Xerox Phaser 8400 Service Manual
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Xerox Phaser 8400 Service Manual

Xerox Phaser 8400 Service Manual

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®
Phaser
Printer

Service Manual

Warning
The following servicing instructions are for use by qualified service
personnel only. To avoid personal injury, do not perform any servicing other
than that contained in the operating instructions, unless you are qualified to
do so.
December, 2005
721P58550
http://printer1.blogspot.com
8400/8500/8550 Color

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Summary of Contents for Xerox Phaser 8400

  • Page 1: Service Manual

    ® Phaser 8400/8500/8550 Color Printer Service Manual Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so.
  • Page 2 Copyright © 2005 Xerox Corporation. All Rights Reserved. Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms of matters of copyrightable materials and information now...

  • Page 3: 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 4 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation. Phaser 8400/8500/8550 Color Printer...

  • Page 5: 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 6 This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox. Phaser 8400/8500/8550 Color Printer...

  • Page 7: Electrostatic Discharge (Esd) Precautions

    Electrostatic Discharge (ESD) Precautions 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. The following techniques will reduce the occurrence of component damage caused by static electricity.

  • Page 9: Table Of Contents

    Contents User Safety Summary ......... i Regulatory Specifications.
  • Page 10 Service Diagnostics Menu Map ....... . 4-6 Phaser 8400/8500/8550 Color Printer...
  • Page 11 Check Menu Definition Tables ....... . 4-12 Check / Activators Menu ....... 4-13 Check Shafts Menu.
  • Page 12 Right Side Cover ........8-6 Phaser 8400/8500/8550 Color Printer...
  • Page 13 Left Side Cover ........8-7 Exit Cover .
  • Page 14 Xerox Supplies ........

  • Page 15: 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 Section...

  • Page 16: Printer Introduction And Overview

    The Xerox Phaser 8400/8500/8550 Color Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. To ensure understanding of this product, complete the Xerox Phaser 8400/8500/8550 Color Printer Service Training and self-study guide. Back Left...

  • Page 17: Printer Configurations

    The Configuration Card holds configuration information that enables or disables built-in features as described below. The first table shows the configuration for the 8400 series. The second table shows the configuration for the 8500 series. Phaser 8400-Series Printer Configurations Features 8400B...
  • Page 18 Standard 10/100 Ethernet Connection ** The following features are not included in the Phaser 8400-series printers, but are included with the Phaser 8500/8550 printers with a hard drive: proof print, saved print, secure print, personal print, and font storage. Phaser 8400/8500/8550 Color Printer...

  • Page 19: Control Panel Configuration

    Control Panel Configuration 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. LED Indicators ■ Green = Ready to Print ■...

  • Page 20: Menu Maps

    Then, press the Down Arrow button to select Service Tools then press OK. Service (Internal) (Phaser 8400) Hold the Back and Info button at power up (for about Diagnostics 30 seconds). (Phaser 8500/8550) Wait until Control Panel screen turns black, and then press and hold Back and Help buttons until the message “Beginning Service Mode”...

  • Page 21: Parts Of The Printer

    Parts of the Printer This section shows the main external components of the printer, including interfaces, the electronics module, and the internal sensors. Front View 1. Optional 525-Sheet Feeder Tray 4 2. Optional 525-Sheet Feeder Tray 3 3. Stan. 525-Sheet Feeder Tray 2 4.

  • Page 22: Rear View

    1. Hard drive (optional) 3. Configuration card (Installed from the side under the interface cover.) 2. Memory (RAM) DIMM 1 and DIMM 2 4. NVRAM (configuration card handles NVRAM differences between 8400 and 8500 series). Phaser 8400/8500/8550 Color Printer...

  • Page 23: Routine Maintenance Items And Consumables

    Routine Maintenance Items and Consumables s8500-007 Routine Maintenance Items Consumable 1. Maintenance kit 3. Ink 2. Waste tray Routine Maintenance: Consumable: Extended Capacity 30,000 cycles (0-20% (8400) 1140 prints Maintenance Kit coverage) per stick* (8400 and 8550 only) 20,000-30,000 (20-100% (8500/8550) 1080 coverage) prints per stick*...

  • Page 24: Printer Specifications

    Min. install width - 711 mm (28 in.) Requires placing printer at an angle to remove waste tray. A. Absolute Minimum B. Recommended Minimum 15.5 35.5 28.0 Front Note: All dimensions in inches 1-10 Phaser 8400/8500/8550 Color Printer...

  • Page 25: Functional Specifications

    Functional Specifications Characteristic Specification Printing Process Solid-ink Color Medium Yellow, cyan, magenta, and black ink sticks, each shape-coded. The printer uses the subtractive color system to produce the colors red, green, and blue. Operating Modes and (8400) Resolutions Fast Color (300x300 dpi), Standard (300x450 dpi), Enhanced (563x400 dpi), High Resolution/Photo (525x2400) (8500/8550) Fast Color (225 x 400 dpi), Standard (300x450 dpi), Enhanced (525...

  • Page 26: Media And Tray Specifications

    (16–32 lb. Bond) 13 in.) A6 (105 x 60–120 g/m (16–32 lb. Bond) 148 mm) B5 ISO (176 x 60–120 g/m (16–32 lb. Bond) 250 mm) B5 JIS (182 x 60–120 g/m (16–32 lb. Bond) 257 mm) 1-12 Phaser 8400/8500/8550 Color Printer...
  • Page 27 Paper Size Paper Type Paper Weight/Media Type Index Cards (3 x 5 in.) 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 29: Theory Of Operation

    Theory of Operation In this chapter... ■ Main Printer Subsystems ■ Print Process ■ Printer Self-Maintenance ■ Configuration Card Personality Parameters Section...

  • Page 30: Main Printer Subsystems

    The printer is made up of eight major subsystems, which are described in this section: ■ Process Drive ■ Media Path Drive ■ Ink Loader ■ Printhead ■ Drum Maintenance System ■ Purge System ■ Drum Assembly and Transfix Assembly ■ Electronics Module Phaser 8400/8500/8550 Color Printer...
  • Page 31 The Process Drive: is Transmits torque to two main camshaft assemblies. One camshaft assembly controls the transfix roller loading, and the other controls the drum maintenance system and printhead tilt system. The Media Path Drive: Controls each roller in the paper transport system. The paper transport system consists of a drive motor, a gearbox assembly and three solenoids.

  • Page 32: Process Drive

    If either the gearbox or cam gears is out of home during installation, the printer does not function properly. Process drive Swing gear Imaging Transfix Transfix Camshaft Process Motor Gear Process Motor Gear Drum Maintenance Camshaft Drum Maintenance s8500-009 Phaser 8400/8500/8550 Color Printer...

  • Page 33: Media Path Drive

    Media Path Drive The media path drive gearbox and motor assembly controls each roller in the paper transport system. A gear train located behind the motor connects it to the exit rollers, which are built into the exit module. Gear trains located within the media path drive assembly, along with two clutches and a solenoid, allow the motor to control the pick, take away, duplex, and deskew rollers.

  • Page 34: Ink Loader

    Control Panel reports an “Ink Jam” error. The Phaser 8400 features a single Ink-Out sensor, which activates when there is no ink stick in any of the four ink channels. This condition activates the sensor flag.

  • Page 35: Printhead

    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 36 The jet array bonds to a cast aluminum ink reservoir, which supplies the molten ink to the jet array. Heaters in the reservoir and the jet array maintain the ink at a printing temperature of about 140 degrees centigrade. Phaser 8400/8500/8550 Color Printer...

  • Page 37: Theory Of Operation

    X-Axis Hook Printhead X-Axis X-Axis Nose X-Axis Shaft Shaft Cone Motor Tension Spring Gear Drum s8500-014 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.

  • Page 38: Printhead Tilt

    The printhead is limited to the nominal motion of 1.7 mm in the X-Axis (left / right side motion when the printhead is back and locked) by the right lock and the left home stop on the left side frame. 2-10 Phaser 8400/8500/8550 Color Printer...
  • Page 39 Printhead Restraint Drum DM Cam Gear Printhead Tilt Gear (Engaged) Tilt Gear s8500-015 In the print position (0 degrees), the printhead is forward and rests against the right and left head-to-drum buttons. The head-to-drum buttons define the space between the jet stack and the drum. When the process drive is activated, it drives the drum maintenance camshaft to engage the tilt gear train.
  • Page 40 This creates room for the wiper to be moved into position in front of the printhead faceplate. The process drive drives the gears to the tilt compound gear train. The drum maintenance camshaft drives the gear train to tilt the printhead. 2-12 Phaser 8400/8500/8550 Color Printer...

  • Page 41: Drum Maintenance System

    Drum Maintenance System The drum maintenance system creates a thin intermediate liquid transfer surface, a layer of silicone oil, on the surface of the drum prior to printing. The oil keeps the ink from sticking to the drum’s surface and facilitates its transfer to the sheet of paper or transparency film.

  • Page 42: Purge System

    The wiper blade lowers and wipes excess ink from the jets into the ink waste tray. A proper purge will layer the length of the waste tray with a single layer of ink about 20 mm wide. 2-14 Phaser 8400/8500/8550 Color Printer...
  • Page 43 The level of the ink in the reservoir is kept at a constant level. If the pressure purge tubing is pinched, the printhead may not purge properly. In addition, because the purge tubing also acts as a vent to atmosphere when not purging, a more serious failure may occur if the ink overfills.

  • Page 44: Drum Assembly And Transfix System

    The main board interprets the sensor’s signal and turns on the drum heater and drum fan to heat the drum, or turns on the drum fan alone to cool the drum. 2-16 Phaser 8400/8500/8550 Color Printer...
  • Page 45 A closed-loop servomotor drives the drum assembly. Through a single reduction belt drive, the servomotor rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper. The Y-Axis uses an active tension system to allow the pulley to float while the spring actively adjusts the tension.
  • Page 46 Tray 1 or on envelopes. The transfix load springs and double lever arms increase the force when the camshaft engages. Warning Never attempt to adjust or increase the transfix pressure on the springs. s8500-021 2-18 Phaser 8400/8500/8550 Color Printer...

  • Page 47: Electronics Module

    Memory: For Phaser 8400 printers, the main board supports two PC 133 compatible SO-DIMM SDRAM memory modules (128 to 256 MB). Phaser 8500/8550 printers support SIMMs instead of DIMMs. Supported sizes are 128, 256, and 512 MB.

  • Page 48: Power Supply

    NVRAM chip. When removing the configuration card for the Phaser 8400, the printer reboots as a B (non-networking) configuration. Refer to the “Configuration Card Personality Parameters” section at the end of this chapter for a detailed list of “shadowed”...
  • Page 49 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. The main board also has regulators providing + 5 V, + 2.5 V, and + 1.8 V.

  • Page 50: I/O Board

    Position Encoder Front Door Sensor Deskew Tray Paper Sensor Size Sensor Tray Empty Board Sensor (Also in Trays 3 & 4) Pick Sensor (525-sheet Tray Lift Sensor Feeder) (Also in Trays 3 & 4) s8500-023 2-22 Phaser 8400/8500/8550 Color Printer...

  • Page 51: Print Process

    Print Process 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. At the ready state, the print process consists of the following steps: ■...

  • Page 52: Drum Preparation

    When the printer is in the jet substitution mode, the printhead makes a second, right to left movement to deposit the pixel columns of the substituted jets. See "Jet Substitution Mode" on page 6-10. 2-24 Phaser 8400/8500/8550 Color Printer...

  • Page 53: Paper Pick For Tray 1

    Paper Pick for Tray 1 To pick a sheet of paper, the Tray 1 solenoid is fired, 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 54: Paper Pick For Trays 2 - 4

    The deskew rollers do not reverse during duplex printing. Exit Sensor Strip Sensor Preheat Exit Sensor Deskew Roller Deskew Sensor Pick Roller Nudger Roller Retard Roller s8500-025 2-26 Phaser 8400/8500/8550 Color Printer...

  • Page 55: Transfixing And Exiting

    Transfixing and Exiting 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. Stripping the paper from the drum. Exiting the paper from the printer, or exiting the paper for (2-sided) duplex printing.
  • Page 56 Transfer Roller Transfix Load Arm Transfix Load Module Transfix Load Spring Transfix Drum Process Drive Transfix Roller Gear Swing Arm Gear Transfix Cam s8500-026 2-28 Phaser 8400/8500/8550 Color Printer...
  • Page 57 Release Blade Strip Solenoid Exit Sensor Transfix Roller Preheat Sensor Strip Sensor Paper Preheater s8500-027 Theory of Operation 2-29...

  • Page 58: Duplex Printing

    The increased spacing prevents the paper from rubbing as hard against the plates, which can cause smearing to occur. Since the Phaser 8500/8550 preheater operates at a higher temperature than the Phaser 8400, the solenoid is not needed on Phaser 8400 printers.

  • Page 59: Transfix And Print Speeds

    Transfix and Print Speeds Transfix Speeds Characteristic Setpoint, Paper Media Fast Color Standard Enhanced High Res/ Photo Peak Transfix Speed, 20 ips (8400) 17 ips (8400) 13 ips (8400) 7 ips (8400) Simplex tray feed 25 ips (8500) 25 ips (8500) 20 ips (8500) 10 ips (8500) Peak Transfix Speed,...
  • Page 60 24 ppm 14 spm Enhanced (525 x 450 dpi) 16 ppm 10 spm High Res/Photo (525 x 10 ppm 6 spm 2400 dpi) PCL 600 x 300 Mode 16 ppm PCL 600 x 600 Mode 8ppm 2-32 Phaser 8400/8500/8550 Color Printer...

  • Page 61: Printer Self-Maintenance

    Printer Self-Maintenance To maintain peak operation, reliability, and print quality, 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 62: Paper Preheater Cleaning (Remove Print Smears)

    The printer then attempts to reprint the print that jammed. The chase page is processed the same as a regular print, except that the drum is not oiled and no image is printed on the drum (since an image is already printed on the drum). 2-34 Phaser 8400/8500/8550 Color Printer...

  • Page 63: Configuration Card Personality Parameters

    Configuration Card Personality Parameters Configuration Card “Shadowed” Personality Parameters NCL Subject NCL Item Size (bytes) N/A “version” not NCL version (of the layout of personality parameter parameters) NEST Base Printer Name NEST SysAdmin Contact 128 (truncated from 256) NEST Printer Location 128 (truncated from 256) NEST Asset Identifier...
  • Page 64 Admin_Username HTTP KeyUser_Password HTTP KeyUser_Username HTTP Admin_HostAccessList HTTP KeyUser_HostAccessList Notify Authentication Scheme IPP user name IPP password Login Password Security Print Hosts AppSocket AppSocket Enabled Enabled Enabled Enabled MIME MIME Enabled EtherTalk EtherTalk Enabled PSERVER 2-36 Phaser 8400/8500/8550 Color Printer...
  • Page 65 Configuration Card “Shadowed” Personality Parameters (Continued) NCL Subject NCL Item Size (bytes) PSERVER Enabled PSERVER_IPX Enabled Notes: 1. “Parallel” and “USB”, “On” and “Enabled” parameters have not been identified as personality parameters. They are not tied to networking. 2. NCL = Nest Configuration Library Theory of Operation 2-37...

  • Page 67: 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 Section...

  • Page 68: Introduction

    "General Troubleshooting" on page 4-1 or "Print-Quality Troubleshooting" on page 5-1. Check the main menu for current data and historical error data. ■ Status Page ■ Usage Profile ■ Fault History ■ Diagnostic History Phaser 8400/8500/8550 Color Printer...

  • Page 69: Power-Up Error Messages And Led Codes

    Power-Up Error Messages and LED Codes The printer has three sets of tests that are run when first powered on: ■ Built-In Self Tests (BIST) ■ Power On Self Tests (POST) ■ Print Engine Self Tests (PEST) Note BIST and POST errors are not stored in the fault history logs. BIST Error Reporting BIST verifies basic electronics module CPU operation and reports failures by utilizing the rear interface panel PS and PE LEDs.

  • Page 70: Post Error Reporting

    Plug in the AC power cable and power on the printer electronics module. If the error blink pattern is now different from the original error reported before Step 1, the problem may not be in the electronics module, (see "Miscellaneous Electrical Troubleshooting" on page 4-65). Phaser 8400/8500/8550 Color Printer...
  • Page 71 POST Error Reporting Blink Pattern Definition Table 8500/ 8400 8550 Control PS, PE and Control Panel Control POST Panel Error Panel LEDs Error Error Code (for 8400) Type Description Code 01.01 Flutter then Hard Bad error code. 21.1 01 blinks 02.01 Flutter then Hard...
  • Page 72 13 blinks 13.02 Flutter and Hard PHY ID error, mismatch error. then 13 blinks 14.xx Flutter and Hard USB ASIC test errors, N2280 netchip read, 19.1 then 14 write, and mismatch errors, POST hard blinks errors. Phaser 8400/8500/8550 Color Printer...
  • Page 73 POST Error Reporting Blink Pattern Definition Table (Continued) 8500/ 8400 8550 Control PS, PE and Control Panel Control POST Panel Error Panel LEDs Error Error Code (for 8400) Type Description Code 15.01 Flutter and Hard CPU interrupt error, spurious CPU 19.3 then 15 interrupts.

  • Page 74: Pest Error Reporting

    PEST checks the connections and operation of various printer components. Error codes for PEST tests are displayed on the Control Panel and are all in the 37,XXX.xx series. For troubleshooting PEST error codes, "37,0XX.xx Errors - PEST Faults" on page 3-41. Phaser 8400/8500/8550 Color Printer...

  • Page 75: Fault Code Error Message Troubleshooting

    Fault Code Error Message Troubleshooting Fault Code Error Reporting 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 Error - 525-Sheet Feeder Faults

    Is the wiring defective? 1,0XX.6x Errors: 525-Sheet Feeder program faults Reseat the printer onto the 525-sheet feeder. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on page 4-77). Reset NVRAM. Replace the 525-sheet feeder. 3-10 Phaser 8400/8500/8550 Color Printer...

  • Page 77: 2,0Xx.4X Error - I/O Circuit Board Fault

    2,0XX.4x Error - I/O Circuit Board Fault 2,001.47: The print engine cannot detect the presence of the I/O circuit board. Troubleshooting Procedure for I/O Board Step Questions or Actions Are all wiring connections to and from the Go to Step 3. Go to Step 2.

  • Page 78: 3,0Xx.6X - Ipc Program Faults

    Turn on printer. If problem continues, replace the electronics module. 3,0XX.6x - IPC Program Faults There is a communication problem between the engine and PostScript regions. Reset NVRAM, and then retest. Replace the EEPROM chip. 3-12 Phaser 8400/8500/8550 Color Printer...

  • Page 79: 4,0Xx.4X Errors - Process Control System Fault

    4,0XX.4x Errors - Process Control System Fault 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: This fault code indicates a problem with the process control system. The printhead temperature dropped below the head cleaning needed threshold.
  • Page 80 Did this fix the problem? Ensure the wiring around the printhead is Re-route all Go to Step 3. routed properly. wiring to the printhead. Is the wiring blocking the printhead? 3-14 Phaser 8400/8500/8550 Color Printer...
  • Page 81 Troubleshooting Procedure for 4,025 Error Code (Continued) Step Questions and Actions Remove the waste tray and printhead and Clean any ink or Go to Step 4. look for ink build-up in the printer. debris which may be Is there ink build-up anywhere in the printer? restricting movement of the drive train or...

  • Page 82: 5,0Xx.4X Errors - Y-Axis Sub-System Fault

    There is a problem with the Y-Axis sub-system. 5,005.67: If not in the homeless or idle state, the system faults out. Software fault. 5,006.68: 5,007.60: Software fault. Software fault. 5,008.61: PostScript failed to fill the race buffer during imaging. Software fault. 3-16 Phaser 8400/8500/8550 Color Printer...
  • Page 83 5,009.62: There were errors during imaging. Possible jets on/off outside of the deadband area. Software fault. Reset NVRAM and retest. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on page 4-77). Replace the EEPROM chip. Reboot the printer. Service Manual 3-17...

  • Page 84: 6,0Xx.4X Errors - X-Axis Fault

    Could not find a solution to the described home motion profile. 6,033.60: Could not allocate memory for X-axis move parameters. Reset NVRAM, and then retest. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on page 4-77). 3-18 Phaser 8400/8500/8550 Color Printer...

  • Page 85: 7,0Xx.4X Errors - Process Motor Gearbox Faults

    7,0XX.4x Errors - Process Motor Gearbox Faults 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 Complete.
  • Page 86 (see "Homing the Process Gear process Drive Train" on page 6-8). gearbox. Are the gears damaged? Check the process gearbox for obstructions Replace the Go to Step 6. or damaged. process gearbox. Remove any obstructions. Is the gearbox damaged? 3-20 Phaser 8400/8500/8550 Color Printer...
  • Page 87 Troubleshooting Procedure for 7,008 Error Code (Continued) Step Questions and Actions Use service diagnostics to run the Tilt Axis Replace the Go to Step 7. Drive test. process gearbox. Did the test fail? Use service diagnostics to run the Head Replace the Go to Step 8.
  • Page 88 Set them in their home positions. Does the X-axis motor drive the printhead to Go to step 6. Troubleshoot its center position (so it can tilt forward)? the X-axis drive. 3-22 Phaser 8400/8500/8550 Color Printer...
  • Page 89 Troubleshooting Procedure for 7,010 to 7,015 Error Code (Continued) Step Questions and Actions Check the process gearbox for obstructions Complete. Go to Step 7. or damaged. Ensure the gears are correctly aligned and homed. Verify the process shaft and drive module shaft are at their home positions.

  • Page 90: 8,0Xx.xx Error - Wiper/Media Path Gearbox Faults

    Remove the pick solenoid to view the meshing of the take away roller’s gears to the paper path drive module. Ensure the feed rollers are properly engaged in the drive gears. Did this correct the problem? 3-24 Phaser 8400/8500/8550 Color Printer...
  • Page 91 Troubleshooting Procedure for Wiper/Media Gearbox (Continued) Step Questions and Actions Run the Wiper Drive test. Go to Step 5. Go to Step 6. Did the test pass? Run the Wiper Alignment test (see "Wiper Go to Step 7. Go to Step 6. Alignment Procedure"...

  • Page 92: 9,0Xx.xx Errors - Ink Loader Faults

    9,03x.41, where x= 5 for cyan, 6 for magenta, 7 for yellow, and 8 for black. Troubleshooting Procedure for Ink Loader Step Questions and Actions Are the ink sticks all Xerox ink? Are they the Go to Advise correct ink sticks for the printer model? Step 2.

  • Page 93: 11,0Xx.xx Errors - Electronics Module Interface Fault

    Troubleshooting Procedure for Ink Loader (Continued) Step Questions and Actions Manually verify that the ink stick is able to Go to Remove any advance in the ink loader chute. Check for Step 3. blockage and/ or replace the broken or wrong type ink sticks. ink stick.
  • Page 94 11,003.49 and 11,0014.42 Replace the I/O board. ■ 11,004.41 and 11,013.41 Replace the I/O board or the Control Panel. ■ 11,006.43 and 11,015.43 Replace the printhead. ■ 11,009.46 Replace the I/O board or the electronics module. 3-28 Phaser 8400/8500/8550 Color Printer...

  • Page 95: 13,0Xx.xx Errors - Thermal Faults

    Troubleshooting Procedure for Electronic Module Interface (Continued) Step Questions and Actions ■ For all other 11,000.4x errors: Replace the electronics module. 11,100.60 - Temperature Error The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. Ensure room temperature is not too high. Ensure also that the electronics fan runs correctly.
  • Page 96 Did the test pass? sensor. 13,067.43: The drum thermistor circuit is open. 13,069.45: The drum thermistor circuit is shorted. 13,071.47: The drum thermistor returned a bad reading, or the reading was corrupted by ESD (Electrostatic Discharge). 3-30 Phaser 8400/8500/8550 Color Printer...
  • Page 97 Troubleshooting Procedure for 13,067 to 13,071 Error Code (Drum Thermistor) Step Questions and Actions Using service diagnostics, run the Drum Go to Step 2. Replace the Temperature Sensor test. drum temperature Did the test pass? sensor. Inspect the sensor wiring harness. Replace the Replace the drum...
  • Page 98 Use service diagnostics to run the Left Go to Step 4. Replace the Jetstack Temperature test. printhead. Did the test pass? Check and reseat all wiring to the printhead. Complete. Replace the printhead. Did this correct the problem? 3-32 Phaser 8400/8500/8550 Color Printer...
  • Page 99 13,200.41: The printhead right jetstack heater is too hot. 13,202.43: The printhead right jetstack heater took too long to reach its setpoint. 13,259.46: The printhead right jetstack thermistor circuit is open. 13,261.48: The printhead right jetstack thermistor circuit is shorted. 13,263.41: The printhead right jetstack thermistor returned a bad reading, or the reading was corrupted by ESD.
  • Page 100 The ink loader BLACK heater took too long to reach its setpoint. 13,579.42: The ink loader BLACK thermistor circuit is open. 13,581.44: The ink loader BLACK thermistor circuit is shorted. 13,583.46: The ink loader BLACK thermistor returned a bad reading, or ESD corruption. 3-34 Phaser 8400/8500/8550 Color Printer...
  • Page 101 Troubleshooting Procedure for 13,326 to 13,583 Error Code (Ink Loader) Step Questions and Actions Verify that the ambient temperature of the Advise Go to Step 2. room is within the printers optimal customer of environmental specification (see specification "Environmental Specifications" on requirements.

  • Page 102: 19,0Xx.xx Errors - Printhead Calibration Faults

    22,0XX.6x Errors - Jam Codes For jam codes, "Jam Codes" on page 3-55. 23,0XX.6x Errors - NVRAM Fault Reset NVRAM, and then retest. Replace the NVRAM. 3-36 Phaser 8400/8500/8550 Color Printer...

  • Page 103: 31,0Xx.4X Errors - Mechanical Initialization Jam

    26,0XX.6x Errors - Printing Faults Reboot the printer if one of these faults occur. 26,962 Errors - “Fall Out” Code Check the previous error in the fault history and troubleshoot that code. 27,0XX.6x Errors - Profile Library Ensure the ground integrity of the printer (see "Ensuring Ground Integrity" on page 4-77).
  • Page 104 31,0XX.6x Errors - Program Faults Reset NVRAM, and then retest. Ensure ground integrity for the printer (see "Ensuring Ground Integrity" on page 4-77). 3-38 Phaser 8400/8500/8550 Color Printer...

  • Page 105: 33,0Xx.xx Errors - Tray Manager Device Faults

    33,0XX.xx Errors - Tray Manager Device Faults 33,001.42: Tray 1 width value too low. 33,002.43: Tray 1 width value too high. Troubleshooting Procedure for Tray 1 Step Questions and Actions Check the wiring and connectors from the Go to Step 2. Replace the front door to the I/O board.

  • Page 106: 36,000.40 Errors - Drum Maintenance Faults

    Replace the pivot plate. Replace the drum maintenance unit. 36,002.44 Errors Printer can’t write to Drum Maintenance Unit. Ensure the DMU sits correctly in the pivot plate. Replace the DMU. Replace the drum maintenance pivot plate assembly. 3-40 Phaser 8400/8500/8550 Color Printer...

  • Page 107: 37,0Xx.xx Errors - Pest Faults

    37,0XX.xx Errors - PEST Faults AC power supplied by power sources such as uninterruptible power supplies (UPS’s) or DC-to-AC inverter systems, may not supply enough current to properly power up the printer. In these cases, the printer may report printhead jet-stack or reservoir heater disconnect, drum heater, or preheater errors (37,002.47 thru 37,012.48).
  • Page 108 = (8400) Ink Melt 2 37,011.47 = (8500/8550) Ink Melt 2 = (8400) Ink Melt 3 37,012.48 = (8500/8550) Ink Melt 3 = (8400) Ink Melt 4 37,013.48 = (8500/8550) Ink Melt 4 Did the test pass? 3-42 Phaser 8400/8500/8550 Color Printer...
  • Page 109 8400 PEST Description 8500/8550 PEST description 37,013.40: Electronics module cooling fan disconnect. The electronics cooling fan is not drawing the expected power from the supply. 37,014.41: Drum cooling fan disconnect. Electronics Cooling Fan Disconnect. The drum cooling fan is not drawing The Electronics Cooling Fan is not the expected power from the supply.
  • Page 110 8500/8550 PEST description 37,016.43: PEST 50 V power supply test. For 50 V power supply test. The power Phaser 8400 printers, the 50 V supply is loaded with the head power supply is loaded with the maintenance, the deskew, and the pick Head Maintenance clutch, and then clutches.
  • Page 111 50V Power Supply Fault Troubleshooting Procedure (Continued) Step Questions and Actions Unplug the following electronics module Go to Step 3. Replace the connectors. This step disconnects all other electronics external circuits so the electronics module module. can be tested alone: ■...
  • Page 112 J270, Pin 1. Find any shorted components? Connect the wave Amp. Leave power on Go to Step 8. to ensure the Any problems. problem is fixed. Connect printhead. Power up printer and retest. 3-46 Phaser 8400/8500/8550 Color Printer...
  • Page 113 8400 PEST Description 8500/8550 PEST description 37,017.44: Head maintenance clutch Head Maintenance Clutch disconnect. The main tray deskew Disconnect. The Head Maintenance clutch is not drawing the expected Clutch is not drawing the expected power from the supply. power from the supply. 37,018.45: Main tray (Tray 1) deskew clutch Main Tray Deskew Clutch Disconnect.
  • Page 114 Run the Tray 2 Lift Motor test. Replace the Go to Step 2. electronics Did the test pass? module. Check the wiring to the tray 2 lift motor. Replace the Replace the wiring harness tray lift motor. Is the wiring damaged? 3-48 Phaser 8400/8500/8550 Color Printer...
  • Page 115 8400 8500/8550 8400 PEST Description 37,022.40: 37,025.43: Pressure pump motor disconnect. The pressure pump motor is not drawing the expected power from the supply. Troubleshooting Procedure for Pressure Pump Step Questions and Actions Run the Pressure Pump Motor test. Replace the Go to Step 2.
  • Page 116 Troubleshooting Procedure for X-axis Motor Step Questions and Actions Run the X-axis Drive test. Replace the Go to Step 2. electronics Did the test pass? module. Check the X- axis motor wiring for damage. Replace the X-axis motor. 3-50 Phaser 8400/8500/8550 Color Printer...
  • Page 117 8400 8500/8550 PEST Description 37,032.41: 37,035.44: Y-axis motor disconnect. The Y-axis motor is not drawing the expected power from the supply. 37,033.42: 37,036.45: Y-axis motor short. The Y-axis motor is drawing too much power from the supply. Troubleshooting Procedure for Y-axis Motor Step Questions and Actions Remove any obstructions interfering with...
  • Page 118 Power supply +3.3 volt under limit. Power supply +3.3 volt under limit. 37,047.47: Power supply +12 volt over limit. Power supply +12 volt over limit 37,048.48: Power supply +12 volt under limit Power supply +12 volt under limit 3-52 Phaser 8400/8500/8550 Color Printer...
  • Page 119 8400 PEST Description 8500/8550 PEST description 37,049.40: Power supply -12 volt over limit. Power supply -12 volt over limit. 37,050.41: Power supply -12 volt under limit. Power supply -12 volt under limit. 37,051.42: Power supply current over limit. Power supply current over limit. 37,052.43: Power supply current under limit.
  • Page 120 Run the Voltages check test. Go to Step 2. Replace the electronics Did the test pass? module. Check the printhead power cable. Reseat or Replace the replace the wave amp. Is the wiring damaged or not connected? wiring. 3-54 Phaser 8400/8500/8550 Color Printer...

  • Page 121: Jam Codes

    Jam Codes The printer stores the most recent 20 events in Jam History. To access this information for Phaser 8400 printers, press the Up Arrow button when the jam code displays. Then, scroll to Jam History and press OK to display the most recent jam list.
  • Page 122 Z Tray 4 Pick Flag Z Tray 4 Pick Flag Q Pick from Tray 1 R Pick from Duplex S Stage for Transfix T Transfix V Print Drum Maintenance W Imaging X Exit Z Shutdown 3-56 Phaser 8400/8500/8550 Color Printer...

  • Page 123: Jam Code Definition Table

    Jam Code Definition Table Not all jam code combinations are documented in this manual, only the codes that occur most commonly. Note The following table only shows the 3-digit jam code. For Phaser 8500/8550 Printers, an additional 4th digit represents the tray number (5 represents a chase page and 6 represents duplex).
  • Page 124 3. Check the Front Door for obstructions or damage, replace the Front Door if necessary. 4. Test the operation of the exit roller and the duplex roller using diagnostic Duplex Paper Lead Edge Times test. 5. Test the deskew sensor using the diagnostic Sensors test. 3-58 Phaser 8400/8500/8550 Color Printer...
  • Page 125 Jam Code Troubleshooting Procedures (Continued) Preheat exit sensor unexpected state during mechanical recovery. 1. Clear jam and let printer finish mechanical recovery. 2. Ensure ground integrity of the printer, see page 4-77. Preheater exit sensor in unexpected state during fault. Preheater exit sensor in unexpected state during stage.
  • Page 126 The strip flag timed out waiting for the paper picked from Tray 3. The strip flag timed out waiting for the paper picked from Tray 4. The strip flag timed out waiting for the paper picked from Tray 1. 3-60 Phaser 8400/8500/8550 Color Printer...
  • Page 127 Jam Code Troubleshooting Procedures (Continued) Strip flag time-out during transfix. 1. Ensure media is correct size and type for the tray. If envelope jam, try a different style. 2. Check the drum maintenance unit for proper operation, replace if necessary. 3.
  • Page 128 2. Ensure the front door is closed and the wiring is properly connected and seated. 3. Run the Tray 1 sensor test. 4. Inspect the Tray 1 wiring to the I/O board. 5. Replace the I/O board, then retest. 3-62 Phaser 8400/8500/8550 Color Printer...
  • Page 129 Jam Code Troubleshooting Procedures (Continued) The front door open flag unexpectedly tripped while the printer was warming up. The front door open flag unexpectedly tripped while the printer was in a fault state. The front door open flag unexpectedly tripped when the printer pick from Tray 2. The front door open flag unexpectedly tripped when the printer pick from Tray 3.
  • Page 130 Y-Axis motor stalled during an printer warm-up. Y-Axis motor stalled while the printer was in its ready state. Y-Axis motor stalled while the printer was in a fault state. Y-Axis motor stalled while the printer performed an auto drum maintenance cycle. 3-64 Phaser 8400/8500/8550 Color Printer...
  • Page 131 Jam Code Troubleshooting Procedures (Continued) Y-Axis motor stalled while the printer performed printhead maintenance. Y-Axis motor stalled while the printer performed printhead purge. Y-Axis motor stalled while the printer performed an oil transfix roller cycle. Y-Axis motor stalled while the printer was in standby mode. Y-Axis motor stalled while the printer staged for transfix.
  • Page 132 4. Replace the process motor if necessary. 5. Run the Transfix Fast and Slow tests. 6. Replace the transfix camshaft and load arms if necessary. 7. Run the Tilt Drive test, replace if necessary. 8. Replace the process drive gearbox assembly. 3-66 Phaser 8400/8500/8550 Color Printer...
  • Page 133 Jam Code Troubleshooting Procedures (Continued) The exit door open flag unexpectedly tripped while the printer was performing an abnormal shutdown. The exit door open flag unexpectedly tripped while the printer was performing a normal shutdown. The exit door open flag unexpectedly tripped while the printer was performing a mechanical recovery.
  • Page 134 5. Replace the pivot arm. Tray 3 media size sensor unexpectedly activated during warm-up. Tray 3 media size sensor unexpectedly activated during printer ready. Tray 3 media size sensor unexpectedly activated while printer in fault state. 3-68 Phaser 8400/8500/8550 Color Printer...
  • Page 135 Jam Code Troubleshooting Procedures (Continued) Tray 3 media size sensor unexpectedly activated while printer in standby. Tray 3 media size sensor unexpectedly activated while picking from Tray 2. Tray 3 media size sensor unexpectedly activated while picking from Tray 3. Tray 3 media size sensor unexpectedly activated while picking from Tray 4.
  • Page 136 Tray 3 pick flag sensor timed out while transfixing the print. Tray 3 pick flag sensor timed out while the printer drum maintenance cycle was being performed. Tray 3 pick flag sensor timed out while printer imaging. 3-70 Phaser 8400/8500/8550 Color Printer...
  • Page 137 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 138 Tray 4 pick flag sensor timed out while pick from Tray 4. Tray 4 pick flag sensor timed out while pick from Tray 4. Tray 4 pick flag sensor timed out while pick from Tray 1. Tray 4 pick flag sensor timed out while duplexing. 3-72 Phaser 8400/8500/8550 Color Printer...
  • Page 139 Jam Code Troubleshooting Procedures (Continued) Tray 4 pick flag sensor timed out while the printer drum maintenance cycle was being performed. Tray 4 pick flag sensor timed out while printer imaging. Tray 4 pick flag sensor timed out while paper staged for print. Tray 4 pick flag sensor timed out while transfixing the print.

  • Page 141: General Troubleshooting

    General Troubleshooting In this chapter... ■ Service Diagnostics ■ Service Diagnostics Mode Menu ■ Check Menu Definition Tables ■ Electronics Troubleshooting ■ Ensuring Ground Integrity ■ Paper Path and Media-Based Problems ■ Operating System and Application Problems Section...

  • Page 142: Introduction

    Jam History Displays available information regarding the last 20 Jams reported by a test and/or the print engine. Diagnostic History (8500) Displays each diagnostic test performed on the printer. Phaser 8400/8500/8550 Color Printer...
  • Page 143 Menu Item Description Diagnostic History (8500/8550) Displays a list of all recent diagnostic tests. Enter Diagnostic Mode See "Service Diagnostics Mode Menu" on page 4-5 for a complete explanation of each diagnostic routine. Reset NVRAM Provides access to reset the printer back to its factory- default settings and erase all network settings.

  • Page 144: Service Diagnostics

    Before the logo is centered on the display (stops moving), press and hold the Back and Help buttons on the Control Panel. Hold both buttons until the display reads Beginning Service Mode Initialization. Release the buttons and the printer reboots into service mode with the Service Diagnostics menu displayed. Phaser 8400/8500/8550 Color Printer...

  • Page 145: Service Diagnostics Mode Menu

    Service Diagnostic Control Panel Button Descriptions 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 146: Service Diagnostics Menu Map

    Monitors each of the heaters. Shows if the heater is currently enabled (first value) and what percentage of maximum power is currently allocated (second value). Line Voltage Monitors line voltage as seen by the power supply. Reports max and min values. Phaser 8400/8500/8550 Color Printer...
  • Page 147 Menu Map (Continued) Menu Description Control Panel Monitors Control Panel buttons and Buttons reports button presses. Exercise Menu A submenu containing a set of functions for actively causing mechanical actions which may then be observed. Activators Menu Pulses the specified activator to cause it to generate some sound or motion.
  • Page 148 Control Panel button press. Transfix Cam Cycles the motor/shaft repeatedly until Shaft interrupted by a Control Panel button press. Drum Cycles the motor/shaft repeatedly until Maintenance interrupted by a Control Panel button Cam Shaft press. Phaser 8400/8500/8550 Color Printer...
  • Page 149 Menu Map (Continued) Menu Description Deskew Shaft Cycles the motor/shaft repeatedly until interrupted by a Control Panel button press. Wiper Shaft Cycles the motor/shaft repeatedly until interrupted by a Control Panel button press. Tray 1 Pick Shaft Cycles the motor/shaft repeatedly until interrupted by a Control Panel button press.
  • Page 150 Sets the LCD display light. Function Menu A submenu containing a set of functions for commanding more complex actions by portions of the printer mechanism. Initialize Mechanism Performs a simplified version of the power up mechanical initialization sequence. 4-10 Phaser 8400/8500/8550 Color Printer...
  • Page 151 Menu Map (Continued) Menu Description Print DMU Blot Raises the DM unit up against the drum, then does a Chase sequence. The result is an oil print of the contact of the DM unit with the drum (about 2/3 of the way down the page). Display Fault History A function that displays the current contents of the Fault History NVRAM...

  • Page 152: Check Menu Definition Tables

    To access the Check Menus enter Service Diagnostics and go to Check Menu --> Check Activators Menu. Check All selection will run all check tests, taking 1.5 hours to complete and is not for use by field technicians. 4-12 Phaser 8400/8500/8550 Color Printer...

  • Page 153: Check / Activators Menu

    Check / Activators Menu Head Maintenance Clutch Gathers data on the performance of the head maintenance clutch coil. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Peak Power (watts) 3.0 to 5.9 3.2 to 6.3 Reports the profile max power value.
  • Page 154 Peak Power (watts) 8.0 to 15 22 to 27 Reports the profile max power value. Average Power 8.0 to 15 20.0 to 30.0 Reports the average power (watts) during the constant portion of the profile. 4-14 Phaser 8400/8500/8550 Color Printer...

  • Page 155: Drum Heater Relay

    Purge Vent Solenoid Gathers data on the performance of the purge vent solenoid coil. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Peak Power (watts) 0.5 to 1.2 -.12 to Reports the profile max power value. Average Power 0.4 to 1.2 .15 to 1.2 Reports the average power (watts)
  • Page 156 Definition 8550) Actions 110 V Coil Peak Reports time after solenoid Power Time (sec) power on that the peak power occurred. 110 V Coil Initial Reports the average power Average Power following power on. (watts) 4-16 Phaser 8400/8500/8550 Color Printer...

  • Page 157: Check Shafts Menu

    Check Shafts Menu Deskew Shaft Runs the media path drive train and engages the deskew clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc. Typical Typical Value...
  • Page 158 (such as paper dust increasing the effective diameter of a roller). 4-18 Phaser 8400/8500/8550 Color Printer...
  • Page 159 Deskew Shaft (Continued) Runs the media path drive train and engages the deskew clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc. Typical Typical Value Value...

  • Page 160: Check Paper Path Menu

    Reports the variation of effort needed to rotate the wiper shaft in the CCW direction at a constant velocity. A larger value could indicate particles in the gears or non uniform contamination of a roller (causing a lump). 4-20 Phaser 8400/8500/8550 Color Printer...
  • Page 161 Wiper Shaft (Continued) Runs the media path drive train and engages the head maintenance clutch on the fly then disengages the clutch. The test is repeated in both directions to determine clutch characteristics, steady state drive requirements, bearing status, etc. Typical Typical Value...
  • Page 162 (missing teeth, etc.). 4-22 Phaser 8400/8500/8550 Color Printer...
  • Page 163 Tray 1 Pick Shaft (Continued) Runs the media path drive train and engages the tray 1 pick solenoid on the fly. The pick shaft goes through two full revolutions while drive requirements are determined. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions...
  • Page 164 Reports the time it takes the MP (sec). motor servo system to "settle down" after the sudden release of the Tray 2 pick shaft load. A larger value could indicate a dragging or slow to release clutch. 4-24 Phaser 8400/8500/8550 Color Printer...
  • Page 165 Tray 2, Tray 3, and Tray 4 Pick Shaft (Continued) Test is the same for each pick shaft although for tray 2 the media path motor is used and for the 525-sheet feeders the corresponding pick/transport motor is used. Test determines if the shaft can be driven by the clutch, if the nudger rollers are being driven, and the pick pad/nudger roller friction.
  • Page 166 3 pick process until the Tray 3 Pick sensor activates. Tray 3 Transport Reports the interval from the Tray Interval (us) 3 Pick sensor activation until the Deskew sensor activates. Tray 2 Pick Unused Unused 4-26 Phaser 8400/8500/8550 Color Printer...
  • Page 167 Paper Lead Edge Times (Continued) Paper is picked and moved through either simplex or duplex paper path to determine leading edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Typical Value...
  • Page 168 Tray 3 Pick Trailing Reports the interval from the time Edge Interval (us) the engine software is commanded to start the tray 3 pick process until the Tray 3 Pick sensor deactivates. Tray 2 Pick Unused 4-28 Phaser 8400/8500/8550 Color Printer...
  • Page 169 Paper Trail Edge Times (Continued) Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Typical Value...
  • Page 170 Tray 2 Pick unused unused Tray 1 Pick unused unused Common Deskew Bounce Reports the interval during which Interval (us) the Deskew sensor bounces following the passage of the paper trailing edge. 4-30 Phaser 8400/8500/8550 Color Printer...
  • Page 171 Paper Sensor Bounce Times (Continued) Paper is picked and moved through either the simplex paper path to determine the paper trailing edge bounce interval at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Typical Value...
  • Page 172 Exit sensor activates (part way through the paper transfix motion). Duplex Exited Reports the interval from the time Interval (us) the engine software is commanded to start the exit process until the Exit sensor deactivates. 4-32 Phaser 8400/8500/8550 Color Printer...
  • Page 173 Duplex Paper Trail Edge Times Paper is picked and moved through either the simplex or duplex paper path to determine the paper trailing edge arrival time at each paper path sensor. R values have alternate definitions or are unused depending on the pick tray and if simplex or duplex path was selected. Typical Typical Value...
  • Page 174 Interval (us) the Strip sensor bounces following the passage of the paper trailing Duplex Exit Bounce Reports the interval during which Interval (us) the Exit sensor bounces following the passage of the paper trailing edge. 4-34 Phaser 8400/8500/8550 Color Printer...

  • Page 175: Check Drive Menu

    Check Drive Menu Wiper Drive 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. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Up Motion Drive 120 to...
  • Page 176 Swing Arm .03 to .06 Reports the time that the lower Transition Time (sec) portion of the paper path drive is disconnected while the swing arm transitions to the other drive position. 4-36 Phaser 8400/8500/8550 Color Printer...
  • Page 177 X-Axis Drive This test drives the X-Axis motor in each directions until the printhead stalls into the stops and then moves the printhead into the clear and performs an on the fly reversal. The power profile is used to confirm operational goals. Typical Typical Value...
  • Page 178 Roll With Transfix Roller Down interval (mpts) Time to last .300 to 0.30 to Reports the time from the unload contact (sec) 0.450 0.80 command to the engine until the drum indicates no further contact. 4-38 Phaser 8400/8500/8550 Color Printer...
  • Page 179 Drum Maintenance Drive With the Y-axis rotating, the drum maintenance unit is loaded against the drum for a short time in each configuration (roller and blade/blade only) Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Time to blade first .01 to .35 .15 to .4 Reports the time from the load...
  • Page 180 Should be in degrees, but currently units/scaling are unverified. Post Wipe peak -4000 to -130 to Reports the pm motor following Magnitude (pm ticks) error at the post wipe peak location. 4-40 Phaser 8400/8500/8550 Color Printer...
  • Page 181 Tray 2, Tray 3, Tray 4, Lift Plate Drive This test raises the lift plate to verify motion and sensor operation. If the test is requested for a 525-sheet feeder that is not installed, an “Option Not Detected” message is generated. Typical Typical Value...

  • Page 182: Check Drum Menu

    450000 to 200000 min Cosine Sum average units) amplitude values. Cosine Sum Data 300000 to 300000 to Reports difference between the Amplitude (cosine 500000 500000 max and min Cosine Sum sum units) average amplitude values. 4-42 Phaser 8400/8500/8550 Color Printer...

  • Page 183: Y-Axis Geometry

    Y-axis Geometry Rotates the drum at a constant velocity and samples the Y-axis position. Uses the data to determine Y-axis motor and drum vibration and the most significant other vibrational frequencies. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Drum Normalized -3900 to Reports the normalized FFT...

  • Page 184: Y-Axis Drive

    HAHVN Delta Print 0.02 to 0 to .11 Reports the time following the Velocity Settle Time 0.10 start of motion that it takes the Y- (sec) axis delta velocity to enter the CCW delta velocity ripple band. 4-44 Phaser 8400/8500/8550 Color Printer...
  • Page 185 Y-axis Belt Slip This test does a chase using a special sheet of preprinted media and records the y-axis following error. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Initial Peak Y-axis 0 to 1200 to Reports the amplitude of the first FE (mpts) 12000 8000...
  • Page 186 R0. Engaging Amplitude 3 to 18 5.0 to 35 Reports the magnitude of the (mpts) reaction of the drum to the contact of the blade. (See R2) 4-46 Phaser 8400/8500/8550 Color Printer...
  • Page 187 Stripper Contact (Continued) This test holds the drum stationary while the stripper solenoid is activated and released. The drum servo error signal illustrates activation/deactivation timing and how strongly the drum was contacted by the blade. Typical Typical Value Value (8400) (8500/ Definition 8550)

  • Page 188: Check Motors Menu

    Ripple (volts). the motor phase A drive voltage over the recording interval. Motor Voltage A -0.120 to .10 to .05 Reports the motor phase A drive Average (volts) 0.13 voltage average value over the recording interval. 4-48 Phaser 8400/8500/8550 Color Printer...
  • Page 189 X-Axis Motor This test turns on the X-axis motor and runs it very slowly for one revolution. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Motor Voltage B 84 to 86 59 to 62 Reports amount of variation of Ripple (volts) the motor phase B drive voltage over the recording interval.

  • Page 190: Media Path Motor

    Reports amount of variation of ripple (watts) the motor drive power over the recording interval. Motor drive power 1.9 to 7 2 to 8 Reports the motor drive power average (watts) average value of the recording interval. 4-50 Phaser 8400/8500/8550 Color Printer...
  • Page 191 Tray 2, Tray 3, Tray 4, Lift Motor his 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 a 525-sheet feeder that is not installed will generate an “Option Not Detected”...
  • Page 192 525-sheet feeder that is not installed will generate an “Option Not Detected” message. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Motor drive power Reports motor drive power average (watts) average value over the recording interval. 4-52 Phaser 8400/8500/8550 Color Printer...

  • Page 193: Check Misc Menu

    Check Misc Menu Paper Path Status 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; R3 = tray 3; and R4 = tray 4. The display is a string of 0’s and 1’s (one digit for each sensor state) and is listed below from most significant bit to least significant bit.
  • Page 194 ~134 ~138 Preheater Temp Reports the current temperature Drum Temp Reports the current temperature Ink Melt 1 Temp Yellow (usually off) Ink Melt 2 Temp Cyan (usually off) Ink Melt 3 Temp Magenta (usually off) 4-54 Phaser 8400/8500/8550 Color Printer...
  • Page 195 Temperature Status (Continued) This test scans the thermocouples and reports data on the current temperature with the goal of providing a picture of the current temperature state of the printer. All degrees are reported in celsius. Typical Typical Value Value (8400) (8500/ Definition...
  • Page 196 (plugged, etc.). Voltages This test determines averaged readings for key system voltages. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions Main Board Voltages 5 Volts (volts) 1.8 Volts (volts) ~1.8V ~1.8V 4-56 Phaser 8400/8500/8550 Color Printer...
  • Page 197 Voltages (Continued) This test determines averaged readings for key system voltages. Typical Typical Value Value (8400) (8500/ Definition 8550) Actions 2.5 Volts (volts) ~2.5V ~2.5V 3.3 Volts (volts) +/-2.5% +/-2.5% unregulated12 Volts +/- 20% +/- 20% (volts) 2.5 Volts (volts) ~ 2.5 ~ 2.5 unregulated...

  • Page 198: Drum Maint/Transfix Home

    Reports the height of the initial (pm motor counts) peak when starting rotation of the tf drive gear. TF Initial FE Peak Reports the time since the start Time (sec) of CW motion until the peak was detected. 4-58 Phaser 8400/8500/8550 Color Printer...

  • Page 199: Electronics Troubleshooting

    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. If the test detects an error, the error message displays on the LCD and the printer flashes the LEDs with a repeating error code pattern.

  • Page 200: Mechanical Initialization (8400)

    Mechanical Initialization (8400) 4-60 Phaser 8400/8500/8550 Color Printer...
  • Page 201 General Troubleshooting 4-61...

  • Page 202: Mechanical Initialization (8500/8550)

    Mechanical Initialization (8500/8550) 4-62 Phaser 8400/8500/8550 Color Printer...
  • Page 203 General Troubleshooting 4-63...
  • Page 204 A cleaning page is printed at this time, if a purge was performed. A start page is printed (if enabled). The Control Panel displays a message that the printer is initializing and then ready. The print engine is initialized and is ready to print. 4-64 Phaser 8400/8500/8550 Color Printer...

  • Page 205: Miscellaneous Electrical Troubleshooting

    Miscellaneous Electrical Troubleshooting The electronics module contains the Power Supply, Image Processor board and the Power Control board. If a component of the electronics module fails, and service is necessary, the entire electronics module is replaced as a unit. No individual board troubleshooting is required.
  • Page 206 Damage to circuits within the electronics module may occur if the power supply capacitors are not allowed to fully. Unplug the Control Panel connector (J220) on the I/O board. This removes the Control Panel from the I/O board. 4-66 Phaser 8400/8500/8550 Color Printer...
  • Page 207 Plug in the Power Control to I/O board connector (J800). This step adds the I/O board back to the working electronics module - nothing else is connected. Turn on power to the printer If the PE and PS indicators do not flash momentarily, the short is on the I/O board or related cabling.
  • Page 208 Plug in all cables removed during service. Trace through all service steps performed to reattach any cables that were unplugged during debugging. Attach printer covers. Perform full test of printer. 4-68 Phaser 8400/8500/8550 Color Printer...
  • Page 209 Printer Is On and Can Print Pages, but the Control Panel Appears Frozen and No Error Messages Are Displayed Note Opening and closing the front door of the printer causes a reset of the entire Control Panel. Electrostatic Discharge. If the printer is currently powered on and frozen, open then close the front door of the printer and see if the LCD responds.
  • Page 210 Cycle power to ensure printer initializes during stable AC power. Internal fault Record any error codes and report to Xerox Office Group. If the printer detects an error, the printer will attempt to 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 211 Printer Fails to Enter E Mode NERGY Model not certified as an model. ENERGY STAR Use the Control Panel to enable Energy Star mode (Printer Setup -> Printer Control -> Select Power Saver Timeout). Some printers are not shipped as energy star compliant and don't have the power saving mode enabled by default.
  • Page 212 If the PS and PE indicators are blinking, brightly-on, or totally off, continue debugging. A dim but steady on condition indicates some firmware was not properly loaded into a logic circuit. 4-72 Phaser 8400/8500/8550 Color Printer...
  • Page 213 With power cord connected, touch the metal electronics module to discharge any static electricity. Turn off printer and wait 30 seconds for power supply capacitors to discharge. Unplug power cord and remove printer's covers. Unplug the following electronics module connectors: ■...
  • Page 214 Print it is now possible to print any built-in pages. If the printer prints the Page, the print engine is working correctly. If the printer does not print the Page, then a problem exists with the print engine. 4-74 Phaser 8400/8500/8550 Color Printer...

  • Page 215: Verifying Power Supply Operation

    Verifying Power Supply Operation Required Tools ■ TORX T-20 screwdriver ■ Digital Multi-Meter (DMM) The power supply is divided into two sections: the AC section used for heaters and the DC section for control logic, printhead drivers, and motors. Verifying the power supply involves three steps: Checking for proper AC voltage.

  • Page 216: Measuring Dc Power Supply Voltages

    Note DC voltage test points can be found on the power control board. When you remove the rear access cover, you will see the test points below the RAM DIMM’s on the power control board. 4-76 Phaser 8400/8500/8550 Color Printer...

  • Page 217: Ensuring Ground Integrity

    Ensuring Ground Integrity Intermittent or missing ground connections can result in minor interferences in the printer. As examples: ■ Control Panel display can be affected (blank) ■ I/O board errors ■ False jam reporting ■ Erroneous thermistor readings ■ Major interruptions ■...

  • Page 218: Testing Motor And Solenoid Resistances

    X-axis motor 12.5 ohms/phase (red-to-yellow and blue-to-orange) Media path motor 1.5 +/- 20% ohms Wiper drive clutch 186 ohms +/- 15% Paper-pick clutch 186 ohms +/- 15% Deskew clutch MPT Pick solenoid 124 ohms +/- 5% 4-78 Phaser 8400/8500/8550 Color Printer...

  • Page 219: Paper Path And Media-Based Problems

    Paper Path and Media-Based Problems For paper path and media-based problems, first check the displayed error codes using the Error Code Definition Table beginning on page 3-9 to help determine where the error is occurring. Run paper path diagnostics to help eliminate problems with printer components.

  • Page 220: Paper-Pick Errors - Tray 1

    Check the stripper blade for damage, replace the stripper carriage if necessary. Check for ink shards on top of the preheater next to the flag (see page 8-23). 4-80 Phaser 8400/8500/8550 Color Printer...

  • Page 221: Checking The Process And Media Path Drive

    Checking the Process and Media Path Drive Determine if the process motor runs. If it does not rotate, go to Step 2. If it does rotate, go to Step 4. Measure to determine if +50 VDC is being supplied to the motor. If power is applied, go to Step 3.

  • Page 222: Operating System And Application Problems

    On the Control Panel, print the Configuration Page and use this page to verify that TCP/IP is enabled and to determine the current TCP/IP values. Note To enable communication between the computer and printer, both must be configured for the same TCP/IP network. 4-82 Phaser 8400/8500/8550 Color Printer...
  • Page 223 “LOCAL LINK” value within the 169.254.xxx.xxx range. Note To comply with industry standards, Phaser 8400 printers cannot be manually configured for IP addresses within the LOCAL LINK range. Note Always print the Configuration Page to obtain a record of the printer settings before changing the IP address.

  • Page 224: Network Problems

    To test the connection, click the START button. Select SETTINGS and then PRINTERS. Locate the Phaser 8400/8500/8550 Color Printer icon and display its properties. From the General tab, click the Print Test Page button to generate the test print. If the test page prints, the USB port is functioning normally.

  • Page 225: Obtaining Serial Back Channel Trace

    Highlight the appropriate menu item from the list and select OK. Note Phaser 8500/8550 printers use a diagnostic tool for network connections. It Troubleshooting>Network is available using the menu path Problems>Network >Diagnostics. To troubleshoot network problems, you can select the standard Network Log Pages or the new Network Diagnostics.
  • Page 226 COM1: is correct. Turn on the printer. The trace should appear in the terminal dialog window. Examine the trace to troubleshoot the problem. If necessary, save the trace file to capture the text. 4-86 Phaser 8400/8500/8550 Color Printer...

  • Page 227: Print-Quality Troubleshooting

    Print-Quality Troubleshooting In this chapter... ■ Print-Quality Problems Overview ■ Analyzing Service Test Prints Section...

  • Page 228: Print-Quality Problems Overview

    The paper should be from an unopened ream that has been acclimated to room temperature. See the approved media list from, "Xerox Supplies" on page 9-16 for media that has been tested and approved for use in this printer. If the print-quality defect is still present when printing on approved media from an unopened ream of paper, then media, software applications, and environmental conditions need to be researched.

  • Page 229: Random Light Stripes

    Random Light Stripes One or more color bars are missing on the test page. Light Stripes Test This is probably caused by a weak or clogged printhead jet. Step Questions and Actions On the Control Panel, select the Eliminate Complete. Go to Step 3.
  • Page 230 The Advanced cleaning process is similar to the process associated with downloading the “Jet Fix” snippet to Phaser 8400 printers. However, a snippet is not required for Phaser 8500/8550 printers because the feature is embedded in the printer’s firmware.

  • Page 231: Predominate Light Stripes

    Predominate Light Stripes All four color bars are missing on the test page. A thin stripe with no colon is likely due to foreign debris scratching ink off the drum or the print. Note If there are a series of regularly spaced white lines approximately 6 mm (.25 in.) apart see “White Stripes...

  • Page 232: Smudges Or Smears

    Did this correct the problem? Verify the maintenance pivot plate is free Complete. Replace the from damage. preheater. Verify the cam rollers for the drum maintenance are working properly. Replace any defective parts. Did this correct the problem? Phaser 8400/8500/8550 Color Printer...

  • Page 233: Printing Too Light Or Too Dark

    Printing Too Light or Too Dark Step Questions and Actions Verify the paper type at the Control Panel Complete. Go to Step 2. matches the paper type in the driver and in the software application being used, especially if printing on transparency. Verify the paper type is a supported media type for this printer.
  • Page 234 Questions and Actions Inspect and reseat the wave amp and data Complete. Replace in the cables connecting to the printhead. following order: Replace or repair any defective cables. ■ electronics module Did this correct the problem? ■ printhead Phaser 8400/8500/8550 Color Printer...

  • Page 235: Color Is Uneven Or Color Is Wrong

    This may be due to incorrect colors in the ink loader, old ink in the printhead, color mixing at the faceplate, or drum thermal problems. Note Using non-Xerox ink may cause unpredictable color results. s8500-034 Step Questions and Actions To remove discolored jets in the printhead, Complete.
  • Page 236 Verify the drum temperature sensor is in Complete. Replace in the contact with the drum. following order: Clean or replace the drum temperature ■ Drum heater relay board sensor. ■ Drum Did this correct the problem? assembly ■ Electronics module 5-10 Phaser 8400/8500/8550 Color Printer...

  • Page 237: 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. s8500-035 Step Questions and Actions Check for and remove any media, jammed Complete. Go to Step 2. paper, or debris found in the printers exit path.
  • Page 238 Run the service diagnostics Duplex Path test to check the paper preheater’s temperature. Is the operating temperature within the correct value range? 5-12 Phaser 8400/8500/8550 Color Printer...

  • Page 239: 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 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 240 Be careful of the paper-sensor flags. Did this correct the problem? Inspect all paper guides inside the printer for Clean or replace any defective nicks, cuts, or debris. paper guide(s). 5-14 Phaser 8400/8500/8550 Color Printer...

  • Page 241: White Portion Of Print Is Colored

    White Portion of Print is Colored Color on a print where no color should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. An insufficient amount of oil on the drum, provided by a dirty, defective, or old maintenance kit may be the problem.
  • Page 242 Inspect the feed rollers. An accumulation of Complete. paper dust and oil can produce dark rectangular marks on transparency film. Run the Remove Print Smears from the printer’s Control Panel. Replace the rollers if necessary. Did this correct the problem? 5-16 Phaser 8400/8500/8550 Color Printer...

  • Page 243: Fuzzy Text

    Fuzzy Text Text appears indistinct and difficult to read. There are three typical reasons for fuzzy text, as called out in this illustration. 1.Top left image displays a Y-axis drum rotation problem. 2.Lower left image displays the wrong drum temperature problem. 3.Lower right image displays an X- axis movement problem.
  • Page 244 See "White Stripes (Pinstripes)" on page 5-30 for troubleshooting this problem. Did this correct the problem? Verify the printhead is tilted forward against Complete. the drum in the proper print position. Did this correct the problem? 5-18 Phaser 8400/8500/8550 Color Printer...

  • Page 245: Poor Primary Color Fills

    Poor Primary Color Fills Primary fills appear banded and inconsistent. s8500-039 Step Questions and Actions Banded and inconsistent primary fills may Complete. Go to Step 2. indicate a missing, weak, or discolored jet. Print the Service Test Print 1: Weak/Missing Jet.

  • Page 246: Ghosting

    Does this correct the problem? Inspect and clean the maintenance kit wiper Complete. Go to Step 4. blade. If necessary, replace the maintenance kit. Did this correct the problem? 5-20 Phaser 8400/8500/8550 Color Printer...
  • Page 247 Step Questions and Actions Run service diagnostics to verify the drum Complete. Go to Step 5. maintenance system is operating correctly. Inspect or replace the following parts, check for cracking: ■ Drum maintenance pivot plate Drum maintenance cam shaft ■ Did this correct the problem? Run service diagnostics to check the Complete.

  • Page 248: Poor Small Text Resolution

    Did this correct the problem? Verify the X-axis drive system is correctly Complete. Replace the assembled and lubricated, see "X-Axis x-axis motor Motor Assembly" on page 8-53 for more assembly. information. Did this correct the problem? 5-22 Phaser 8400/8500/8550 Color Printer...

  • Page 249: Vertical Lines Appear Wavy

    Vertical Lines Appear Wavy Straight vertical lines appear to be wavy and ill-formed. s8500-041 Step Questions and Actions There may be too much oil on the drum. Complete. Go to Step 2. Inspect and clean the maintenance kit wiper blade. If necessary, replace the maintenance kit.

  • Page 250: Oil Streaks On Print

    Remove Print Smears routine from the printer’s Control Panel. Did this correct the problem? Clean the paper release blade and the exit Complete. Go to Step 5. guides. Did this correct the problem? 5-24 Phaser 8400/8500/8550 Color Printer...
  • Page 251 Step Questions and Actions Use service diagnostics to verify the drum Complete. Replace the maintenance cam roller and pivot plate are pivot plate or operating correctly. drum maintenance Did this correct the problem? cam roller if damaged. Print-Quality Troubleshooting 5-25...

  • Page 252: Incomplete Image Transfer To Paper

    Inspect for cracked pivot plate or cracked drum maintenance cams. Did this correct the problem? Inspect and clean the maintenance kit wiper Complete. Go to Step 6. blade. If necessary, replace the maintenance kit. Did this correct the problem? 5-26 Phaser 8400/8500/8550 Color Printer...
  • Page 253 Step Questions and Actions Inspect the drum temperature sensor and Complete. Go to Step 7. check for contamination and improper positioning between the sensor and the drum surface. Clean and position the sensor as necessary Did this correct the problem? Is the incomplete image transfer on the left Complete.

  • Page 254: Ink Smears On First Printed Side Of Duplex Print

    Control Panel. Did this correct the problem? Use service diagnostics to check the paper Replace in the following order: preheater temperature. ■ preheater Is the preheater operating within normal ■ electronics module range? 5-28 Phaser 8400/8500/8550 Color Printer...

  • Page 255: 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. Transfix Roller defects show up as light spots in solid fill areas. s8500-045 Step Questions and Actions Repeating defects that occur every 11.6 cm Complete.

  • Page 256: White Stripes (Pinstripes)

    Verify there are no wiring harnesses Complete. Replace the interfering with the horizontal movement of X-axis drive. the printhead. Redress any faulty wiring. Repair or replace any defective part or interference with the printhead. Did this correct the problem? 5-30 Phaser 8400/8500/8550 Color Printer...

  • Page 257: Wrinkling

    Wrinkling The print is usually damaged in a corner with solid fills. This problem is more often seen on short-grain media. Some wrinkling on envelopes flaps is an acceptable limitation of this printer. You may see wrinkling on the second side of a 2-sided print on the secondary colors.

  • Page 258: 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 259: Analyzing Service Test Prints

    This section shows how to select and analyze all test prints available to the Phaser 8400 printer. To access the Service Tools menu: From anywhere within the menu (not diagnostics), press and hold the Up Arrow button, and then press the OK button.
  • Page 260 This is a text print This is a text print This is a text print This is a text print Xerox Photo Paper. Using a lower grade paper This is a text print < current setpoint This is a text print...

  • Page 261: Reverse Text

    Test Print Examples (Continued) Reverse Text 10 point Times-Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890 The print indicates if the printhead is producing 8 point Times-Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890!@#$%^&* 6 point Times-Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890!@#$%^&* properly-sized drops of ink and that the drum 5 point Times-Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890!@#$%^&* 4 point Times-Roman ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz1234567890!@#$%^&* temperature is not too high.

  • Page 262: Big Bands Ohp

    Clean or replace the paper release blade. For more information about scratches, see "Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Film" on page 5-13. s8500-052 5-36 Phaser 8400/8500/8550 Color Printer...
  • Page 263 Test Print Examples (Continued) Gray Fill, Dot Size Uniformity This print is made up of a 66% black fill. It reveals variations in the ink-drop-spread Light band Light band caused by thermal variations, transfix roller pressure variations, or drum oiling variations. Look for: 1.

  • Page 264: Ymckrgb Solid Fills

    As a last resort to fix wrinkling, replace the transfix roller, transfix load module, and transfix load arm. Drum Seal (8400 only) This print is not supported for this printer. Manuf. Paper Path These prints are used by Manufacturing and Engineering. 5-38 Phaser 8400/8500/8550 Color Printer...
  • Page 265 Test Print Examples (Continued) Head-to-Drum Gap (8400 only) These prints indicate if the gap between the printhead and the drum is correct. Lines: The horizontal lines of the print are made up of long and short dashes. Inspect the first and last 1/2 in. (12 mm) of the black lines EFGHIJKLMNOPQ for the vertical distance between the short EFGHIJKLMNOP...

  • Page 266: Ohp Color Bands

    4. If there are repeating white stripes on the print, there may be a problem with the X-Axis motion, see“White Stripes (Pinstripes)” on page 30. OHP Color Bands (8400 only) This print is used by Manufacturing and Engineering. 5-40 Phaser 8400/8500/8550 Color Printer...

  • Page 267: Primary Solid Fills 10X

    Test Print Examples (Continued) Primary Solid Fills 10x This item enables you to print 10 cyan solid fill prints, 10 magenta solid fill prints, 10 yellow solid fill prints, or 10 black solid fill prints. These prints can be used to determine if the drum or transfix roller have a defect.
  • Page 268 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. 5-42 Phaser 8400/8500/8550 Color Printer...
  • Page 269 Test Print Examples (Continued) Manuf. Banding (8400 only) This print is used by Manufacturing. Head Roll (8400 only) This print is used by Manufacturing. Head Height (8400 only) This print is used by Manufacturing and Engineering. X Dot Position (8400 only) This print is used by Manufacturing and Engineering.

  • Page 270: Cleaning Page

    Cleaning Page This page is automatically printed following a purge. It is used to flush the jet nozzles of any possible contamination or color mixed jets. It can also be printed on its own. s8500-058 s8400-162 5-44 Phaser 8400/8500/8550 Color Printer...

  • Page 271: Adjustments And Calibrations

    Adjustments and Calibrations In this chapter... ■ Printer Component Homing Positions and Indicators ■ Printer Calibrations ■ Jet Substitution Mode Section...

  • Page 272: Adjustments

    Remove the printer covers using the procedures that begin on page 8-4. Remove the left head maintenance drive gear (see the following figure) by removing the e-clip from the drive shaft. Left Idler Gear Left Drive Gear s8500-059 Phaser 8400/8500/8550 Color Printer...
  • Page 273 At the same time, rotate the left and right idler gears until the wiper is all the way to the bottom and the gears cannot be rotated further. Rotating the left and right gears together ensures that the wiper stays parallel and does not pop out of the belts.

  • Page 274: Printer Component Homing Positions And Indicators

    When the wiper is homed, the wiper should be moved all the way to the bottom of the printer. When the wiper is at the bottom, you can easily remove the waste tray. See the "Wiper Alignment Procedure" on page 6-2. Phaser 8400/8500/8550 Color Printer...

  • Page 275: Homing The Head Tilt Gear

    Homing the Head Tilt Gear The Printhead Is Not in the Printer If the printhead is not in the printer, move the tilt gear, located on the inside of the left frame, manually to its disengaged position. Drum Printhead Tilt gear (disengaged) DM Cam Gear Tilt Gear s8500-061...
  • Page 276 If the printhead is engaged, manually assist the movement of the printhead. Note The hole on the drum maintenance camshaft drive gear should be at the 6:00 position after the rotation. Insert screwdriver and rotate clockwise. Drum maintenance camshaft gear s8500-062 Phaser 8400/8500/8550 Color Printer...
  • Page 277 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 Adjustments and Calibrations...

  • Page 278: Homing The Process Gear Drive Train

    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. ■ The hole in the transfix camshaft gear align with the hole on the frame. Phaser 8400/8500/8550 Color Printer...

  • Page 279: Drum Maintenance

    When installing or homing the Process Gear Train, ensure the pivot plate is fully engaged to the drum maintenance cams by pushing the Drum Maintenance Holes in process Unit to the left. drive frame aligns with holes in gears Hole in gear aligns with arrow on Hole in gear...

  • Page 280: Printer Calibrations

    See the Wiper Alignment Procedure on page 6-2. Jet Substitution Mode On Phaser 8400 printers, the Jet Substitution Mode provides a temporary solution for print-quality problems when weak or missing jets cannot be recovered. When Jet Substitution Mode is active, adjacent jets are used to print over the area covered by the problem jet to restore the print-quality.

  • Page 281: Enabling Jet Substitution Mode (8400)

    Enabling Jet Substitution Mode (8400) To add Jet Substitution Mode to the Control Panel menu: Troubleshooting, On the Control Panel, scroll to then press the OK button. Scroll to Print Quality Problems, then press the OK button. Press and hold the Up Arrow button, then press the Back button. The Jet Substitution Mode is now displayed on the Control Panel.

  • Page 282: Disabling Jet Substitution Mode (8400)

    The print counts and the Adobe firmware serial number are not affected by this reset. You can reset the PostScript NVRAM using the Service Tools Menu or the Service Diagnostics Menu. 6-12 Phaser 8400/8500/8550 Color Printer...

  • Page 283: Cleaning And Maintenance

    Cleaning and Maintenance In this chapter... ■ Maintenance ■ Inspection ■ Cleaning Section...

  • Page 284: Service Cleaning Maintenance Procedure

    Never use water to clean the printer’s internal components. Clean dust build-up on the exterior of the printer. Inspect the grills on the exterior of the printer for dust. Clean if necessary Phaser 8400/8500/8550 Color Printer...

  • Page 285: Media Jams

    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...

  • Page 286: Pick Roller Cleaning Method

    With a dry swab, clean any buildup around the drum temperature sensor. You can access the sensor through the opened exit cover. Also, make sure the sensor rides evenly on the drum surface. You can remove the sensor, if necessary, to clean under it. Phaser 8400/8500/8550 Color Printer...

  • Page 287: Maintenance

    The waste tray collects ink that has been purged from the printer’s ink jets. A Control Panel message indicates when the waste tray is full. Refer to the printer’s Phaser 8400 Reference Guide or the Phaser 8500/8550 User’s Guide for instructions on removing and emptying the waste tray.

  • Page 288: Lubrication

    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. Phaser 8400/8500/8550 Color Printer...

  • Page 289: Service Parts Disassembly

    Service Parts Disassembly In this chapter... ■ Overview ■ General Notes on Disassembly ■ Covers ■ Imaging ■ Paper Path ■ Motors, Gears, Solenoids, Clutches, and Fans ■ Electronics Section...

  • Page 290: Overview

    When needed the orientation of the printer is called out in the procedure for locating printer parts. Refer to the printer orientation graphic for locating the right, left, front and back sides of the printer. Back Left Right Front s8500-002 Phaser 8400/8500/8550 Color Printer...

  • Page 291: General Notes On Disassembly

    General Notes on Disassembly Caution Follow the steps of all disassembly procedures in the order given to avoid damaging printer components. Before servicing the printer, switch OFF the printer power, wait until the printer completely shuts down, and disconnect the power cord from the wall outlet. Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards.

  • Page 292: Covers

    1. Front Door, Tray 1 (MPT) 6. Exit Cover 2. Control Panel Cover 7. Ink Loader Assembly and Door 3. Control Panel 8. Interface Cover 4. Right Side Cover 9. Side Door 5. Left Side Cover Phaser 8400/8500/8550 Color Printer...

  • Page 293: Front Door (Tray 1) Assembly

    Front Door (Tray 1) Assembly (PL 1.1) Open the Front Door assembly (Tray 1) by pulling out on the handle to the right side of the door. s8500-065 Remove the right and left stay retainers from the Front Door (MPT). Open the plug cover and disconnect the plug from the right side of Front Door (Tray1/MPT).

  • Page 294: Control Panel Cover

    Pull forward on the latching tab located by the power plug (see Covers figure on page 8-4) to release it. Release the front latching tab and pull out on the top to remove the Right Side Cover. Phaser 8400/8500/8550 Color Printer...

  • Page 295: Left Side Cover

    Left Side Cover (PL 1.9) Remove the Control Panel Cover. Open the Exit Cover and Front Door. Remove the rear screw. Release the latching tabs (see Covers figure on page 8-4) and remove the Left Side Cover. Exit Cover (PL 1.7) Remove the Right and Left Side Covers.

  • Page 296: Ink Loader Assembly And Door

    Lift the Ink Loader Assembly clear of the chassis and hold it in position against the rear of the chassis to allow access to the connectors. For Phaser 8400 printers, the Ink Loader disconnects from the printer frame. For Phaser 8500/ 8550 printers, the wiring harness that plugs into the right side frame disconnects directly from the Ink Loader.

  • Page 297: Imaging

    Replacement Note: Note For the Phaser 8400, the gray cable from the side chassis must be routed between the Ink Loader and the printer side. The cable from the ink loader must be routed towards the left side (see inset). For the Phaser 8500/8550, the cable comes from the side of the chassis and plugs directly into the inkloader.
  • Page 298 The three screws securing the arm to the motor remain in place. 20 in-lbs. Y-Axis Motor Assembly s8500-071 If replacing the motor, remove 3 motor screws to separate the motor from the arm and remove the spring arm. 8-10 Phaser 8400/8500/8550 Color Printer...

  • Page 299: Replacement Notes

    Replacement Notes: Note Ensure the spring arm screws are in the right locations and that the arm floats freely. Also, torque the screws connecting the spring arm to the motor to 20 in.-lbs. Caution Ensure that the ground lug is replaced on the mounting screw (see figure above) during replacement.

  • Page 300: Printhead Assembly, Right And Left Printhead Restraints

    Printhead Assembly, Right and Left Printhead Restraints (PL 2.4) (PL 2.5 and 2.6) Videos are available with instructions for replacing the printhead assembly. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Printhead Procedures. Warning The printhead is hot when the printer is operating.
  • Page 301 Rotate the gears as shown by #2 above to lower the wiper all the way down. Caution To prevent damage to the ink jets, be careful not to place your fingers on the faceplate of the printhead. While pulling back slightly on the printhead to keep it away from the drum surface, unlock (push down) the right and left printhead restraint arms, #3 above, then slowly allow the spring-loaded printhead to tilt forward.
  • Page 302 Adjust printhead position as required to remove the right restraint. Remove the Roll Block on the left end of the printhead shaft. Caution The roll block may be hot if the printer was just shut down. Printhead Shaft Roll Block s8500-076 8-14 Phaser 8400/8500/8550 Color Printer...
  • Page 303 Disconnect the heater harness plug and free the harness (see the following figure) from its restraint. Finger Holes Cable Restraint Cradle Notch Flex Cable Flex Cable (8400 Only) Data Cable Heater Cable EMI Tape Heater Harness Plug (8500/8550) Ground Strap (8500/8550 Only) s8500-077 Service Parts Disassembly 8-15...
  • Page 304 Cradle Notches s8500-078 Disconnect the data cable from the print head (see the figure above). Disconnect the flex cable from the printhead (Phaser 8400 printers have two cables). Warning Do not pinch or tear the air hose while removing the printhead as this will damage the printer.
  • Page 305 Insert the ribbon cable fully and squarely into the flex connector. Caution Ensure that the flex cable is inserted into the flex connector on the printhead fully and squarely. If the cable is not inserted incorrectly, it can short out the Wave Amp.

  • Page 306: Head Tilt Solenoid

    Using a screwdriver from the right side of the chassis, turn the lower screw of the process drive clockwise until you hear the tilt head solenoid snap into place. 8-18 Phaser 8400/8500/8550 Color Printer...

  • Page 307: X-Axis Bias Spring

    X-Axis Bias Spring (PL2.19) Remove the printhead (see page 8-12). Caution The spring is in close proximity to the drum. Be careful with the removal tools and the spring to ensure that you do not damage the drum. Using your hands, a spring hook, or pliers, remove the X-Axis bias spring from inside the printer cavity.

  • Page 308: Printhead Wiper

    Printhead Wiper (PL 2.7) Videos are available with instructions for replacing the printhead assembly. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Replacement Videos). Remove the printhead (see page 8-12). Caution Place several sheets of paper between the printhead and the drum to protect the drum from damage.

  • Page 309: Replacement Note

    Wiper Belt Wiper Clip s8500-082 Later versions of Phaser 8500/8550 serial numbered WYN1xxxxx or WYP1xxxxx use the wider style wiper drive belt and wiper of the Phaser 8400. Refer to the Service Bulletin 701 for more information. Service Parts Disassembly 8-21...

  • Page 310: Media Release Blade Carriage Assembly And Transfix Roller

    Roller (PL 2.13) Videos are available with instructions for replacing the Transfix Roller. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Transfix Load Module Procedures). Remove the Right Side Cover (see page 8-6).

  • Page 311: Paper Preheater And Deskew Assembly

    Paper Preheater and Deskew Assembly (PL 2.17) Open the Front Door. Remove the Lower Duplex Guide (see page 8-41). Remove the Inner Simplex Guide (see page 8-41). Unplug the AC and sensor flag connectors from the bottom of the Preheater. Note Release the lock on the back of the AC connector.
  • Page 312 Slide the Preheater off the shelves and out of the printer as shown by (3). Note Phaser 8500/8550 preheater is more difficult to slide out than the Phaser 8400 preheater because there is less clearance with the Preheater Lift solenoid.

  • Page 313: Duplex Roller

    Duplex Roller (PL 3.10) Open the Front Door. Remove the upper and lower duplex guides (see page 8-41). Remove the Duplex Roller by removing the left KL-clip on the shaft and sliding the left side bearing down the shaft toward the right (1). Then slide the shaft toward the left (2) to free the right end of the shaft.

  • Page 314: Transfix Load Module

    Transfix Load Module (PL 3.9) Videos are available with instructions for replacing the Transfix Load Module assembly. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service, and then select Transfix Load Module Procedures. Remove the Front Door (MPT) assembly (see page 8-4).
  • Page 315 Insert a T-20 Torxbit through the slotted hole in the Transfix Load Module, engage the hole on the back of the module, and gently lever the module’s spring cam toward the center of the printer to release/unhook the spring hooks from the Transfix Load Arms.
  • Page 316 Remove the clevis pins (1) securing the Transfix Load Arms (2) to the chassis, and remove the Transfix Load Arms and Transfix Roller. Clevis Pin Transfix Load Arm Add Grease s8500-088 Remove the Transfix Camshaft (see page 8-31) 8-28 Phaser 8400/8500/8550 Color Printer...
  • Page 317 Remove the grounding springs from the Transfix Load Module. Grounding Springs s8500-089 Remove two screws securing each end of the Transfix Load Module to the chassis. Transfix Load Module s8500-090 Service Parts Disassembly 8-29...
  • Page 318 Transfix Load Arm (see figure at Step 9) before reattaching the spring hooks. Note After installing the Exit Module, perform the Wiper Alignment (see page 6-2). The printer may report error code 7,009.4x if the wiper assembly is misaligned. 8-30 Phaser 8400/8500/8550 Color Printer...

  • Page 319: Transfix Camshaft Assembly

    Transfix Camshaft Assembly (PL 3.8) Perform Steps 1 through 7 (remove Transfix Load Arms) of the Transfix Load Module removal procedure (see page 8-26). Remove the Process Drive Gearbox assembly (see page 8-51). Slide the shaft to the right (1) and make sure the bearing slides over to the gear, move the shaft down and slightly to the right (2) and then up and to the left (3) to remove it from the printer chassis cavity.

  • Page 320: Drum Maintenance Camshaft Assembly

    Rotate the left end of the shaft slightly toward the rear of the printer, lift the shaft through the slot, and pull it out to the right through the large hole. Drum Maintenance Camshaft Bushing s8500-094 8-32 Phaser 8400/8500/8550 Color Printer...

  • Page 321: Drum Maintenance Pivot Plate Assembly

    Drum Maintenance Pivot Plate Assembly (PL 2.10) Remove the Drum Maintenance Kit Assembly. Remove both the Right and Left Side Covers (see page 8-6). 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 322: Drum Assembly

    Drum Assembly (PL 2.8) Videos are available with instructions for replacing the Drum Assembly. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Replacement Videos). Remove the Front Door Assembly as described on page 8-4.
  • Page 323 Remove the Exit Module assembly (see page 8-40). Exit Module Assembly J850 Media Release Blade Assembly Drum Thermistor Cable Connector to I/O Board Transfix Load Arm Drum Heater Cable 110 Connector (J250) to Control Panel Cable (Not Shown) Drum Encoder Cable Drum Heater Relay Board Power Control Left Cable...
  • Page 324 Note To help seat the drum properly, the following steps 2-6 provide an explicit order of placement for installing the screws to secure the drum assembly to the chassis. 8-36 Phaser 8400/8500/8550 Color Printer...
  • Page 325 Align the screw holes in the left and right sides of the drum assembly to the holes in the chassis sides. Install one silver screw at the rear position of the left-side of the chassis to hold the left side of the drum assembly and torque the screw to 25 in.-lbs. Install the remaining two silver screws into the bottom and front chassis locations to the left side of the drum assembly.
  • Page 326 Pass the Media Release Blade Solenoid cable through the right side of the chassis and seat the Lower Inner Duplex Guide on the four mounting pins on the chassis. Install the Ink Loader Assembly (see page 8-8). Reinstall all covers and doors. 8-38 Phaser 8400/8500/8550 Color Printer...

  • Page 327: Purge Pressure Pump

    Purge Pressure Pump (PL 2.7) Remove the left side cover (see "Left Side Cover" on page 8-7). Disconnect the air hose from the Purge Pressure Pump. Disconnect the wiring harness from the Purge Pressure Pump. Remove three screws and remove the Purge Pressure Pump. s8500-097 Service Parts Disassembly 8-39...

  • Page 328: Paper Path

    You may need to remove the paper path motor to access the screw. s8500-132 Replacement Note: After installing the Exit Module, perform the Wiper Alignment (see page 6-2). The printer may report error code 7,009.4x if the wiper assembly is misaligned. 8-40 Phaser 8400/8500/8550 Color Printer...

  • Page 329: Paper Guides

    Paper Guides Inner Simplex Guide (PL 3.1) Open the printer 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. Slide the guide down and forward to remove. Replacement Note: Note The fingers on the Inner Simplex Guide, go over the segmented roller.
  • Page 330 Disconnect the solenoid connector from the I/O board and extract the harness from the right side frame. Remove the Upper Duplex Guide from the printer. Outer Duplex Paper Guide Lower Inner Duplex Guide Inner Simplex Guide Lower Exit Guide Assembly s8500-098 8-42 Phaser 8400/8500/8550 Color Printer...
  • Page 331 Solenoid Lever Upper Duplex Guide Hole for Solenoid Lever s8500-099 Replacement Notes: Note Route the solenoid harness through the right side frame when replacing the Upper Duplex Guide. Note Verify that the solenoid lever engages the hole in the Paper Release Guide. Service Parts Disassembly 8-43...

  • Page 332: Take Away Roller

    Note Pressure from the idler rollers makes it difficult to move the Take Away Roller shaft to the right during removal. Take Away Roller KL-Clip Bushing s8500-100 8-44 Phaser 8400/8500/8550 Color Printer...

  • Page 333: Pick Assembly

    Pick Assembly (PL 3.10) Remove Tray 2 from the printer. Reach into the tray cavity and release the orange colored catch holding the Pick Roller in place. The catch is located on the ceiling of the tray cavity about 1/4 of the way across the unit from the right side and about 12.5 cm (5 inches) back.
  • Page 334 8-46 Phaser 8400/8500/8550 Color Printer...

  • Page 335: Media Tray Lift Motor

    Media Tray Lift Motor (PL 4.6) Remove the Electronics Module (see page 8-55). Remove Tray 2. Disconnect the wiring harness from the Media Tray Lift Motor. From the rear of the printer, inside the cavity, remove the push nut (this is a press fit).

  • Page 336: Motors, Gears, Solenoids, Clutches, And Fans

    Media Drive Gearbox with Two Clutches and Solenoid (PL 4.8) Videos are available with instructions for replacing the Media Drive Gearbox. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Media Drive Procedures). Remove the Left side (page 8-7) and Exit cover (page 8-7).

  • Page 337: Tray 1 Pick Solenoid

    Replacement Note: Note To replace the Media Drive Gearbox, first remove the paper tray. Rotate the Pick Roller Shaft until the clutch seats. Then work upwards, rotating the Take Away rollers and the Duplex Roller until all shafts seat properly. Ensure that the Media Drive Gearbox is correctly positioned on the side frame.

  • Page 338: Preheater Lift Solenoid

    Disconnect the three-wire cable that attaches the solenoid to the media-box motor. Remove the single screw holding the solenoid to the transfix load module and lift out. s8500-134 8-50 Phaser 8400/8500/8550 Color Printer...

  • Page 339: Process Drive Motor And Gearbox

    Process Drive Motor and Gearbox (PL 4.9) Videos are available with instructions for replacing the Process Drive Motor and Gearbox. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Process Drive Procedures). Remove the right side cover (see page 8-6).
  • Page 340 Remove pins from the new gearbox after installation. Note Ensure that the drum heater harness, Y-Axis encoder harness, and the drum fan harness are replaced in the cable restraint on the gearbox. 8-52 Phaser 8400/8500/8550 Color Printer...

  • Page 341: X-Axis Motor Assembly

    X-Axis Motor Assembly (PL 4.5) Remove the Right Side Cover from the printer (see page 8-6). Disconnect the wiring harness. Remove four screws securing the motor to the chassis and remove the motor. X-Axis Motor Side Rail s8500-108 Replacement Note: Note When reinstalling the X-Axis motor, ensure that the fork, extending out from the side of the cone nut on the motor shaft, is engaged with the side rail.

  • Page 342: Head Tilt Compound Gear

    On reassembly, the leaf spring on the back side of the chassis must be behind the gear to engage. Note On reassembly, lubricate the curved (cam) surfaces of the gear using a small quantity of Rheolube 768 grease (P/N 00679900). 8-54 Phaser 8400/8500/8550 Color Printer...

  • Page 343: Electronics

    Electronics Electronics Module (PL 5.1) Videos are available with instructions for replacing the Electronics Module. Videos are located on the Phaser 8400/8500/8550 Product Training CD-ROM. Select Service and then select Replacement Videos). Caution Touch the back of the Electronics Module before starting this procedure to discharge any electrostatic charge present on the case.

  • Page 344: Wave Amp Board

    Wave Amp and printhead. If the cables are inserted incorrectly, they can damage the Wave Amp Board. Route the ribbon cables carefully through the slots. Ensure that the T-shaped strain relief on the cable is nearest the Wave Amp on installation. 8-56 Phaser 8400/8500/8550 Color Printer...

  • Page 345: I/O Board

    I/O Board (PL 5.4) Remove the right side cover (see page 8-6). Disconnect the wires to the I/O Board. Remove the two screws attaching the I/O Board to the printer. Remove the I/O Board. I/O Board Ground Tab s8500-112 Replacement Note: Note Ensure the corner of the board is behind the ground tab on reassembly.

  • Page 346: Drum Heater Relay Board

    Warning Ensure that no wires are routed behind the Drum Heater Relay Board during reinstallation. Some of these wires carry AC line voltage and a short could result in AC being shorted to accessible locations. 8-58 Phaser 8400/8500/8550 Color Printer...

  • Page 347: Nvram Replacement

    NVRAM Replacement (PL 5.8) Remove the back cover from the Electronics Module. Caution Some semiconductor components, such as the NVRAM chip, are vulnerable to damage by Electrostatic Discharge (ESD). Review the "Electrostatic Discharge (ESD) Precautions" on page 1-v before continuing with this procedure.

  • Page 348: Dimm Replacement

    DIMM boards are inverted to each other. Pull the connector release tabs away from the DIMM’s to release (see illustration). The Phaser 8400 includes a clip that secures the Dimms in place. For the 8500/8550 DIMM’s, the top DIMM swings down and the bottom DIMM swings up in the removal position, while they clip in place in the flat position.

  • Page 349: Hard Drive Replacement

    Hard Drive Replacement (PL 5.2) Remove the back cover from the Electronics Module. Caution Some semiconductor components, such as the NVRAM chip, are vulnerable to damage by Electrostatic Discharge (ESD). Review the “Electrostatic Discharge (ESD) Precautions” on page v before continuing with this procedure.

  • Page 351: Parts Lists

    Parts Lists In this chapter... ■ Serial Number Format ■ Using the Parts List ■ Xerox Supplies Section...

  • Page 352: Serial Number Format

    Serial Number Format Changes to Xerox products are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: ■ Component's part number ■ Product type or model number ■ Serial number of the printer Serial numbering.

  • Page 353: Using The Parts List

    Using the Parts List No.: The callout number from the exploded part diagram. Part Number: The material part number used to order specific parts. Qty: This number represents the parts per printer, not the number of parts supplied in the actual part order. Name/Description: Details the name of the part to be ordered and the number of parts supplied per order.

  • Page 354: Covers

    Covers s8500-117 Phaser 8400/8500/8550 Color Printer...
  • Page 355 Parts List 1.0 Covers Name/Description Qty Part Number Front Door (MPT) Assembly 200467880 (8400) 802K93580 (8500/8550) Front Door Stay Retainer Clip 131714380 Front Door Stay with Spring 386740780 Hinge Pins, Front Door 131713880 Control Panel Cover 200467380 (8400) 802E93850 (8500/8550) Control Panel with Bezel 657012880 (8400) 802K93650 (8500/8550)

  • Page 356: Imaging

    Imaging Phaser 8400/8500/8550 Color Printer...
  • Page 357 Parts List 2.0 Imaging Name/Description Part Number Ink Loader Assembly and Door 200469880 (8400) 133K25031 (8500/8550) 133K25660 (Metered PagePack 8550) Printhead Assembly 650430300 (8400) 046K00510 (8500/8550) Drum Assembly, includes Encoder 105115080 (8400) 020K14790 (8500/8550) Belt, Y-Axis Drum 214498780 (8400) 023E30670 (8500/8550) Printhead Wiper (for wide-style belts) 367053480 (8400, 8500/8550) Belt, Wiper Drive (wide-style)

  • Page 358: Paper Path

    Paper Path s8500-119 Phaser 8400/8500/8550 Color Printer...
  • Page 359 Parts List 3.0 Paper Path Name/Description Part Number Inner Simplex Guide 351111480 (8400) 032E29480 (8500/8550) Lower Inner Duplex Guide 038K16870 Lower Exit Guide Assembly with Strip Flag 038K16880 Outer Duplex Paper Guide with Sensors (Safety 351113680 Interlocks) Upper Duplex Paper Guide with Solenoid 351113280 (8400) 032E29490 (8500/8550) Exit Roller...

  • Page 360: Motors, Gears, Solenoids, Clutches, And Fans

    Motors, Gears, Solenoids, Clutches, and Fans s8500-120 9-10 Phaser 8400/8500/8550 Color Printer...
  • Page 361 Parts List 4.0 Motors, Gears, Solenoids, Clutches, and Fans Name/Description Part Number Pre-heater Lift Solenoid 121K44430 (8500/8550) Motor, Y-Axis Drive 147101780 Pick Solenoid, Tray 1 119640880 Head Tilt Solenoid 121K44480 (8500/8550) Gearbox, Media Drive with 2 Clutches, Solenoid 401098480 (8400) 807E16050 (8500/8550) Tray Lift Motor Kit and Gear (plus item 10) 650429500...

  • Page 362: Circuit Boards

    Circuit Boards s8500-121 9-12 Phaser 8400/8500/8550 Color Printer...
  • Page 363 Parts List 5.0 Circuit Boards and Cables Name/Description Part Number Cable, Y-Axis Motor Ground 117E28740 Wiring Harness, Left Side Power Control 174449480 (8400) 117E28720 (8500/8550) Cable, Wave Amp Signal 174446580 (8400) 117E28680 (8500/8550) Wave Amp Assembly 671522380 (8400) 960K21180 (8500/8550) Electronics Module (no RAM, NVRAM, or 119649580 (8400) Configuration Card)

  • Page 364: Sensors And Flags (Actuators)

    Sensors and Flags (Actuators) s8500-122 9-14 Phaser 8400/8500/8550 Color Printer...
  • Page 365 Parts List 6.0 Sensors and Flags (Actuators) Name/Description Part Number Drum Temperature Sensor Assembly 119643080 Optical Sensor (Generic Snap-In) 119640580 Safety Interlock Switch (Mech) 119645580 Exit Module Sensor Assembly 119648180 Paper Present Flag 386731280 Exit Flag 386732680 Sensor Assembly, Paper Tray 441223780 Waste Tray Sensor 119648780...

  • Page 366: Xerox Supplies

    161006610 Cable Power AUST 240 V, 96 L 161006611 Cable Assembly SWISS 220/240 V, 50 Hz 161015400 Cable Assembly PWR. DANISH, 250 V 161024000 Cable Assy PWR, CHINESE 161030400 Cable Power, 240 V, ARGENTINA 161030700 9-16 Phaser 8400/8500/8550 Color Printer...
  • Page 367 Upgrade Kits and Options Description Part Number Hard Drive Upgrade Kit 097S03172 (8400) 121K44410 (8500/8550) Hard Drive Upgrade with Japanese Fonts 097S03173 (8400) 121K44420 (8500/8550) Memory (8400) 128 MB, 16M x 64, PC133; Memory DIMM ZMD128 256 MB, 32M x 64, PC133; Memory DIMM ZMD256 Memory (8500) 128 MB, SDRAM...
  • Page 368 Consumables and Routine Maintenance Items Description Part Number Genuine Xerox Solid Ink Black (3 sticks) 108R00604 (8400 series) 108R00668 (8500 series) 108R00706 (8550 Metered PagePack - 6 sticks) Genuine Xerox Solid Ink Cyan (3 sticks) 108R00605 (8400 series) 108R00669 (8500 series)
  • Page 369 Phaser Color Printing Media Description Part Number Phaser Premium Color Printing Paper, 016136800 24 lb. Letter, 500 Sheets Phaser Premium Color Printing Paper, 016136900 24 lb. A4, 500 Sheets Phaser Premium Cover Paper, Letter, 016182300 100 Sheets Phaser Premium Cover Paper, A4, 016182400 100 Sheets Phaser Professional Solid Ink...
  • Page 370 Phaser Color Printing Media (Continued) Description Part Number Supplies Startup Kit, Standard Size Media 097S03180 Supplies Startup Kit, Metric Size Media 097S03181 9-20 Phaser 8400/8500/8550 Color Printer...

  • Page 371: Wiring Diagrams

    Wiring Diagrams In this chapter... ■ Main Wiring Diagram ■ Right-Side Wiring Diagram ■ Left-Side Wiring Diagram ■ Inside Front Wiring Diagram ■ Inside Top Wiring Diagram ■ Inside Top - Printhead Wiring Diagram Section...

  • Page 372: Main Wiring Diagram

    J160 24 V PWM Heat maintenance clutch J820 Width sense (3) switch Length sense (2) switch Media Tray sense ECB Elevator plate motor Width sense (3) switch Length sense (2) switch Tray 4 HCF s8500-123 10-2 Phaser 8400/8500/8550 Color Printer...

  • Page 373: Main Wiring Diagram (Continued)

    Main Wiring Diagram (Continued) Printhead AC Resv. heaters (2) AC Jetstack heaters (2) Drum Heater Series/parallel heater J620 J480 30 connector JDC1 Power Control Power J3AC X- axis motor J820 Supply Drum fan J2AC +/-50 V +/-12 V unreg +3.3 V generates: J790 +/-50 V...

  • Page 374: Right-Side Wiring Diagram

    J600 Add Paper Tray Kit Missing J840 Dead Power J610 No Handfeed 37006.4x Drum Heater (Pre-heater) Ground Clip Drum AC is routed thru pre-heater prior to relay board and drum 37014.4x Drum Fan 5002.42 s8500-125 10-4 Phaser 8400/8500/8550 Color Printer...

  • Page 375: Right-Side Wiring Diagram (Continued)

    Right-Side Wiring Diagram (Continued) The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the Control Panel. Routes to Top of Channel 13387.4x J4AC 37006.4x J800 Dead Power J400 37027.4x Signal Cable (Routed on 37027.4x X-Motor Ribbon Cable (Routed in...

  • Page 376: Left-Side Wiring Diagram

    Control Panel. 37023.4x Purge Valve 37022.4x Purge Motor J280 37032.4x Y-Motor J790 37062.4x Head VSS J390 37034.4x MP Motor 37021.4x MT Elevator Channel (Connected to 37013.4x Electric Fan Ground Strap) s8500-127 10-6 Phaser 8400/8500/8550 Color Printer...

  • Page 377: Left-Side Wiring Diagram (Continued)

    Left-Side Wiring Diagram (Continued) The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the Control Panel. 37034.3x MP Motor 37015.4x MP Fan (8400 Only) 370xx.4x Preheater Lift Solenoid (8500/8550 Only) 37017.4x Deskew Clutch Ground Clip 37018.4x Pick Clutch...

  • Page 378: Inside Front Wiring Diagram

    The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the Control Panel. 37036.4x Process Motor 37008.4x Preheat Power (AC Connector) Load Paper Paper Jam (Open Front Cover) J860 13131.41 Sensor Flag s8500-129 10-8 Phaser 8400/8500/8550 Color Printer...

  • Page 379: Inside Top Wiring Diagram

    Inside Top Wiring Diagram The arrows indicate which connectors you should look at for the Pest codes. The Pest codes are displayed on the Control Panel. 8400 37010.4x Ink 1 Heater J1AC 37009.4x J2AC 37002.4x (Ink Load Power) JSL Heater J130 34062.4x (Data Cable) 8500/8550 37010.4x...

  • Page 380: Inside Top - Printhead Wiring Diagram

    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 (8400 Only) J140 37063.4x Head VPP Heater Cable s8500-131 10-10 Phaser 8400/8500/8550 Color Printer...

  • Page 381: Appendix

    Appendix Contents... ■ Menu Map (8400) ■ Menu Map (8500/8550) ■ Paper Weight Equivalence Table ■ On-site Printhead Troubleshooting Checklist (8400) Appendix...
  • Page 382 USB Port CentreWare IS Wait Timeout NetWare Page Description Language Requires: IPX Frame Type Job Pipelining* Network Configuration Duplex Configuration Optional Lower Tray(s) Page 1 of 2 **** Hard Drive ***** 8400DX only with stored jobs present Phaser 8400/8500/8550 Color Printer...
  • Page 383 Paper Source 2-Sided Printing** Tray 1 Setup PostScript Error Info Font Number Tray 2 Paper Type Print-Quality Mode Pitch Tray 3 Paper Type*** TekColor Correction Point Size Printer Setup Tray 4 Paper Type*** Image Smoothing Symbol Set (continued) Load Paper Timeout Reset PostScript Setup Orientation Cleaning Page Source...

  • Page 384: Menu Map (8500/8550)

    CentreWare IS USB Port Wait Timeout NetWare Page Description Language Requires: IPX Frame Type Job Pipelining* Network Configuration Duplex Configuration Optional Lower Tray(s) **** Hard Drive Page 1 of 2 ***** 8400DX only with stored jobs present Phaser 8400/8500/8550 Color Printer...
  • Page 385 Paper Source 2-Sided Printing** Tray 1 Setup PostScript Error Info Font Number Tray 2 Paper Type Print-Quality Mode Pitch Tray 3 Paper Type*** TekColor Correction Point Size Printer Setup Tray 4 Paper Type*** Image Smoothing Symbol Set (continued) Load Paper Timeout Reset PostScript Setup Orientation Cleaning Page Source...
  • Page 386 111.125 101.125 112.9 3 x 5 Card 76.2 66.2 6 x 9 Envelope 152.4 228.6 142.4 188.6 Custom 76.2 - 127 - 12.5 12.5 51.2 - 102 - 215.9 355.6 (8400) 190.9 330.6 5 mm (8500) Phaser 8400/8500/8550 Color Printer...
  • Page 387 Paper Weight Equivalence Table US Bond US Text US Index US Tag Metric Postcard Weight Book Cover Bristol Weight Weight Weight Thickness (lb.) Weight Weight Weight (lb.) (lb.) (g/m (mm) (lb.) (lb.) (lb.) 0.18 0.20 0.23 Service Manual...

  • Page 388: On-Site Printhead Troubleshooting Checklist (8400

    PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8400/WorkCentre C2424 Version 2 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 Service Company...
  • Page 389 IDU lists any values, record 10-29: _____________ the numbers here: 30-99 _____________ 100+: ______________ Xerox U.S. personnel please record these dates in the FIST system as well as in this document Step Does the printer If YES please write down the error code. _______________...
  • Page 390 Assembly faceplate)? correctly If YES, perform the wiper alignment procedure as described in the aligned? Phaser 8400 Color Printer Service Guide. Circle Is there color mixing from one row to the next row for the same jet? Step Print Service...
  • Page 391 ____________________________________________________________________________ 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 392 It will be subjected to complete analysis at responsibility of the customer.

  • Page 393: On-Site Printhead Troubleshooting Checklist (8500/8550

    8550) PRINTHEAD TROUBLESHOOTING CHECKLIST Phaser 8500/8550 Version 1.0 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 Service Company...
  • Page 394 IDU lists any values, record 10-29: _____________ the numbers here: 30-99 _____________ 100+: ______________ Xerox U.S. personnel please record these dates in the FIST system as well as in this document Step Does the printer If YES please write down the error code. _______________...
  • Page 395 Cap/Wipe/ faceplate)? Purge assembly If YES, perform the wiper alignment procedure as described in the correctly Phaser 8400/8500/8550 Color Printer Service Guide. aligned? Circle Step Print Service Is there color mixing from one row to the next row for the same jet?
  • Page 396 ____________________________________________________________________________ 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 397 Index Numerics ink loader media drive motor 8-37 525-sheet feeder, parts list pick solenoid 8-49 8-pin NVRAM, parts list 9-13 power cord parts list 9-16 printhead data printhead power 3-18 ribbon connector AC power 2-20 serial modem 4-85 adjust x-axis scale, service menu 4-84 wave amp 3-45...
  • Page 398 DIMM media jams disassembly notes cleaning cycle 2-33 disassembly procedures cleaning page 2-14 2-33 5-44 control panel cover cleaning procedures Phaser 8400/8500/8550 Color Printer Index – 2...
  • Page 399 covers assembly and transfix system 2-16 DIMM chips 8-60 drum cleaning 2-34 drum heater relay drum preparation 8-58 2-24 drum maintenance assembly maintenance system 8-32 2-13 duplex roller 8-23 purge system 2-14 electronics module 8-55 relation to printhead 2-10 exit module assembly drum preparation 8-40 2-24...
  • Page 400 5-20 lift motor 4-51 ground connection integrity 4-77 lift motor, disassembly 8-47 ground connection warning 1-ii lower inner duplex guide ground integrity 4-77 parts list grounding 4-77 removal 8-41 guidelines, energy lubrication Phaser 8400/8500/8550 Color Printer Index – 4...
  • Page 401 paper path check menu 4-20 main board electronics module 2-19 drive problems 4-36 main board memory 2-19 exit module assembly 8-40 main subsystems ink residue maintenance kit jams 3-37 maintenance kit, eprom chip 2-13 motor jam codes 3-64 mechanical initialization 4-60 4-62 parts list...
  • Page 402 3-13 specifications, printer 1-10 process drive 2-18 status indicator LED assembly train streaks 5-11 definition supplies, Xerox 9-16 error faults 3-19 homing 8-52 parts list 9-11 relation to drum 2-13 Phaser 8400/8500/8550 Color Printer Index – 6...
  • Page 403 test prints 5-33 tilt cam 2-10 2-11 tilt gear 2-12 transfix roller 2-16 2-18 2-27 transfix speeds 2-31 transfix system 2-16 transfixing 2-27 troubleshooting, jam codes 3-57 uneven color waste ink 2-14 waste tray wavy vertical lines 5-23 wiper alignment procedure wiper assembly lock 8-12 wiper faults...

This manual is also suitable for:

Phaser 8550Phaser 8500

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