loaded. b.
  • Page 86 Close door or tray 22,901.05 Unexpected exit cover event 1. Media perfect in media path a. Unknown (static?) a. Run again b. Someone opened a door b. Close door or tray 2 - 70 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 87 Table 2-7 Front Panel & Fault History Log Error Codes and Messages Error code Definition 23,000: NVRAM SYSTEM FAULTS 23,003.65 Head Tweak Read Failed. A read of the head tweak value from SYS_NVRAM_PROG_ non-volatile memory failed. The tweak value is saved twice in FAULT(3) NVRAM.
  • Page 88 Blank Page 2 - 72 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 89: Troubleshooting

    Troubleshooting The troubleshooting section discusses Repair Analysis Procedures (RAPs) for the Phaser 840/850/860 printers. This section is broken into the following groups: Network Event Logs Electrical Interface Problems Media and Paper Path Problems Printing and Print Image Quality Problems Windows Printing problems Macintosh Printing problems Cap/Wipe/Purge Troubleshooting: Evaluating and troubleshooting the printhead cap/wipe/purge system can be found on page 106.
  • Page 90: Macintosh Printing Problems Rap Table

    Table 3-4 Macintosh Printing Problems RAP Table Problem on Page Image Never Prints page 115 Image is rotated 90 degrees page 115 Image prints in black and white page 115 Printer isn’t the Chooser page 116 3 - 74 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 91: Network Event Logs

    Network Event Logs Phaser 850 The Phaser 850 printer maintains three logs in memory detailing network functions. The logs contain TCP/IP and Netware initialization landmarks and limited print-time processes. The log also shows the state of the networking hardware. The logs are useful for troubleshooting network setup problems and isolate network problems from printer problems.
  • Page 92: Electronics Troubleshooting

    If an error is detected, the Phaser 850 printer flashes the front panel Error LED with a repeating error code pattern as well as the rear panel PS LED. On the Phaser 840 printer, the pattern is displayed only on the rear panel PS LED (left side of the DIP switches).
  • Page 93 The front panel indicates the printer is in a clean cycle. If the printer senses ink or debris on the drum, a drum cleaning page is printed (Phaser 840 printer only). The temperature of the printhead, drum and paper preheater are allowed to stabilize at their operating temperatures and ink is melted if needed.
  • Page 94 This test takes about 8 seconds. All LEDs are off during the test. If POST diagnostics pass, the front panel displays the Xerox logo. If an error is detected, the error message is displayed on the LCD and the printer flashes the LEDs with a repeating error code pattern.
  • Page 95 The x-axis motor activates to move printhead off its locking post. The x-axis motor activates for three short bursts to ensure the printhead is in its far-left travel (printhead home position). Then the x-axis motor is reversed to move the printhead to the center the of the x-axis travel.
  • Page 96: Inoperative Printer Problems

    220 VAC setting Remove the power cord, wait 30 seconds, then reinstall the power cord. The printer should power-up at its 110 VAC setting within two seconds, refer to SF156, Phaser 840 only. If the fans “twitch” and the LEDs flash, There may be a short in the power supply system.
  • Page 97: Verifying Print Engine Operation By Printing A Built In Page

    Inspecting the power supply fuses. Testing for a shorted motor or solenoid driver, which shuts down the power supply. See SF 156 ( Phaser 840 only). Measuring power supply voltages AC line voltages are present on the power supply and possibly in...
  • Page 98: Inspecting The Power Supply Fuses

    If the fuses are functional, but the printer's power supply does not output DC voltages, proceed to the topic, "Testing for shorted drivers" on page 3-83. Also refer to SF157. 3 - 82 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 99: Testing For Shorted Drivers

    The 40 volt service load connector is not needed for the Phaser 860 printer, go to step 4. For the Phaser 840/850 attach the service load connector to J250 on the top of the power control board (behind the printhead) to simulate a load on the power supply.
  • Page 100: Testing For A Shorted Motor

    Phaser 850 only Cap/wipe/purge 125 ohms +/- 12% 124 ohms +/- 5% clutch, feed clutch and Phaser 860 pick clutch. Transfix cam solenoid 108 ohms +/- 10% 108 ohms +/- 10% 3 - 84 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 101: Paper Path And Media-Based Problems

    Check that the pick roller is being rotated. Diagnostics can be used to verify. Use diagnostic’s to run “Verify Drive Current Requirement Test” ( Phaser 840/850) or “Paper Path Drive” test (Phaser 860), to check the operation of the paper-pick system.
  • Page 102: Print Transfer Jams

    Inspect the gear train on the left side of the printer frame; look for stripped gears, loose or damaged belts, unseated bushings, or broken teeth. Be sure to inspect the inner teeth on the process-motor gear. 3 - 86 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 103: Media Skews Passing Through The Paper Path

    Media skews passing through the paper path Check to see if the media is excessively curled. Curled media can get mistracked in the paper path. Examine the paper path; ensure it is clear of obstructions. Ensure that the pick roller is not visibly dirty so that it picks up a sheet of media smoothly and evenly.
  • Page 104: Print Image Quality Problems

    Replace the Power Contol Board. Refer to the topic “ "Evaluating the printhead and cap/wipe/purge system" on page 3-106. A properly functioning printhead maintenance system is essential for proper printhead operation. Replace the Printhead. 3 - 88 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 105: Missing Ink Or Light Colored Ink Band Running Length Of Print

    Missing ink or light colored ink band running length of print Possible missing or weak jet. 0388-42 Table 3-7 Missing or light colored ink band Step Question and Actions Inspect the exit area for anything that may be touching the drum. Print the Service Test Print 2: Weak or Missing Jet, to determine which jet is not performing.
  • Page 106: Color Is Uneven

    Refer to the topic "Evaluating the printhead and cap/wipe/purge system" on page 3-106. A properly functioning printhead maintenance system is essential for proper printhead operation. Perform the procedure, "Printhead-to-drum spacing adjustment (Phaser 840 Printer Only)" on page 4-146 and "Transfix roller pressure spring adjustment" on page 4-154.
  • Page 107: Streaks Or Lines Down The Print

    Streaks or lines down the print There are several possible causes of streaks running down the length of a print. 0388-41 Table 3-9 Streaks or lines down the print Step Question and Actions Clean the wiper blade of the drum maintenance drawer. Inspect the operation of the drum maintenance kit.
  • Page 108: Scratches Parallel To The Long Axis Of Printing, Particularly With Film

    Be careful of the paper-sensor flags. Clean the stripper fingers or the rapid release guide. 3 - 92 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 109: Printing Too Light Or Too Dark

    Printing on paper in transparency mode significantly darkens a print. Try a different color correction setting. Perform the procedure, "Printhead-to-drum spacing adjustment (Phaser 840 Printer Only)" on page 4-146. Verify that the printhead setting “Head Adjust,” in the hidden service menu is set to 128.
  • Page 110: White Portion Of Print Is Colored

    Run 2 or 3 sheets of blank paper through the printer to clean the rollers or manually clean the rollers. Replace the Power Control Board Replace the Main Board Replacd the Printhead 3 - 94 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 111: Fuzzy Text

    Step Question and Actions Head-to-drum gap is too great. Verify the gap with the adjustment as explained in the topic "Printhead-to-drum spacing adjustment (Phaser 840 Printer Only)" on page 4-146. Verify the drum temperature using diagnostics. Ensure the drum temperature sensor is clean and properly positioned.
  • Page 112: Poor Primary Color Fills

    Head-to-drum gap is too small. Verify the gap with the adjustment explained in the topic "Printhead-to-drum spacing adjustment (Phaser 840 Printer Only)" on page 4-146. Verify the operation of the Y-axis encoder using diagnostics. Replace the encoder if needed.
  • Page 113: Ghosting

    Ghosting Drum is too warm. 0388-71 Table 3-15 Ghosting Step Question and Actions Occasionally, if the prints have been sitting atop one another, the pressure of the stack and the heat of the printer can cause blocking. This has the appearance of ghosting.
  • Page 114: Poor Small Text Resolution

    Refer to the topic "Evaluating the printhead and cap/wipe/purge system" on page 3-106. A properly functioning printhead maintenance system is essential for proper printhead operation. If the problem persists, replace the printhead. 3 - 98 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 115: Vertical Line Appear Wavy

    Vertical line appear wavy Straight vertical lines appear to be wavy and ill-formed. 0388-50 Table 3-17 Vertical line appears wavy Step Question and Actions Too much oil on the drum. Inspect the drum maintenance drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer. Are the drum maintenance cam roller and electric clutch operating correctly? Test them using diagnostics.
  • Page 116: Oil Streaks On Print

    Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller. Replace Maintenance Drawer 3 - 100 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 117: Incomplete Image Transfer To Paper

    Incomplete image transfer to paper All of the image does not transfer to the paper. Part of the image remains on the drum to be picked up by a chase page or the next print, usually caused by insufficient or non-uniform drum oiling. 0388-72 Table 3-19 Incomplete image transfer to paper Step...
  • Page 118: Ink Smears On First Side Of Duplex Print

    See SB439. 0388-73 Table 3-20 Ink smears on first side of duplex printt Step Question and Actions Verify the paper preheater temperature using diagnostics. Replace the paper preheater, if necessary. 3 - 102 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 119: Repeating Print Defects On Print

    Repeating print defects on print The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect. 0388-54 Table 3-21 Repeating print defects on the print Step Question and Actions Repeating defect 13.6 cm (5.34 in.) are caused by the transfix roller. Clean the transfix roller.
  • Page 120: Wrinkling

    Inspect the maintenance drawer wiper blade. Replace the maintenance drawer if necessary. The transfix spring pressure is incorrect. Perform the procedure "Transfix roller pressure spring adjustment" on page 4-154. Replace the drum/transfix assembly. 3 - 104 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 121: Image Is Offset Or Cut Off

    Image is offset or cut off Check the application for the correct image sizing and orientation. Ensure that Letter or A4 is the selected paper-size. Oil streaks on top of print Clean the stripper fingers or the rapid release guide. Run chase pages through the printer to clean the drum.
  • Page 122: Evaluating The Printhead And Cap/Wipe/Purge System

    (but not present on the test page), the problem is not with the cap/wipe/purge assembly or printhead. Check for something binding the x-axis (such as a cable rubbing the printhead). 3 - 106 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 123: Faceplate Showing Blade Wipe With No Drops, Smudges Or Streaks

    Closely examine the printhead's faceplate 3. Visually check printhead faceplate. to help evaluate whether the cap/wipe/purge assembly’s wiper blade and gasket are damaged. Fig 3-2 Faceplate showing blade wipe with no drops, smudges or streaks If you see spattered ink on the edges of the printhead, the cap/wipe/purge assembly’s gasket may be leaking during the purge cycle.
  • Page 124: Connecting The Vacuum Gauge To The Printer

    With a flashlight, closely examine the cap/wipe/purge assembly. Inspect the gasket for defects and signs of separation. Tilt the printhead all the way back and raise the cap/wipe/purge assembly to its purge position. Inspect the rubber wiper, especially at the ends, for signs of separation.
  • Page 125 Phaser 860 Only - Step 5 is as follows, for the 840/850 go to step 6. Check the purge performance. BEFORE running the diagnostic test, empty the Waste Bin. Enter diagnostic mode and select the “Cap Vacuum” test from the check menu. Results should be: R0 - (normally 20 - 200) R1 - (normally 40 - 1600)
  • Page 126 Alternately, the cap/wipe/purge assembly gasket is bad. With a flashlight, closely examine the cap/wipe/purge assembly. Inspect the gasket for defects and signs of separation. 3 - 110 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 127: Maintenance Tray Showing Good Purge

    Ensure that the cap/wipe/purge heater is operational. Verify that the heater resistance is about 350 ohms (+/- 50). Inspect inside the cap for ink build up; a lot of built up ink inside the cap indicates that the heater is not melting it out. The ink built up interferes with the wiper compressing, and can prevent the cap/wipe/purge assembly from sealing on the printhead.
  • Page 128: Troubleshooting Following Cap/Wipe/Purge Installation

    Check cap/wipe/purge assembly purge performance. After installing a new printhead, you must recheck the cap/wipe/purge assembly system vacuum and decay as described earlier. If the printhead is not installed correctly, the cap/wipe/purge assembly gasket may leak. 3 - 112 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 129: Damaged Printhead Data Cable

    Check for Service Required ... errors. After installing the printhead, you may get one of the following service errors due to mis-adjustment or cabling problems: 4,002.41 and 4,006.45 errors: printhead NVRAM all zeroes. If the data cable between the power control board and the printhead is not plugged in properly or damaged, this error will occur.
  • Page 130 Breakage or separation can interfere with head tilt, resulting in a poor seal with the cap/wipe/purge assembly during the purge process. Replace the ink loader if broken or defective. 3 - 114 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 131: Macintosh Printing Problems

    Landscape orientation, as you expect. Image prints in black-and-white In the Chooser, ensure a color printer icon is displayed next to the Phaser 840 or Phaser 850 in the list of available printers. This indicates the printer’s PPD has been selected and configured.
  • Page 132: Printer Isn't In The Chooser

    Locate and remove and Windows NT shared printers that have captured the AppleTalk queue for the printer. Verify the driver version for the built-in Ethernet port on a Macintosh G3. Reset the printer’s NVRAM settings. Disable QuickDraw GX. 3 - 116 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 133: Windows Printing Problems

    Windows printing problems Image never prints The printer’s front panel Receiving data message is displayed as if receiving data but nothing comes out of printer or the printer goes back to Ready to Print mode without printing an image. From the printer driver, under the printer's set up options, set TRANSMISSION RETRY = 850.
  • Page 134: Phaser 840/850/860/8200 Color Printer - Service Manual

    3 - 118 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 135: Diagnostics, Adjustments And Nvram

    Switches 1, 3 and 4 are up. (Normal operation is all switches up.) 2. Turn on the printer. The printer will not print a Cleaning Page (Phaser 840 printer) nor a Startup Page when placed in Bypass Mode. Restricted Menu When the front panel is locked, the 1.
  • Page 136 Hold the Left Arrow key and power printhead is off the printer. If the head locked for successfully locks, the red and shipping green front panel LEDs will blink back and forth. 4 - 120 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 137: Hidden Service Menu

    Hidden Service Menu Table 4-2 Hidden Service Menu (Phaser 840) (Phaser 850) (Phaser 860) Previous Menu Previous Menu Test Prints Test Prints Test Prints Print Startup Page Fault History Energy Star Mode (On/Off) Eliminate Light Stripes Reset NVRAM Energy Star Timeout...
  • Page 138: Built-In Diagnostics (Phaser 860 Only)

    ID: xx - The ID number from the test, refer to the Check Menu test results for the ID’s associated with the tests. TS: x - The Termination Satus, the status the test was in when it ended (in case the test failed or was interupted before completion). 4 - 122 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 139: Diagnostic Menu Map

    0 = Initializing 1 = OK 2 = Interupted by front panel button press 3 = Abort (encountered a status condition which prevented it from continuing) 4 = Failed (test completed but did not produce the expected results) 5 = Fault (the print engine declared a fault during the test) 6 = Pass PC: xx - The current page count.
  • Page 140 DM Axis Performance Measures the motion of the drum maintenance system. Cap Vacuum Measures the vacuum generated by the printhead maintenance system. Cap Axis Geometry Mesures the alignment of the cap/wipe/purge assembly. 4 - 124 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 141 Table 4-3 Diagnostic Menu Map Cap Axis Drive Measures the minimum drive current needed for cap/wipe/purge motion. Y Axis Encoder Measures the fastest rate at which the encoder home pulse can be detected. Y Axis Geometry Measures the frequency and magnitude of Y axis velocity variations.
  • Page 142: Check Menu Value Keys And Descriptions (Phaser 860 Only)

    Ensure that the printer is not out of paper, ink or maintenance kit life. The diagnostics routines are not designed to address all of these conditions consistently. 4 - 126 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 143: Check Menu Value Key

    Table 4-4 Check Menu Value Key Paper Path Status (Test ID #3) - This test looks at the paper path sensor to identify if anything would prevent a prage from printing. The front panel will display messages indicating if anything unexpected is found.
  • Page 144 The pick roller may be Tray 1 pick clutch > 800 contaminated with paper debris to tray 1 pick flag and coatings from specialty media, try cleaning the roller and pick pad. 4 - 128 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 145 Table 4-4 Check Menu Value Key Test ID# Definition Results Interpretation/Actions Paper is not feeding smoothly through the paper path or is Tray 1 pick flag to > 1000 skewed. If the paper came from a preheat entry flag lower tray, ensure the tray is loaded properly to eliminate skew.
  • Page 146 14 = Duplex Width A4 sensor ID 6 = Preheat Entry 15 = Duplex Preheat Exit 7 = Width A4 16 = Duplex Stripper Exit 8 = Preheat Exit 17 = Duplex Exit 4 - 130 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 147 Table 4-4 Check Menu Value Key DM Axis Performance (Test ID# 6) - This test exercises multiple aspects of the drum maintenance system. Test ID# Definition Results Interpretation/Actions The test could not establish control of the drum maintenance cam shaft. Verify that the shaft Controllability flag bushings are properly installed and the shaft is not obstructed.
  • Page 148 Cap axis > 0 Cap Axis Drive hysteresis < -0.1 ID# 9 > 0.120 Plus position loss < -0.120 Minus position > 0.120 loss < -0.120 4 - 132 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 149 Table 4-4 Check Menu Value Key Y-Axis Encoder (Test ID# 10) - This test finds the encoder home positon at faster rates with each cycle to find the maximum rate at which the home location can be seen. Test ID# Definition Results Interpretation/Actions...
  • Page 150 Do not use for troubleshooting. Ensure the printer was fully warmed up and the temperatures Preheat 60 + 2 are stable before taking the measurement. Drum 60 + 2 4 - 134 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 151: Check Value Menu Parameters

    Check Value Menu Parameters Pressing OK will initiate the current test using the How to change parameters: indicated parameter values. Pressing the Down and Up buttons may be used to review and/or modify the parameter values. The ‘current’ parameter, if any, is indicated by a > symbol. If there is no > symbol present, pressing OK will initiate the current test using the indicated parameter values.
  • Page 152: Adjustments

    Turn on the printer. When the display reads “Ready to Print”, Scroll to Menu and press OK. Scroll to Printer Setup Menu, press OK. Scroll to Print Configuration Pages and press OK. 4 - 136 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 153: Selecting Duplex (2-Sided) Oil Chase

    Access the Hidden Service Menu. Scroll to the menu item (Phaser 840) Duplex Oil Chase, (Phaser 850/860) 2-sided Printing Oil Chase. Press Select (Phaser 840/850) or OK (Phaser 860) to turn the menu item on. Exit the Hidden Service Menu. Selecting Envelope Oil Chase...
  • Page 154: Locking The Printhead

    Rotate the x-axis gear in the opposite direction (about 1 rotation). This prevents the x-axis drive from binding so tightly that the motor cannot free it upon power-up. Reverse these steps to unlock the printhead. 4 - 138 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 155: Process Belt Tension Adjustment

    Process belt tension adjustment Required tool: Spring Scale Turn off the printer and remove the left-side cabinet panel. To adjust the belt tension, loosen the process belt tensioner. With a spring scale, press inward on the tension idler of the process belt with a pressure of 0.7 kgs (1.5 lbs.) and then tighten the tensioner in place.
  • Page 156: Exit Roller Drive Belt Tension Adjustment

    Exit roller drive belt tension adjustment Turn off the printer and remove the left-side cabinet panel. To adjust the belt tension, loosen the exit roller drive belt tensioner. With a spring scale, press downward on the idler tensioner of the exit roller drive belt with a pressure of 0.5 kg (1 lb.) then tighten the tensioner in place.
  • Page 157 Press here to set belt deflection Exit roller drive belt tensioner 0388-29 Fig 4-2 Setting exit roller drive belt tension Diagnostics and Adjustments 4 - 141...
  • Page 158: Y-Axis Belt Tension Adjustment (Phaser 840 Printer)

    Y-axis belt tension adjustment (Phaser 840 printer) Perform this procedure after replacing, loosening or removing the Y-axis belt drive assembly. Follow the complete tensioning procedure. Pay special attention to the following: Never loosen or remove the screws holding the assembly together. The assembly is put together in a precision fixture and loosening these screws affects the alignment of the assembly.
  • Page 159 Tighten 3 mounting screws after setting tension Mark the pulleys Never loosen these 3 screws Attach tension tool to keyholes Y-axis belt assembly Pull lever arm to set tension 0388-30 Fig 4-3 Pull the lever arm and press the tool firmly against the printer frame to set tension.
  • Page 160: Y-Axis Belts Tension Adjustment (Phaser 850/860 Printer)

    Use a distinct color if the pulleys have been previously marked. Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re-tighten the screws to 30 in.-lbs. Reassemble the printer and make a test print. 4 - 144 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 161 Tighten screws (3) after setting tension Mark the pulleys Y-axis belt assembly 0388-78 Fig 4-4 Setting the Y-axis belt tension Phaser 850/860 Diagnostics and Adjustments 4 - 145...
  • Page 162: Printhead-To-Drum Spacing Adjustment (Phaser 840 Printer Only)

    If properly installed they will not snap off. Attach a gap clip to each end of the printhead. Clips should touch hard stop Hook under both metal edges Partially Fully installed installed 0388-85 Fig 4-5 Attaching clips. 4 - 146 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 163 Install the adjustment tension spring by hooking one end through the backside of the tilt arm, stretching the spring and hooking the other through the hole in the printer frame bracket. Due to the spring force, stand in front of the printer to hold it in Note place while you pull the spring toward you to install it.
  • Page 164 Print service test print 11: Head to Drum Check to check alignment. This print indicates if the gap between the printhead and the drum is correct. Refer to "Test Prints", on page 5-159". Refer to Service Bulletin 447 for additional information. Note 4 - 148 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 165: X-Axis Scale Adjustment

    To correct thin, parallel pin stripes running the length of the page, appearing evenly-spaced across the width of the page (not due to a weak or missing jet). Anytime the NVRAM chip (Phaser 840 printer) or BootROM/Printer ID chip (Phaser 850/860 printer) is replaced Anytime an X-axis component is replaced.
  • Page 166: Cap/Wipe/Purge Assembly Belt Adjustments

    Repeat until the right-side timing lock’s pointer points at the index mark on the right-side frame as the left-side timing belt lock’s pointer points between its index marks on the left-side frame. 4 - 150 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 167 Belt lock Index mark on right frame Unlock Latch For new belt, break off actuator on left-side belt lock Left belt lock: align pointer between two index marks Idler pulley Lock Right Leave gap cap/wipe/purge between latch assembly belt and belt tensioner 0388-32 Fig 4-9 Aligning (timing) the cap/wipe/purge assembly drive belts...
  • Page 168: Drum Position Encoder Gap

    Phaser 840 printer only: Ensure that the retaining spring is not in the drum-position sensor assembly’s encoder wheel groove. This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft.
  • Page 169 Gap tool Groove (Phaser 840) Retaining spring (Phaser 840) Drum position sensor assembly 0388-33 Fig 4-10 Setting the drum position encoder gap Diagnostics and Adjustments 4 - 153...
  • Page 170: Transfix Roller Pressure Spring Adjustment

    If wrinkling continues to occur, replace the drum/transfix assembly. Original registration mark 3/8 turn 3/8 turn maximum maximum Tension spring set screws 0388-38 Fig 4-11 Adjusting the transfix roller pressure springs 4 - 154 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 171: Vacuum Check (Phaser 840/850 Only)

    Vacuum check (Phaser 840/850 Only) Tools required: Magnetic screwdriver Vacuum gauge T-20 TORX tip T-15 TORX tip PC diagnostics Use this check to verify the actions of the vacuum pump and the solenoid valve. In addition, you can determine if the cap/wipe/purge assembly is sealing properly against the printhead faceplate.
  • Page 172: Resetting Nvram

    Adobe firmware serial number, the usage profile and the authorization codes. Print engine NVRAM values are not changed by the following procedure. See SB419 for the Phaser 840. Resetting NVRAM returns all the image processor's NVRAM-stored parameters, except the print counts, the Adobe firmware serial number, and the network address, to their factory defaults.
  • Page 173 Phaser 840/850 - Running Reset PE NVRAM to Default or Clear PS NVRAM downloads a file to the printer that performs the indicated reset function; there is no confirmation or cancel function. Fig 4-13 Resetting print engine NVRAM menu item...
  • Page 174 4 - 158 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 175: Test Prints

    Access the Hidden Service Menu, for help accessing the Hidden Menu go to "Front Panel Shortcuts", on page 4-119. Scroll to Test Prints and press Select (Phaser 840/850) or OK (Phaser 860). Table 5-1 Test Print Menu 1: X Axis Motion...
  • Page 176: 1: X-Axis Motion

    In the second print, the jagged black bars in the four purple columns should align horizontally. if they do not, adjust the x-axis scale using the procedure, "X-axis scale adjustment", on page 4-149. 0388-40 5 - 160 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 177: 2: Weak/Missing Jet

    2: Weak/missing jet 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 This print shows which jets are not outputting enough, if any, ink compared to its neighboring jets.
  • Page 178: 4: Reverse Text

    Causes: The ink drops from the jets are traveling in incorrect trajectories. The printhead is incorrectly mounted or its printhead-to-drum spacing (Phaser 840 only) is incorrect. 9923-117 5 - 162 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 179: 6: 66% Gray, Dot Size Uniformity

    Also check the printhead-to-drum gap (Phaser 840 only). Ensure the drum fan is running properly. A vertical band, 1/5 of a page 9923-88 wide, running the length of the page, is caused by a stuck heating plate in the paper preheater.
  • Page 180: 7: Manuf. Dot Position (Scanner)

    The transfix pressure may be incorrect. Perform the transfix spring adjustment described in "Transfix roller pressure spring adjustment", on page 4-154. As a last resort, replace the drum/transfix assembly. 9923-119 5 - 164 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 181: 9: Drum Seal

    9: Drum Seal These five prints are used to treat a newly installed drum. To seal a newly installed drum: 1. Power up the printer in Bypass Mode to skip any pages at power up (refer to "Front Panel Shortcuts", on page 4-119). 2.
  • Page 182: 11: Head-To-Drum Gap

    (Phaser 840 Printer Only)", on page 4-146. The Phaser 850/860 printer. should never require this adjustment 12.: Manuf x-axis (scanner) This print is used for manufacturing and engineering evaluation of printhead performance. 5 - 166 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 183: 13: Black Solid Fill

    13: Black Solid Fill This prints shows uniformity of fill. Look for: Even, uniform fills throughout the print. There should be no wrinkling or deformity of the paper throughout the print. Causes: Weak jets or uneven drum heating may cause uneven fills. To solve wrinkling, try different print media.
  • Page 184: 15: Green Solid Fill

    Reverse Text. The transfix pressure may be incorrect. Perform the transfix spring adjustment described in "Transfix roller pressure spring adjustment", on page 4-154. As a last resort, replace the drum/transfix assembly. 5 - 168 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 185: 17: Cyan Solid Fill

    17: Cyan Solid Fill This prints shows uniformity of fill. Look for: Even, uniform fills throughout the print. There should be no wrinkling or deformity of the paper throughout the print. Causes: Weak jets or uneven drum heating may cause uneven fills. To solve wrinkling, try different print media.
  • Page 186: 19: Yellow Solid Fill

    20: OHP Color Bands This print consists of sequential bands of primary and secondary colors followed by a blue tint. This print is used for manufacturing and engineering evaluation of printhead performance. 0388-37 5 - 170 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 187: 21: Primary Solid Fills 10X

    21: Primary Solid Fills Phaser 850/860 printer only. This item prints 10 cyan solid fill prints, then 10 magenta solid fill prints, then 10 yellow solid fill prints, and then 10 black solid fill prints. 22: Manuf. Skew Margins Phaser 850/860 printer only. This print consists of an image used by manufacturing to gauge skew on 2-sided prints.
  • Page 189: Cleaning And Maintenance

    Cleaning and Maintenance The printer requires periodic cleaning to keep it in peak operating condition. Some cleaning procedures, such as purging the ink-jets are done automatically when necessary. Other procedures, such as scrubbing the paper-feed rollers with an alcohol-soaked cloth, must be done by customers, but only if the rollers are visibly dirty.
  • Page 190: Cleaning

    Clean the preheat, duplex and exit rollers. Use the blue thumbwheel on the duplex roller to manually rotate the rollers. Double picks Clean pick pad with clear packaging tape using the procedure "Pick Roller Cleaning Method", on page 6-175. 6 - 174 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 191: Pick Roller Cleaning Method

    Reinsert the paper tray and maintenance drawer. Cleaning Page (Phaser 840 printer only) Under certain conditions, the printer purges its ink-jet nozzles to clear any jets plugged with ink. When the purge is completed, the printer outputs a cleaning page to clear the purge pattern from the print drum.
  • Page 192: Maintenance

    Refer to the instructions included with the kit to replace the maintenance roller kit. Phaser 840 and Phaser 850 maintenance cartridges are interchangeable. The drum fluid, an oil, poses no known adverse health effects.
  • Page 193: Lubrication

    Lubrication Tools and supplies required: Light oil Grease 006-7997-00 In general, all of the printer's bearings and motors are lifetime factory-lubricated. However, over time and under certain extreme operating conditions, oil and grease may dry out, causing squeaks and rumbling noises in the printer. Look for fine metal particles, a clear sign of an old or worn bearing.
  • Page 194: Inspection

    Also the cap/wipe/purge system could fail. In such cases, replace the clutch. Intermittent jams are often caused by failing clutches. 6 - 178 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 195: Key Fru Removal And Replacement

    Key FRU Removal and Replacement This topic illustrates how to remove and replace key printer Field Replaceable Units (FRUs). For more detailed removal/replacement procedures, refer to the Color Printer Service & Support Resources CD-ROM. Procedures included here are: Main board and its components 7 - 180 Power supply 7 - 183...
  • Page 196: Main Board And Its Components

    Also swap the SCSI riser board, code ROM DIMM and the SDRAM DIMMs. Realtime clock/NVRAM DIMMS Code ROM DIMM SCSI riser board Printer Main board Press here when installing 840-4-36 Fig 7-1 Removing the Phaser 840 printer main board 7 - 180 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 197: Removing The Phaser 850 Printer Main Board

    Phaser 850 printer: Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove the interface cables. Loosen the two rear panel securing screws. Slide out the main board. If you are replacing the main board, transfer the printer ID chip to the new board so that the printer’s settings and Ethernet address are retained.
  • Page 198 DIMM and the RAM SODIMM(s) and the upgrade Code ROM DIMM and internal IDE hard drive, if applicable. Factory Code ROM SODIMM EEPROM Printer ID Upgrade Code ROM P860-006 P860-007 Fig 7-3 Removing the Main Board (Phaser 860) 7 - 182 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 199: Power Supply

    Power supply Even when the printer is off, AC line voltages may be present at Warning the printer heaters while the printer is plugged into AC power. Turn off the printer and remove the power cord. Remove the right cover. Remove the left cover.
  • Page 200: Power Control Board

    Remove the four screws securing the power control board cover plate. Remove the plate. Remove the four screws securing the power control board in place. Lift and remove the board. Cover plate Power control board Fig 7-5 Removing the power control board 7 - 184 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 201: Upper Feed Roller Assembly

    Upper feed roller assembly Remove the right cover. Remove the left cover. Disconnect the head tilt spring. Left side: Remove the upper feed roller electric clutch from the end of the upper feed roller shaft. Remove the feed-roller drive belt and compound gear from the left end of the upper feed roller.
  • Page 202 Right maintenance Key pin drawer guide on right frame aligns Remove upper feedroller screw from assembly right side 840-4-14 Fig 7-7 Removing the upper feed roller assembly (front) 7 - 186 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 203: Paper/Drum Heater

    Paper/drum heater Disconnect the power cord. AC voltages may be present at the Warning heaters, even with the printer turned off. Turn off the printer and remove the power cord. Remove the right cover. Remove the left cover. Remove the upper feed roller as described in the topic "Upper feed roller assembly", on page 7-185.
  • Page 204: Drum/Transfix Assembly

    Remove the duplex roller. Remove the tilt-arm spring. For Phaser 840 printers, refer to Service Bulletin 409 regarding Note firmware version 8.24, and preventing stripper finger jams.
  • Page 205: Removing The Drum Transfix Assembly (Left Side)

    Exit roller drive-belt tensioner Wiring harness Tilt- spring Exit roller drive belt screw Compound gear Remove drum/transfix assembly screws C-clip 840-4-19 Fig 7-9 Removing the drum transfix assembly (left side) Removal and Replacement Procedures 7 - 189...
  • Page 206: Removing The Drum/Transfix Assembly (Right Side)

    Left frame harnesses bridge Transfix Right frame solenoid bridge bracket Drum transfix assembly Remove 2 inside screws Remove 4 Remove screws screw 840-4-20 Fig 7-10 Removing the drum/transfix assembly (right side) 7 - 190 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 207 6-177. Set the Y-belt tension; refer to the topic "Y-axis belt tension adjustment (Phaser 840 printer)", on page 4-142 or "Y-axis belts tension adjustment (Phaser 850/860 printer)", on page 4-144. Power up the printer in Bypass Mode to skip the startup and mud pages.
  • Page 208: Drum Position Sensor Assembly (Phaser 840 Printer)

    Rotate the tilt gear to orient the gear’s missing teeth to the drum position sensor assembly’s rear mounting screw. With a small, flatblade screwdriver, slide the retaining spring out of the encoder wheel’s groove toward the encoder disk. 7 - 192 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 209: Removing The Drum Position Sensor Assembly (Phaser 840 Printer)

    840-4-18 Fig 7-12 Removing the drum position sensor assembly (Phaser 840 printer) Reverse these steps to reinstall the drum position sensor assembly. The drum must be in the same position relative to the drum position encoder wheel when the drum position sensor assembly was removed.
  • Page 210: Drum Position Sensor Assembly (Phaser 850/860)

    840-4-77 Fig 7-13 Marking the shaft for drum home alignment Rotate the tilt gear to orient the gear’s missing teeth to the drum position sensor assembly’s rear mounting screw. 7 - 194 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 211 Remove the three screws securing the drum position sensor assembly housing to the print engine. Insert the gap tool to hold the encoder wheel in position. Slide the assembly off the drum shaft. If necessary, use the small flat-blade screwdriver to push the encoder disk hub along the shaft as you remove the assembly.
  • Page 212: Printhead

    Carefully plug the printhead’s reservoir chamber holes with the silicone plugs. The plugs keep liquid ink from spilling if you should inadvertently tip the printhead. Silicone Disconnect reservoir plugs Fig 7-15 Plugging the reservoir holes 7 - 196 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 213 If you use the removal tool, rotate the removal tool’s plastic leg into its up position. Slide the removal tool’s standoff locks inward. Place a sheet of transparency film or 10 sheets of paper between the printhead and the drum to protect the drum surface. If you use the printhead removal tool, carefully, lower it onto the printhead.
  • Page 214 Be careful not to spill ink out of the hot printhead. Caution For the Phaser 840 only, refer to "Printhead-to-drum spacing adjustment (Phaser 840 Printer Only)", on page 4-146. Plug the printhead’s data ribbon cable and power wiring harness into the power control board.
  • Page 215: X-Axis Motor And Drive Assembly

    X-axis motor X-axis drive yoke (remove bottom first) Phaser 840 only 840-4-22 Fig 7-17 Removing the x-axis motor and drive assembly For reassembly, apply a small amount of grease on the tip of the nose cone. Apply a small amount, 3 dabs, on the threads of the X-axis shaft.
  • Page 216: Y-Axis Belt Drive Assembly (Phaser 840 Printer)

    Remove the three tension set screws securing the Y-axis belt drive assembly to the engine frame. Remove the assembly with its two belts Reverse these steps to reinstall the Y-axis drive assembly. Tension the belts using the "Y-axis belt tension adjustment (Phaser 840 printer)", on page 4-142. Y-axis belt...
  • Page 217: Y-Axis Belt Drive Assembly (Phaser 850/860 Printer)

    Y-axis belt drive assembly (Phaser 850/860 printer) Remove the right cover. Disconnect the wiring harness leading from the front panel to the right I/O board passing beside the Y-axis belt drive assembly. Remove the drum fan. (Note the fan orientation, it blows into the drum.) Never loosen or remove the three screws securing the assembly Caution parts together.
  • Page 218: Wiring Diagrams

    Reverse these steps to reinstall the cap/wipe/purge assembly. Refer to "Wiring Diagrams", on page 9-235 for details on dressing the cap/wipe/purge wiring. 7 - 202 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 219 Cap wipe/purge Vacuum assembly inlet Short pin screw Long pin screw Short pin screw 840-4-43 Fig 7-20 Removing the cap/wipe/purge assembly (Phaser 840 printer) Removal and Replacement Procedures 7 - 203...
  • Page 220: Cap/Wipe/Purge Assembly (Phaser 850/860 Printer)

    Clip the tie wraps securing the cap/wipe/purge wiring harness. Disconnect the green ground wire from the printer frame. From within the maintenance drawer cavity, remove the lower white retainer clip at the lower-right end of the cap/wipe/purge assembly. 7 - 204 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 221: Removing The Lower Cap/Wipe/Purge Retainer Clip

    Plastic retainer Cap/wipe/purge clip assembly 840-4-81 Fig 7-22 Removing the lower cap/wipe/purge retainer clip Rotate the cap wipe drive gear to position the cap/wipe/purge assembly at the top of its travel. Place a few sheets of paper between the drum and the cap/wipe/purge assembly to prevent scratching the drum.
  • Page 222 9-235 for details on dressing the cap/wipe/purge wiring. Vacuum Cap wipe/purge inlet assembly Vacuum tube Plastic retainer clip Guide Guide 840-4-82 Fig 7-23 Removing the cap/wipe/purge assembly (Phaser 850/860 printer) 7 - 206 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 223: Fru Parts List

    FRU Parts List This topic provides a list of field-replaceable units for the Phaser 840 / 850 / 860 and the Phaser 8200 Color Printers. Changes to Tektronix and Xerox products are made to accommodate improved components as they become available. It is important when...
  • Page 224: Cabinet Fru's

    Cabinet FRU’s 0388-21 Fig 8-1 Cabinet FRUs 8 - 208 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 225: Cabinet Frus

    200-4412-00 Right cover, 8408/50 200-4591-00 Right cover, 840GP “Designer Edition” 200-4645-00 Right cover, 860/8200 200-4370-00 Front cover, jam access, Phaser 840 200-4598-00 Front cover, jam access door, 840GP “Designer Edition” 200-4607-00 Front cover, jam access, Phaser 850 200-4638-00 Front cover, jam access, Phaser 860/8200...
  • Page 226: Imaging Fru's

    650-4027-00 Y-axis pulley assembly, Phaser 840 650-4227-00 Y-axis pulley assembly, Phaser 850/860/8200 214-4651-01 Drum maintenance actuators, left and right Phaser 840 367-0515-00 Drum maintenance actuators, left and right Phaser 850/860/8200 8 - 210 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 227 Vacuum hose, rigid. see #12 650-3615-00 Head maintenance drive belt. Part of 650-3615-00 Belt Kit 650-3619-00 Pulley, head maintenance drive. Part of 650-3619-00 Gear Kit, Phaser 840/850 650-4221-00 Part of 650-4221-00 Gear Kit, Phaser 860/8200 650-3615-00 Head maintenance timing belt and ratchet clips.
  • Page 228: Paper Path Fru's

    Paper Path FRU’s 0388-80 Fig 8-3 Paper path FRUs 8 - 212 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 229: Paper Path Frus

    Phaser 860/8200 351-1047-00 Upper feed assy, top half, with circuit bd, Phaser 840 351-1048-00 Upper feed assy, lower half, Phaser 840 351-1079-00 Upper feed assy, lower half, Phaser 850/860 Upper feed assy, top half, with circuit bd, 351-1106-00 Phaser 850/860/8200...
  • Page 230: Motor And Fan Frus

    Motor and Fan FRUs 0388-14 Fig 8-4 Motor and fan FRUs 8 - 214 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 231: Motor And Fan Frus

    147-0180-02 Paper path motor 147-0082-00 Y-axis motor, Phaser 840 147-0113-01 Y-axis motor, Phaser 850/860/8200 147-0108-01 Process motor, with encoder, Phaser 840 147-0112-02 Process motor, with encoder, Phaser 850 147-0114-00 Process motor, with encoder, Phaser 860/8200 119-5781-00 Main fan FRU Parts List...
  • Page 232: Circuit Board Frus

    Blank cover plate (no hard drive) 671-3994-51 100Base T Ethernet card, Phaser 840 671-4034-00 LocalTalk network card, Phaser 840 671-3932-51 Token Ring network card Phaser 840/850 386-6998-00 Blank cover plate, no network card 8 - 216 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 233 Board pull-out handle, Phaser 860 650-3886-01 Dallas Real Time Clock/NVRAM Module, Phaser 840 650-4024-01 Power supply 671-4053-50 SCSI riser board assembly, Phaser 840 386-7074-00 Blank cover plate (no SCSI riser board), Phaser 840 163-1217-00 Boot ROM/Printer ID, Phaser 840/850/860B/8200B 163-1471-00...
  • Page 234: Solenoid And Clutch Frus

    Solenoid and Clutch FRUs 0388-23 Fig 8-6 Solenoid and Clutch FRUs 8 - 218 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 235: Solenoid And Clutch Frus

    Electric clutch, upper feed roller, exit roller, Phaser 840 401-0855-00 Electric clutch, upper feed roller, exit roller, Phaser 850/860/8200 401-0808-02 Electric clutch, pick roller, Phaser 840/850 401-0855-00 Electric clutch, pick roller, Phaser 860/8200 401-0807-02 Electric clutch, drum maintenance, Phaser 840 401-0871-00...
  • Page 236: Gear And Belt Frus

    Gear and Belt FRUs 0388-22 Fig 8-7 Gear and belt FRUs 8 - 220 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 237: Gear And Belt Frus

    The Phaser 840/850/860 printer gears and belts are all part of kits. When referencing a specific part, its associated kit will be listed in the Kit column, with a description of the particular part listed in the Name and description column. The kits are as follows:...
  • Page 238: Sensor And Flag Frus

    Sensor and Flag FRUs 0388-15 Fig 8-8 Sensor and flag FRUs All sensor flags are provided in Flag Kit 650-3618-00 (Phaser 840 printer) or Flag Kit650-4156-00 (Phaser 850/860 printer). 8 - 222 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 239: Sensor And Flag Frus

    Discont’d 650-3618-00 Cap/wipe/purge home flag, Phaser 840 650-4156-00 Cap/wipe/purge home flag, Phaser 850/860/8200 650-3618-00 Drum maint cam home flag, Phaser 840 650-4156-00 Drum maint cam home flag, Phaser 850/860/8200 386-6902-00 Media tray sense flag assy 650-3618-00 Paper out sensor flag, Phaser 840...
  • Page 240: High-Capacity Paper Tray Assembly

    High-capacity Paper Tray Assembly 0388-65a Fig 8-9 High-capacity Paper Tray 8 - 224 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 241: High-Capacity Paper Tray Frus

    Table 8-9 High-capacity Paper Tray FRUs Parts Part number Serial number Name and description Effective Discont’d High-capacity paper tray 436-0328-00 Phaser 840/850 A-size 436-0329-00 Phaser 840/850 A4-size 436-0416-00 Phaser 860/8200 A-size 436-0417-00 Phaser 860/8200 A4-size 116-0272-00 Paper pick roller 118-9588-01...
  • Page 242: Service Tools

    003-1623-00 Spring removal tool 650-4222-00 Hardware kit, Note: Some items are not used in all products 650-3616-00 Cable kit, printer wiring harnesses, Phaser 840 650-4139-00 Cable kit, printer wiring harnesses, Phaser 850 650-4218-00 Cable kit, printer wiring harnesses, Phaser 860/8200...
  • Page 243: Supplies And Accessories

    Discont’d 016-1845-00 Cleaning Kit 016-1604-00 Phaser 840 Black Ink, 3 pack 016-1605-00 Phaser 840 Cyan Ink, 5 pack plus 2 black sticks 016-1606-00 Phaser 840 Magenta Ink, 5 pack plus 2 black sticks 016-1607-00 Phaser 840 Yellow Ink, 5 pack plus 2 black...
  • Page 244 Tray, Paper, A-size, Z840DP “Designer Edition” Tray, Paper, A-size, Phaser 860 436-0409-00 436-0332-00 Tray, Paper, A4-size, Phaser 840/850 436-0396-00 Tray, Paper, A4-size, Z840DP “Designer Edition” 436-0410-00 Tray, Paper, A4-size, Phaser 860 8 - 228 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 245 016-1933-00 Standard maintenance cartridge kit; roller and counter, Phaser 860 016-1932-00 Extended maintenance cartridge kit; roller and counter, Phaser 860 436-0370-01 Waste ink tray, Phaser 840/850 436-0315-00 Waste ink tray, Phaser 860 Media 016-1368-00 A-size paper, 500 sheets 016-1369-00 A4-size paper, 500 sheets...
  • Page 246: Parallel Cable

    Adapter, ATM CD-ROM, 070-9103-00 Advanced Topics and Troubleshooting Manual, English 063-3126-01 Adobe Type Manager, CD SW 063-3166-00 Phaser 840 Drivers and Utilities, CD SW 063-2627-00 Phaser 840 Drivers and Utilities, Diskettes, English 063-2627-10 Phaser 840 Drivers and Utilities, Diskettes, French...
  • Page 247 Table 8-11 Supplies and accessories Parts Part number Serial number Name and description Effective Discont’d 063-2627-30 Phaser 840 Drivers and Utilities, Diskettes, German 063-2627-40 Phaser 840 Drivers and Utilities, Diskettes, Spanish 063-2627-70 Phaser 840 Drivers and Utilities, Diskettes, Simplified Chinese...
  • Page 248 World Kit, Standard 061-4474-00 World Kit, Metric 063-3424-00 Phaser 8200 Drivers and Utilities with Advanced Network Management Tools CD-ROM, all languages 063-3425-00 Phaser 8200 Advanced Network Management Tools, CD S/W 8 - 232 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 249 Table 8-11 Supplies and accessories Parts Part number Serial number Name and description Effective Discont’d Cords 161-0066-00 Power cord, Standard U.S., 115V 161-0066-09 Power cord, Euro, 220V 161-0066-10 Power cord, United Kingdom, 240V 161-0066-11 Power cord, Australian, 250V 161-0154-00 Power cord, Swiss, 220V 161-0240-00 Power cord, Danish 065-0619-00...
  • Page 250: Phaser 840/850/860/8200 Color Printer - Service Manual

    8 - 234 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 251: Wiring Diagrams

    Wiring Diagrams Phaser 840 only SCSI load loader Empty High capacity Size A/A4 Main Board board paper tray 2 Empty Cover Tray present SDRAM hard Power 8 AC Drum SDRAM Printer ID drive supply Network heater card Paper 6 AC...
  • Page 252 Bundle vacuum hose through cable restraint Tie-wrap hose and wiring to corner of fan Tie-wrap wiring harness Wire routing on the right side of the printer near right I/O board 9 - 236 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 253 The power wiring harness for the ink loader is routed through a cable strap located behind the vacuum/pump module Vacuum pump Paper path motor X-axis motor Drum Right I/O board Wire dressing above the x-axis drive Wiring Fold 9 - 237...
  • Page 254 Tie wraps on the vacuum hose should be trimmed closely and each tie-wrap’s “knot” should be oriented inward so that it does not rub against the printer cabinet panel. Do not pinch shut the vacuum hose. Orient knots in ties inward. Tie-wrap cap/wipe/purge wiring harness to Bundle cap/wipe/purge wiring both ends of metal vacuum hose with hose Vacuum hose dressing 9 - 238 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 255 Tie-wrap to frame Main fan Process motor encoder Tie wrap to Process bracket motor Y-axis motor High capacity paper tray Left I/O board Wrap drum position sensor wiring harness around drum temperature sensor wiring harness Routing wiring on the left side of the printer Wiring Fold 9 - 239...
  • Page 256 Printhead ground lugs Printhead cable restraints built into frame Maintenance tray counter sensor wiring harness restraint Wire dressing behind the printhead 9 - 240 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 257: Phaser 8200 Color Printer Addendum

    Phaser 8200 Color Printer Addendum The Phaser 8200 Color Printer is the latest generation of solid ink printing technology. This section provides the differences between the Phaser 860 model and the new Phaser 8200 model as outlined below: Unless otherwise specified, all characteristics of the Phaser 860 Note Color Printer apply to the Phaser 8200 Color Printer.
  • Page 258: Inks

    “Darker Fast Text” will be the default setting. P8200-001 Fig 10-10 New ink sticks Memory The Phaser 8200DX model will include 192 Mbytes of memory, standard. PA - 242 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 259: Appendix

    Appendix This section contains the Printhead and Electronic checklists for the Phaser 840/850 and Phaser 860/8200. Phaser 340/350/360/380/840/850: Printhead Checklist Electronics Checklist Phaser 860/8200 Printhead Checklist Electronics Checklist Disclaimer: These checklists were current as of May 2001, if the checklist included in the FRU is a newer version it supercedes the checklists included here.
  • Page 260: On-Site Printhead Troubleshooting Checklist

    The completed checklist and sample test prints are to be returned with each printhead. Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed checklist and a sample print with each returned printhead.
  • Page 261 No: go to 3b 3b. Is the printhead thermostat open (check for open from common leads to all other heater leads)? No: go to 3c Phaser 840, 850 Phaser 340, 350, 360 Common Leads 3c. If one of the specified error codes below is present, follow the steps indicated, otherwisxe replace the prinhead and perform the C/W/P Checklist with the new printhead.
  • Page 262 If the decay time goes to zero suddenly, check the rubber lines for cracks or holes and replace as necessary. If lines are OK, replace the air solenoid or the vacuum module. Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 263 6. Print Service Test 2: Weak and Missing Jets. Are there weak or missing jet(s)? NO weak or missing jets and Non-Xerox/Tektronix ink is used, go to Test for Non-Xerox/Tektronix Ink Failure Checklist on the next page. NO weak and missing jets and Xerox/Tektronix ink is used, repair is complete! YES and Non-Xerox/Tektronix ink is used, go to Test for Non-Xerox/Tektronix Ink Failure Checklist.
  • Page 264 North America, where credit cards are not commonly available). Xerox Warranty/Service Agreement DOES NOT cover repair cost of the printhead when it has been damaged by Non-Xerox/Tektronix ink and the repair cost is the responsibility of the customer.
  • Page 265 Wilsonville. It will be subjected to complete analysis at that time and if found to be NXTI damaged, the customer will be billed." Xerox Personnel - please provide full documentation in TekLink. Appendix...
  • Page 266: On-Site Electronics Troubleshooting Checklist Phaser 840/850

    Use the checklist below, along with the provided electronics troubleshooting guide, when repairing a Phaser 840 or 850 printer that has experienced a failure related to electronic circuit boards. For each step, fill in all blanks that apply and return the filled-out checklist with any circuit board that is returned to the factory (such as the main board or the power supply).
  • Page 267 ACTION: LOOK FOR: WHAT NEXT: Verify Good Board Con- Check the one that applies: Check the one that applies: nection __Failure corrected due to 2. If error condition is gone reseat, check appropriate after reseat, check printer's box in next column history Reseat main board to __Same failure still exists after...
  • Page 268 Record any additional com- Replaced this job: ments in the space pro- vided below. List all other parts that were replaced on this job in addition to this board in the next column. Comments: Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 269: Z840/Z850 Electronics Troubleshooting Guide

    Z840/Z850 Electronics Troubleshooting Guide This troubleshooting guide is composed of two sections. The first section is to be used for printer failures that occur during the printer's power on sequence. The second section is to be used for all other failures relating to electronics that can occur at any point other than during the power on sequence.
  • Page 270 If the pins are bent, bend them back into place, if possible. If not possible, replace the power control board. 4D.Inspect the main board's edge connector. If residue is present, clean. Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 271 LED. ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS (follow in order) SDRAM Error Codes (2-6) See page 29 in the Phaser 840/850 Service Quick Reference Guide for more information. Condition started A. The Memory DIMM not 1A.Reseat the memory DIMM.
  • Page 272 2D.Reseat the memory DIMM. E. Failed code ROM DIMM. 2E.Replace the Code ROM DIMM. F. Failed memory DIMM. 2F.Replace the memory DIMM. G. Failed main board. 2G.Reseat the main board, Replace the main board. Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 273 VI. Display: on/off, Confirm that all DIP LED flash switches are up and printer is isolated from network ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS (follow in order) Possibly continuous A. Power. 1A.Confirm good power is supplied reboot. to printer and not plugged into B.
  • Page 274 F3 fuse on the power supply. If 9,008.43 (840) failed power supply. blown, replace the power supply AND the cap/wipe/purge 6. 9,005.40; assembly. If not blown, replace 9,069.41; 9,037.42; ink loader. 9,101.43 (850) Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 275 IX. Printer shuts down on its own Loss of power ADDITIONAL CLUES PROBABLE ROOT CAUSE ACTIONS (follow in order) Printer shuts down A. Spurious over-current. 1A. If printer powers back on within with power switch two seconds, do nothing. still “on.” Cycling power brings If printer powers on in about 6 printer back to...
  • Page 276 850 printers). of printer. If serial number is below B9B1458 (840), replace the power control board with -01 or higher version board. 1C. See SF152. Replace Lower Tray Assembly connector inside printer. Notes Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 277: On-Site Printhead Troubleshooting Checklist

    The completed checklist and sample test prints are to be returned with each printhead. Xerox reserves the right to refuse reimbursement to service personnel who do not enclose a completed checklist and a sample print with each returned printhead.
  • Page 278 Select Eliminate Light Stripes from the printer front panel, run up to 3 times as needed to recover a weak or missing jet. If the problem persists, continue to the C/W/P Checklist. Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 279 Select "Unlock DM Tray" from the Function menu. Remove the maintenance tray and note whether or not a normal volume of ink was purged from the printhead (Note: the Phaser 860 purge volume is about half as much as the Phaser 840/850). Purge Volume: NORMAL 5a.
  • Page 280 6. Print Service Test 2: Weak and Missing Jets. Are there weak or missing jet(s)? NO weak or missing jets and Non-Xerox/Tektronix ink is used, go to Test for Non-Xerox/Tektronix Ink Failure Checklist on next page. NO weak and missing jets and Xerox/Tektronix ink is used, repair is complete! YES and Non-Xerox/Tektronix ink is used, go to Test for Non-Xerox/Tektronix Ink Failure Checklist .
  • Page 281 At this time there is insufficient data to support field diagnosis of NXTI failure at the customer site for the Phaser 860/8200. All NXTI work for the Phaser 860/8200 will be done by Xerox Failure Analysis Engineering. Service Support Personnel are encouraged to provide FULL AND COMPLETE documentation packages to assist the Failure Analysis Engineers with any potential NXTI cases.
  • Page 282: On-Site Electronics Troubleshooting Checklist Phaser 860

    Communication Checklist For all other Electronics problems (including intermittent failures), refer to the Normal Operation Checklist . Once the problem is resolved, answer the following (Xerox US personnel please document in TechLink): 1. Which Checklist Item Number addressed the issue? _________________________________________ 2.
  • Page 283 When turned on without the 40V jumper, the printer will get through POST testing and crash with the Xerox logo on the display. If the printer still does not respond with the 40V jumper removed, go to # P5. To isolate a shorted driver, reconnect the 40V jumper and systematically try disconnecting each cable from the power control board.
  • Page 284 If the fault occurs 3 times in a row the fault message will be displayed. N3 . Refer to the Service Quick Reference Guide for other symptoms related to electronics failures. Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 285 Once the hardware is verified, follow your standard procedures to assist the customer with their network or host computer, or refer them to the local Xerox customer support center for software support. If the hardware cannot be verified using the above steps, reseat the main board and try the steps again. If the hardware still fails, replace the main board.
  • Page 286 Phaser 840/850/860/8200 Color Printer - Service Manual...
  • Page 287 071-0723-00...

This manual is also suitable for:

Phaser 850Phaser 860