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Phaser 8500
Xerox Phaser 8500 Service Manual
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4
Chapter
General T
roubleshooting
In this chapter
...
â–
Ser
vic
e Diagnos
tics
â–
Ser
vic
e Diagnos
tics Mod
e Menu
â–
Check Menu Defini
tion T
ables
â–
Electroni
cs T
rou
bleshooting
â–
Ensur
ing G
round Inte
grity
â–
P
ap
er P
at
h and Me
dia-Ba
sed Pro
blems
â–
Operating
System
and Ap
plication P
roblems
130
132
Table of Contents
Default Chapter
5
Service Terms
5
Symbols Marked on the Product
6
Power Safety Precautions
6
Electrostatic Discharge (ESD) Precautions
7
General Guidelines
8
Service Safety Summary
8
Servicing Mechanical Components
9
Regulatory Specifications
10
Manual Organization
12
Table of Contents
13
General Information
19
Printer Introduction and Overview
20
Printer Configurations
21
Control Panel Configuration
23
LED Indicators
23
Control Panel Feature Descriptions
23
Menu Maps
24
Control Panel Shortcuts
24
Parts of the Printer
25
Front View
25
Right Side View with Printer Interfaces
25
Rear View
26
Routine Maintenance Items and Consumables
27
Printer Specifications
28
Physical Dimensions and Clearances
28
Functional Specifications
30
Electrical Specifications
30
Environmental Specifications
30
Media and Tray Specifications
31
Theory of Operation
33
Main Printer Subsystems
34
Printer Subsystem Overview
34
Process Drive
36
Media Drive
37
Ink Loader
38
Printhead
39
Printhead Tilt
42
Drum Maintenance Kit
45
Purge System
46
Drum Assembly and Transfix System
48
Electronics Module
51
I/O Board
54
Sensors
54
Print Process
55
Printing
56
Paper Pick for Tray 1
57
Paper Pick for Trays 2 - 4
58
Transfixing and Exiting
59
Duplex Printing
62
Transfix and Print Speeds
63
Printer Self-Maintenance
65
Printhead Maintenance Cycle (Eliminate Light Stripes)
65
Paper Preheater Cleaning (Remove Print Smears)
66
Transfix Roller Oiling
66
Drum Cleaning - Chase Page
66
Configuration Card Personality Parameters
67
Error Messages and Codes
69
Introduction
70
Power-Up Error Messages and LED Codes
71
BIST Error Reporting
71
POST Error Reporting
72
PEST Error Reporting
74
Fault Code Error Message Troubleshooting
75
Fault Code Error Reporting
75
Interpreting Fault Codes
75
1,000.4X Errors - 525-Sheet Feeder Faults
76
1,0Xx.6X Errors - 525-Sheet Feeder Program Faults
76
2,0Xx.4X Errors - I/O Circuit Board Fault
77
2,0Xx.6X Errors - I/O Board Program Faults
77
3,0Xx.6X Errors - IPC Program Faults
78
4,0Xx.4X Errors - Process Control System Fault
78
4,0Xx.6X Errors - Process Control Software Fault
80
5,0Xx.4X Errors - Y-Axis Sub-System Fault
81
5,0Xx.6X Errors - Program Faults
81
6,0Xx.4X Errors - X-Axis Fault
82
6,0Xx.6X Errors - Program Faults
82
7,0Xx.4X Errors - Process Motor Gearbox Faults
83
7,0Xx.4X Errors- Printhead Tilt Faults
84
7,0Xx.6X Errors - Program Faults
88
8,0Xx.XX Errors - Wiper/Media Drive Faults
89
8,0Xx.6X Errors - Program Faults
90
9,0Xx.XX Errors - Ink Loader Faults
91
9,009.44 and 9,00X.6X Errors - Program Faults
92
11,0Xx.XX Errors - Electronics Module Interface Fault
92
11,100.60 Errors - Temperature Error
94
12,000.60 Errors - Program Faults
94
13,0Xx.XX Errors - Thermal Faults
94
13,000.6X Errors - Program Faults
99
19,0Xx.XX Errors - Printhead Calibration Faults
100
19,0Xx.6X Errors - Waveform Program Faults
101
21,000.69 Errors - Diagnostic Code Version Mismatch
101
22,0Xx.6X Errors - Jam Codes
101
23,0Xx.6X Errors - NVRAM Fault
101
26,0Xx.6X Errors - Printing Faults
101
26,962.6X Errors - "Fall Out" Code
102
27,0Xx.6X Errors - Profile Library
102
29,0Xx.6X Errors - Jam Manager
102
31,0Xx.4X Errors - Mechanical Initialization Jam
102
31,0Xx.6X Errors - Program Faults
103
33,0Xx.XX Errors - Tray Manager Device Faults
103
34,0Xx.XX Errors - Printhead NVRAM Faults
103
36,000.40 Errors - Drum Maintenance Faults
104
36,001.67 Errors - Drum Maintenance Fault
104
36,002.44 Errors - Drum Maintenance Program Fault
104
37,0Xx.XX Errors - PEST Faults
104
Jam Codes
116
Jam Code Definition Table
117
General Troubleshooting
131
Introduction
132
Hidden Service Menu
132
Service Diagnostics
134
Service Diagnostics Mode Menu
135
Service Diagnostics Menu Map
136
Check Menu Definition Tables
140
Check / Activators Menu
140
Check Shafts Menu
143
Check Paper Path Menu
146
Check Drive Menu
161
Check Drum Menu
167
Check Motors Menu
173
Check Misc Menu
176
Electronics Troubleshooting
181
Printer Power-Up Sequence
181
Miscellaneous Electrical Troubleshooting
186
Verifying Power Supply Operation
194
Measuring AC Power Supply Voltages
194
Measuring DC Power Supply Voltages
195
Ensuring Ground Integrity
195
Testing Motor and Solenoid Resistances
197
Paper Path and Media-Based Problems
198
Media-Based Problems
198
Pick Errors - Trays 2, 3, and 4
198
Paper-Pick Errors - Tray 1
199
Preheater and Transfix Jams
199
Checking the Process and Media Path Drive
199
Media Skews Passing through the Paper Path
200
Operating System and Application Problems
201
Testing Communications Ports
201
Network Problems
203
Obtaining Serial Back Channel Trace
203
Obtaining a Back Channel Trace with USB to Serial Adapter
204
Print-Quality Troubleshooting
207
Print-Quality Problems Overview
208
Random Light Stripes
209
Predominate Light Stripes
210
Smudges or Smears
211
Print too Light or too Dark
213
Blank Prints
214
Color Is Uneven or Wrong
215
Streaks or Lines down the Print
217
Scratches or Marks Parallel to the Long Axis of Printing, Particularly with Film
219
Ink on White Portion of Print
221
Fuzzy Text
223
Poor Primary Color Fills
224
Ghosting
226
Poor Small Text Resolution
228
Vertical Lines Appear Wavy
229
Oil Streaks on Print
230
Incomplete Image Transfer to Paper
232
Ink Smears on First Printed Side of Auto-Duplex Print
234
Repeating Defects on Print
235
White Stripes (Pinstripes)
236
Wrinkling
237
Image Is Offset or Cut-Off
239
Poor Ink Adhesion, Poor Image Durability
239
Analyzing Service Test Prints
240
Weak/Missing Jet
240
X-Axis Motion (8400 Only)
241
Color Bands, RGBK Dither
242
Reverse Text
243
Big Bands OHP
244
Gray Fill, Dot Size Uniformity
245
YMCKRGB Solid Fills
246
Primary Solid Fills 10X
246
Head-To-Drum Gap (8400 Only)
247
Black, Red, Green, Blue, Cyan, Magenta, and Yellow Solid Fills
248
Manuf. Skew Margins
249
Cleaning Page
250
Other Test and Specialty Prints
250
Adjustments and Calibrations
251
Adjustments
252
Wiper Alignment Procedure
252
Printer Component Homing Positions and Indicators
254
Wiper Assembly Positions
254
Homing the Head Tilt Gear
255
Homing the Process Drive Train
258
Timing the Drum Maintenance Camshaft
259
Jet Substitution Mode
262
Enabling Jet Substitution Mode (8400)
262
Enabling Jet Substitution Mode (8500/8550/8560)
263
Disabling Jet Substitution Mode (8400)
263
Disabling Jet Substitution Mode (8500/8550/8560)
264
Resetting NVRAM
264
Cleaning and Maintenance
265
Service Cleaning Maintenance Procedure
266
Cleaning
266
Pick Roller Cleaning Method
267
Maintenance
268
Drum Maintenance Kit
268
Waste Tray
269
Lubrication
269
Inspection
269
Service Parts Disassembly
271
Overview
272
Standard Orientation of the Printer
272
General Notes on Disassembly
273
Covers
274
Front Door/Tray 1 Assembly (PL1.0.1)
274
Control Panel Cover (PL1.0.5)
275
Control Panel (PL1.0.6)
275
Right Side Cover (PL1.0.10)
275
Left Side Cover (PL1.0.9)
276
Exit Cover (PL1.0.7)
276
Ink Loader (PL1.0.8)
277
Imaging
278
Y-Axis Belt, Y-Axis Tension Spring, and Y-Axis Motor
278
Printhead, Right and Left Printhead Restraints
280
Head Tilt Solenoid (PL4.0.12)
285
X-Axis Bias Spring (PL2.0.19)
286
Wiper Assembly (PL2.0.17)
287
Stripper Carriage (PL2.0.12) and Transfix Roller (PL2.0.13)
289
Preheater (PL2.0.17)
290
Duplex Roller (PL3.0.8)
291
Transfix Load Module (PL2.0.15)
292
Transfix Camshaft (PL2.0.10)
295
Drum Maintenance Camshaft (PL2.0.11)
295
Drum Maintenance Pivot Plate (PL2.0.16)
296
Drum Assembly (PL2.0.3)
297
Purge Pump (PL2.0.7)
301
Paper Path
302
Exit Module (PL3.0.13)
302
Inner Simplex Guide (PL3.0.1)
303
Lower Inner Duplex Guide (PL3.0.2)
303
Lower Exit-Guide Assembly with Strip Flag (PL3.0.3)
303
Outer Duplex Guide with Safety Interlocks (PL3.0.4)
304
Upper Duplex Guide with Solenoid (PL3.0.5)
304
Take Away Roller (PL3.0.7)
306
Pick Assembly (PL3.0.10)
307
Tray Lift Motor and Gear (PL4.0.6)
309
Motors, Gears, Solenoids, Clutches, and Fans
310
Media Drive with Two Clutches and Solenoid (PL4.0.5)
310
Tray 1 Pick Solenoid (PL4.0.3)
311
Preheater Lift Solenoid (PL4.0.1)
312
Process Drive (PL4.0.14)
313
X-Axis Motor (PL4.0.12)
314
Head Tilt Gear (PL4.0.9)
315
Electronics
316
Electronics Module (PL5.0.5)
316
Wave Amplifier (PL5.0.4)
317
I/O Board (PL5.0.13)
318
Drum Heater Relay Board (PL5.0.17)
319
Nvram (Pl5.0.9)
320
DIMM Memory (PL5.0.8)
321
Hard Drive (PL5.0.7)
322
Parts Lists
323
Serial Number Format
324
Using the Parts List
325
PL 1.0 Covers
326
PL 2.0 Imaging
328
PL 3.0 Paper Path
330
PL 4.0 Motors, Gears, Solenoids, Clutches, and Fans
332
PL 5.0 Circuit Boards
334
PL 6.0 Sensors and Flags (Actuators)
336
Xerox Supplies
338
Wiring Diagrams
343
Main Wiring Diagram
344
Main Wiring Diagram (Continued)
345
Right-Side Wiring Diagram
346
Right-Side Wiring Diagram (Continued)
347
Left-Side Wiring Diagram
348
Left-Side Wiring Diagram (Continued)
349
Inside Front Wiring Diagram
350
Inside Top Wiring Diagram
351
Inside Top - Printhead Wiring Diagram
352
Reference
353
Menu Map (8400
356
Menu Map (8500/8550/8560
356
Media Margin Specification Table
358
Paper Weight Equivalence Table
359
On-Site Printhead Troubleshooting Checklist (8400
360
Ink Failure Checklist
364
On-Site Printhead Troubleshooting Checklist (8500/8550/8560
365
Other manuals for Xerox Phaser 8500
Quick Guide
4 pages
Detailed Specifications
4 pages
Voluntary Product Accessibility Template
9 pages
Quick Reference Guide
9 pages
User Guide
151 pages
5
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Xerox Phaser 8500 Specifications
General
Brand
Xerox
Model
Phaser 8500
Category
Printer
Language
English
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