XEROX Xerox DocuPrint P8e / P8ex Service Manual

XEROX Xerox DocuPrint P8e / P8ex Service Manual
XEROX
Xerox DocuPrint P8e / P8ex
Service Manual
P8e_100
720P41711
3/99
This Service Manual contains information that
applies to the Xerox DocuPrint P8e Electronic
Laser Printer.
NOTICE
This manual is for use by Xerox Technicians and
Xerox trained technicians only.
NOTICE
While every care has been taken in the
preparation of this manual, no liability will be
accepted by Xerox arising out of any inaccuracies
or omissions.
All service documentation is supplied to Xerox
external customers for informational purposes
only. Xerox service documentation is intended for
use by certified, product trained service personnel
only. Xerox does not warrant or represent that
such documentation is complete. Nor does Xerox
represent or warrant that it will notify or provide to
such customer any future changes to this
documentation. Customer’s service of equipment,
or modules, components, or parts of such
equipment may void any otherwise applicable
Xerox warranties. If Customer services such
equipment, modules, components, or parts
thereof, Customer releases Xerox from any and
all liability for Customer’s actions, and Customer
agrees to indemnify, defend, and hold Xerox
harmless from any third party claims which arise
directly or indirectly from such service.
Prepared by:
Xerox Corporation
PSD&E
Mail Stop: ESM1-058
701 S. Aviation Blvd.
El Segundo, CA. 90245
Copyright 1998 Xerox Corporation. All rights
reserved.
Copyright protection claimed includes all forms of
matters of copyrightable materials and information
now allowed by statutory or judicial law or
hereinafter granted, including without limitation,
material generated from the software programs
which are displayed on the screen such as styles,
templates, icons, screen displays, looks, etc.
Xerox, Xerox Europe (XE), and all product names
and product numbers mentioned in this
publication are trademarks.
PCL 5e, HP LaserJet, and Intellifont are
trademarks of Hewlett-Packard Company. IBM is
a trademark of International Business Machines
Corporation. Microsoft, Microsoft Windows,
Microsoft Word, MS, and MS-DOS are trademarks
of Microsoft Corporation. Univers is a trademark
of Linotype AG or its subsidiaries. WordPerfect is
a trademark of WordPerfect Corporation.
Centronics is a trademark of Centronics
Corporation. Macintosh and TrueType are
trademarks of Apple Computer, Incorporated. All
other product names are trademarks/tradenames
of their respective owners.
The Xerox DocuPrint P8e uses PCL 5e emulation.
PCL and PCL 5e are trademarks of Hewlett
Packard Company. These printers contain an
emulation of the Hewlett Packard PCL 5e
command language, recognizes HP PCL PCL 5e
and commands, and processes these commands
in a manner compatible with Hewlett Packard
LaserJet printer products.
Prepared for:
Xerox Channels Group
Personal Printer
555 Aviation Blvd.
El Segundo, California 90245
Copyright 1998 by Xerox Corporation. Xerox and
DocuPrint P8e are registered trademarks of Xerox
Corporation.
Copyright Information
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ii
Xerox DocuPrint P8e Service Manual
Warning
This equipment complies with the
requirements in Part 15 of FCC rules for a
class A computing device. Operation of the
equipment in a residential area may cause
unacceptable interference to radio and TV
reception, requiring the operator to take
whatever steps are necessary to correct the
interference.
Product Safety
Electrostatic Discharge
This caution indicates that there are components
which are sensitive to damage caused by
electrostatic discharge.
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
The laser and output of the laser scanner unit
produces a beam that, if looked into, could cause
eye damage. Service procedures must be
followed exactly as written without change.
When servicing the machine or laser module,
follow the procedures specified in the manual and
there will be no hazards from the laser.
Laser (FDA): Any laser label visible to service
must be reproduced in the service manual with
location shown or indicated. Safe working
procedures and clear warnings concerning
precautions to avoid possible exposure must also
be included.
The Laser contained in the DocuPrint P8e meets
the following standard: Laser class 3B, maximum
5mW, wavelength 780nm.
The following LASER symbol will be displayed at
the start of any procedure where possible
exposure to the laser beam exists.
Shock Hazard
DP8_006
This symbol indicates the presence of potentially
hazardous voltages.
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
DP8_001
Each P8e laser printer has the following laser
warning label on the Laser Assembly.
CLASS 1 LASER PRODUCT
The Xerox DocuPrint P8e laser printers are
certified to comply with Laser Product
Performance Standards set by the U.S.
Department of Health and Human Services as a
Class 1 Laser Product. This means that this is a
class of laser product that does not emit
hazardous laser radiation; this is possible only
because the laser beam is totally enclosed during
all modes of customer operation.
DP8_009
Xerox DocuPrint 4508 Service Manual
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iii
Product Safety
The Laser Label is visible when the Top Cover is removed (Figure 1).
Figure 1. Laser Safety Label
Laser Label.
P8e_321
Finland Laser Safety
Product Safety
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iv
Xerox DocuPrint P8e Service Manual
Introduction
Table of Contents
Title
Page
Introduction .............................................. v
Organization ............................................ vi
Service Call Procedures .......................1-1
Printer Specifications ...........................2-1
Parts Lists ..............................................3-1
Repair Procedures ................................4-1
General Procedures ..............................5-1
Wiring Data ............................................6-1
The Xerox DocuPrint P8e Service Manual is the
primary document used for repairing and
maintaining the P8e Laser Printers.
This manual contains Service Call Procedures,
Diagnostic Procedures, General Information,
Repair Analysis Procedures, Copy Quality
Analysis Procedures, Wiring Data, and Parts Lists
that will enable the Service Representative to
repair P8e failures.
NOTE: In some of the DocuPrint P8e
documentation the Print Cartridge is
referred to as the Image Cartridge. Print
Cartridge is the correct term.
Repair Analysis Procedures.................7-1
P8ex Addendum ....................................8-1
Xerox DocuPrint P8e Service Manual
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v
Contents
Organization
Section 8 - P8ex Addendum
This manual is divided into seven sections. The
title and description of each section of the manual
is as follows:
All procedures and technical information in the
DocuPrint P8e Service Manual apply to the
DocuPrint P8ex printer with the exception of the
information provided in the P8ex addendum. The
P8ex Addendum contains the following
informatiom:
Section 1 - SERVICE CALL PROCEDURES
This section is used to identify a suspected
problem. It contains Call Flow, Initial Actions, and
Final Actions. This part of the service manual
should always be used to start the service call.
1) A description of the PCL 6 emulation
2) A description of the Universal Serial Bus
(USB)
3) A new Repair Procedure for the Controller
PWB, REP 4.6.3A Controller PWB (P8ex)
Section 2 - PRINTER SPECIFICATIONS
This section contains all the specifications for the
P8e / P8ex printers.
— Accessing the Controller Board now
provides easy access to the Memory
SIMM
Section 3 - PARTS LISTS
This section contains illustrations of disassembled
subsystems and a listing of the spared parts.
4) P8ex Parts List.
— This section contains illustrations of
disassembled subsystems and a listing
of the spared parts for the DocuPrint
P8ex.
Part names are listed in this section of the manual
even if the part itself is not spared. All the parts
that are spared will have the part number listed.
Parts that are not spared will not have a number
listed.
Section 4 - REPAIR PROCEDURES
This section contains the instructions for removal,
replacement, and adjustment of the spared parts.
Section 5 - GENERAL PROCEDURES
This section contains diagnostic routines, printer
setup procedures, and a listing of tools and
supplies.
Section 6 - WIRING DATA
This section contains illustrations of the plug/jack
locations and the routing of power and signal
cables.
Section 7 - REPAIR ANALYSIS PROCEDURES
(RAPs)
This section contains the procedures necessary to
repair failures in the printer. This section also
contains the procedures necessary to
troubleshoot print quality problems.
Contents
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Xerox DocuPrint P8e Service Manual
Product
Manual Title
Part Number
P8e Laser Printer
Xerox DocuPrint P8e Service Manual
720P41711
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Revision Control List
Product
Manual Title
Part Number
P8e Laser Printer
Xerox DocuPrint P8e Service Manual
720P41711
Page
Date
Revision Control List
Page
Date
Page
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viii
Date
Page
Date
Xerox DocuPrint P8eService Manual
Section 1
Service Call Procedures
1
1.1 Call Flow Diagram .......................................................................... 1-2
1.2 Initial Actions .................................................................................. 1-3
1.3 Corrective Actions.......................................................................... 1-3
1.4 Final Actions ................................................................................... 1-4
Xerox DocuPrint P8e Service Manual
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1-1
Service Call Procedures
1.1 Call Flow Diagram
The basic troubleshooting steps are outlined in the Call Flow Diagram (Figure 1.1). All service calls
begin with Initial Actions and end with Final Actions.
Figure 1.1 Call Flow Diagram.
Initial Actions
Corrective Actions
Parts List
RAPs
Wiring Data
Repair Procedures
General Procedures
Final Actions
Image Quality
Service Call Procedures
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1-2
Correct Any
Secondary Problems
Xerox DocuPrint P8e Service Manual
1.2 Initial Actions
1 Question the operator and verify the problem.
2 Check that the printer paper path is clear of foreign matter such as staples, paper clips, and
paper scraps.
3 After you have identified the problem symptom, check the following items:
• The printer is connected to a wall power outlet, and the outlet is supplying the correct voltage.
• The printer power cord is not frayed or broken.
• The printer is correctly grounded / earthed.
• The printer is in an appropriate operating environment, with no extremes of heat, humidity,
or dirt.
• The printer is not exposed to direct sunlight.
• The printer is on a level and stable surface.
1.3 Corrective Actions
1 If the printer has an obvious failure or fault, you can go directly to the appropriate Repair
Procedure (Section 4) or Repair Analysis Procedure (RAP) (Section 7) and begin corrective
action.
2 If the fault is not obvious, follow the Entry Level RAP (Section 7) to identify the problem and begin
corrective action.
3 After all corrective actions have been made, perform Final Actions.
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1-3
Service Call Procedures
1.4 Final Actions
1 Run Test Prints to evaluate print quality.
2 Perform the Image Quality Checkout procedures in section 7 to correct any print quality defects.
3 Correct any secondary problems (return to Corrective Actions, if necessary).
4 Reinstall the machine covers.
5 Clean the machine and the work area.
6 Ask the customer to send a print job to verify printer operation.
7 Provide operator training as required.
8 Close the call.
Service Call Procedures
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1-4
Xerox DocuPrint P8e Service Manual
Section 2
Printer Specifications
2
2.1 Electrical Specifications ................................................................ 2-2
2.1.1 Power Sources and Consumption ........................................... 2-2
2.1.2 Power On/Off ........................................................................... 2-2
2.1.3 Power Saver ............................................................................ 2-2
2.1.4 Mechanical............................................................................... 2-2
2.1.5 Consumables........................................................................... 2-2
2.2 Physical Location ........................................................................... 2-3
2.3 Functional Specifications .............................................................. 2-3
2.4 Environment.................................................................................... 2-4
2.5 Options ............................................................................................ 2-4
2.6 Paper Specifications ...................................................................... 2-4
2.6.1 Paper limitations ...................................................................... 2-4
2.7 Operating Language and Emulation ............................................. 2-6
2.8 Communication Interfaces ............................................................ 2-6
2.9 Status Display / Controls ............................................................... 2-6
Xerox DocuPrint P8e Service Manual
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2-1
Printer Specifications
2.1 Electrical Specifications
Video Controller (Video I/F)
Video Controller Board (Video I/F) is installed in the printer.
Video Interface Specification to be provided, if necessary.
2.1.1 Power Sources and Consumption
The Xerox P8e printers are available in either a 110 or a 220 volt configuration.
Line
Voltage
Line Voltage
Tolerance
Frequency
Frequency
Tolerance
Running Power
Consumption
Power
Saver
100/115 VAC
90 - 132 VAC
60 Hz
57 - 63 Hz
450 Watts
25 Watts
220/240 VAC
198 - 264 VAC
50 Hz
47 - 53 Hz
450 Watts
25 Watts
2.1.2 Power On/Off
The Xerox P8e printers have an on/off power switch located on left rear corner of machine. The machine
is equipped with a grounded power socket. Printer will power down automatically when not used for a
period of time (see Power Saver).
2.1.3 Power Saver
The Power Saver reduces power automatically when the printer does not receive data for a period of
time. Power Saver is a menu selection in the Remote Control Panel (RCP) software which provides the
user with the ability to control, when the printer enters the power saver state. The default value is 30
minutes. In Power Save mode, the power consumption is under 25 watts.
2.1.4 Mechanical
Unit
Width
Depth
Height
Weight
Metric
345 mm
364.9 mm
224 mm
7.5 Kg
SAE
13.58 in.
14.36 in.
8.8 in
15.4 lbs
2.1.5 Consumables
PRINTER CARTRIDGE: 5000 pages at 5% coverage; more with use of the toner saving Econo Mode.
The starter kit cartridge shipped with the printer is 2.5 K pages with 5% coverage.
Printer Specifications
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2-2
Xerox DocuPrint P8e Service Manual
2.2 Physical Location
224 mm
8.8 in
367 mm
14.36
in
P8e_100
345 mm
13.6 in
Place your printer on a flat, stable surface near your workstation. Leave enough space around the
printer, so that you can easily:
•
open the printer cover
•
load the paper
•
retrieve paper
•
open the front single sheet output tray and retrieve the paper in the front output tray
•
allow air circulation around the vents to prevent the printer from overheating
2.3 Functional Specifications
Warm Up Time
First Print Out
Print Speed - ppm
(pages per minute)
Resolution - dpi
(Dots per inch)
From Sleep mode to
Standby mode
under 30 seconds
From Standby mode
20 seconds
From Power save mode
30 seconds
8 ppm
True 600 x 600 dpi
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2-3
Printer Specifications
2.4 Environment
Temperature
Humidity
Noise
Level
Operating
10o - 32o C
50o - 90.5o F
20 - 80% RH
Sleep (Power Saver) - Background
Standby - Under 29 dB
Printing - Under 47 dB
Within 5o
Shipping
-20o - 40o C
-4o - 104o F
10 - 95% RH
------
------
The printer must not be exposed to:
•
abrupt changes in temperature or humidity
•
any condensation
•
direct sunlight
•
chemicals
•
vibration
•
dusty or dirty environments.
2.5 Options
MEMORY/DRAM: 4MB on board memory standard.
•
With the one available memory expansion slot, memory can expand to include a 4, 8, 16, or 32MB
SIMM. Maximum memory is 36 MB.
•
The SIMM is a customer supplied item (72 pin, 60ns, 32 bit, No Parity, EDO SIMM).
2.6 Paper Specifications
Papers that meet the specifications may be fed either through the Multipurpose Paper Feeder, or the
Manual Single Sheet Feeder. If you use thick paper with a weight of more than 90 g/m2 (40lb), or
envelope, you must insert paper into the Manual Single Sheet Feeder and select Thick Paper.
The Multipurpose Paper Feeder will hold 150 sheets of 60 - 90 g/m2 (16 - 24 lb), or 10 envelopes, 10
labels, 10 transparency films.
The Manual Single Sheet Feeder capacity is 1 sheet 60 - 135 g/m2 paper.
Printer Specifications
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Xerox DocuPrint P8e Service Manual
2.6.1 Paper Limitations
The following are recommended for optimum performance:
•
Adhesive label sheets specifically designed for laser printers.
•
Transparencies specifically designed for laser printers
•
Envelopes with peel-off adhesive strips or more than one fold-over flap to seal must have
adhesives compatible with the heat and pressure of the printer's fusing process.
•
Avoid:
— Paper with embossed lettering, perforations, or rough texture.
— Paper to which color was added after the paper was made.
— Printed forms whose ink is not for laser printing.
Most papers that meet the above specifications may be fed either through the multisheet or the single
sheet paper feeder. Some media meets the specifications but is not ideal for feeding, e.g., paper that is
either highly textured, thicker than normal for its weight, or unusually smooth.
Paper types
Paper Type
Capacity (Sheets)
A4/Letter
Letter
Executive, Legal
B5
A5
Monarch (7 3/4)
COM10
#9
C5
D5
DL
150
2.7 Operating Language and Emulation
The Xerox P8e uses the enhanced PCL5 language (PCL 5e).
The Xerox P8e emulates the HP 5P and lower (PCL 5e).
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Printer Specifications
2.8 Communication Interfaces
Parallel port - Centronics IEEE V1284 compatible bi-directional (Nibble, Byte and ECP).
2.9 Status Display/Controls
The printer’s status is controlled and displayed by both:
•
a panel with a Front Panel Key and three LED's
1)
2)
3)
4)
•
Error Light
Paper light
On-Line light
On-Line / Reset Key
software programs that enable the user to:
— monitor the printer's status on the computer screen (the Status Monitor). The Status Monitor is
a program that runs in background and automatically displays a message(s) on your computer
screen whenever the printer status changes (not available for NT 4.0).
— change printer settings from the computer screen (Remote Control Panel). The Remote
Control Panel (RCP) program allows you to view and change print settings for the following
operating systems; DOS, Windows 3.1, Windows 95, Windows 98, and NT 4.0.
Printer Specifications
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Xerox DocuPrint P8e Service Manual
Section 3
Parts Lists
3
PL 1 Covers ........................................................................................... 3-2
PL 2 Front Cover................................................................................... 3-4
PL 3 Paper Trays................................................................................... 3-6
PL 4 Feeder ........................................................................................... 3-8
PL 5 Paper Transport ......................................................................... 3-10
PL 6 Frame Assembly (1 of 2) ........................................................... 3-12
PL 7 Frame Assembly (2 of 2) ........................................................... 3-14
PL 8 Fuser ........................................................................................... 3-16
PL 9 Main Drive Motor ........................................................................ 3-18
PL 10 Electronics................................................................................ 3-20
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3-1
Parts Lists
PL 1 Covers
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
A)
-----802E00400
---------------802E00380
-----113R00296
600K72020
Top Cover}
Rear Cover
Right Side Cover
Bottom Cover
Face Up Cover
Front Cover
Left Side Cover
Print Cartridge
Hardware Kit
Parts Lists
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Xerox Docuprint P8e Service Manual
1
7
8
6
2
3
P8e_308
5
Xerox DocuPrint P8e Service Manual
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Parts Lists
PL 2 Front Cover
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
A)
--------------------802E00380
----------3E50440
107E16960
101E19680
-----802E00390
600K72020
Front Cover {Includes Items 2 through 7}
Stacker Extender
Stacker
Duct
Front Cover
Stacker Guide
Stopper
Key
LED
Control Panel
Control Panel Cover
Face Up Exit Cover
Hardware Kit
Parts Lists
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Xerox Docuprint P8e Service Manual
1
3
2
7
6
4
5
9
10
12
8
11
P8e_301a
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Parts Lists
PL 3 Paper Trays
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
A)
------------------------------------------------------------50E15050
802E00400
600K72020
Media (Paper) Tray {Includes Items 2 through 12}
Gear Adjust Rack, Left
Gear Adjust Rack, Right
Pinion Gear
Auto Tray Adjust, Right
Manual Tray Adjust, Right
Film Guide Sheet
Manual Tray Adjust, Left
Manual Paper Tray
Auto Tray Adjust, Left
Paper Guide Plate
Rear Cover Assembly {Includes Items 13 & 14}
Tray Extender
Rear Cover
Hardware Kit
Parts Lists
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Xerox DocuPrint P8e Service Manual
1
11
2
10
3
9
4
8
5
7
6
12
13
14
P8e_302
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Parts Lists
PL 4 Feeder
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)
32)
A)
19K04760
----------809E18310
19K04770
---------------15K39950
-------------------------7K10890
----------------------------------------32E14350
130E09080
--------------------22E23240
----------600K72020
Paper Separator Unit {Includes Items 2 & 3}
Separator Pad
Separator Holder
Knock Up Spring
Knock Up Spring Holder Assembly {Includes Items 6 & 7}
Knock Up Spring Holder
Knock Up Ground
Separator Spring
Media Unit Knock Up Assembly {Includes Items 10 through 13}
Knock Up Holder, Right
Knock Up Pad
Knock Up Holder, Left
Knock Up Plate
Extension Spring
Media Unit Clutch {Includes Items 16 through 19}
Clutch Hub
Clutch Spring
Clutch Collar
Pick Up Gear
Media Unit Pick Up Assembly {Includes Items 21 through 31}
Knock Up Cam
Paper Guide Roll
E-Ring
Paper Feed Guide
Pick Up Rubber
Pick Up Housing
Knock Up Cam, Right
Pick Up Shaft Pin
Feed Idler Shaft
Feed Roller, Left
Pick Up Shaft
Shaft Lock Bushing
Hardware Kit
Parts Lists
7/98
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Xerox DocuPrint P8e Service Manual
5
1
6
3
12
13
4
2
14
32
21
22
7
24
23
8
22
11
25
26
28
30
22
24
9
29
10
22
20
23
28
30
31
29 28
27
16
17
14
18
19
15
P8e_303
Xerox DocuPrint P8e Service Manual
7/98
3-9
Parts Lists
PL 5 Paper Transport
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
A)
22K64020
------------------------------120E19120
695E58680
130K64640
600K72020
Media Frame Support Unit {Includes Items 2 through 6}
Feed Rubber
Idler Feed Shaft
Feed Shaft Bearing
Feed Spring
Feed Support Frame
Media Feed Gear Unit
Paper Empty Actuator
Paper Separator
Paper Empty Assembly
Hardware Kit
Parts Lists
7/98
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Xerox Docuprint P8e Service Manual
1
2
3
4
2
7
5
8
9
10
6
P8e_304
Xerox DocuPrint P8e Service Manual
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Parts Lists
PL 6 Frame Assembly (1 of 2)
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
A)
62K09270
001K72470
----------------------------------------121E15480
600K72020
LSU (Laser) Unit
Upper Frame Unit
Cover Open Actuator Spring
Cover Open Actuator
Cover Open Micro Switch
Developer Plate, Left
Developer Plate Spring
Developer Plate, Right
Cover Open Sensor Cover
Upper Frame
Paper Feed Solenoid
Hardware Kit
Parts Lists
7/98
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Xerox Docuprint P8e Service Manual
1
2
3
4
9
5
10
6
7
8
P8e_305
Xerox DocuPrint P8e Service Manual
11
7/98
3-13
Parts Lists
PL 7 Frame Assembly (2 of 2)
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)
32)
33)
34)
35)
36)
37)
38)
39)
40)
A)
22E23250
19K04780
---------------------------------------------007E59210
15K39960
---------------------------------------------130E09090
120E19130
101E19690
------------------------------108K00690
---------------38K12830
---------------127E12600
600K72020
Transfer Roller
Transfer Unit Holder {Includes Items 3, 4, & 5}
Transfer Roller Bushing
Transfer Roller Spring
Transfer Roller Holder
Media Unit Operator, Left {Includes Items 7 & 8}
Pad Holder, Left
Separator Pad, Left
Media Unit Operator, Right {Includes Items 10 & 11}
Separator Pad, Right
Pad Holder, Right
Transfer Gear
Lower Frame Unit
Base Frame
Parts Lists
Rubber Foot
Saw Plate
Saw Plate Holder
Feed Sensor Assembly
Exit Actuator
Fuser Cover
Transfer Roller Terminal Unit {Includes Items 27 & 28}
High Voltage Shaft, Large
High Voltage Spring, Large
High Voltage Terminal Unit
High Voltage Shaft, Small
Developer Unit Fuse {Includes Items 32, 33, & 34}
Developer Unit Fuse Contact, Upper
Developer Unit Fuse Plate
Developer Unit Fuse Contact, Lower
Off / On Switch
ELA Unit-PTL
DC Fan Motor
Hardware Kit
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3
12
2
1
4
5
2
3
39
36
4
37
7
38
8
5
6
9
35
10
31
32
22
33
29
11
21
34
30
26
28
13
27
25
14
15
16
24
20
17
18
19
23
40
P8e_306a
Xerox DocuPrint P8e Service Manual
7/98
3-15
Parts Lists
PL 8 Fuser
Item
Part Number
Description
1)
126K12920
126K12970
--------------------------------------------------130E09100
----------122E02490
122E02480
--------------------9K01910
---------------126K12890
17E09150
---------------115E06360
600K72020
Fuser Unit Assembly (115 VAC) {Includes Items 2 through 19}
Fuser Unit Assembly (220 VAC) {Includes Items 2 through 19}
Rubber Exit Roller
Exit Bearing
Exit Gear
Roller
Fuser Cover
AC Electrode, Left
AC Electrode, Right
Thermostat
Fuser Frame
Bracket
Thermistor
Bracket
Exit Spring
Halogen Lamp (115 VAC)
Halogen Lamp (220 VAC)
Heat Roll Bearing, Left
Heat Roller
Heat Roll Bearing, Right
Fuser Gear
Pressure Roller Holder Assembly {Includes Items 21, 22, & 23}
Pressure Roller Bearing
Pressure Roller Bearing Holder
Pressure Roller Bearing Spring
Pressure Roller
Exit Roller Assembly {Includes Items 26, 27, 28, & 29}
Rubber Exit Roll F/Up
Exit Shaft F/Up
Exit Gear
Exit Shaft Bushing - TX
Hardware Kit
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
A)
Parts Lists
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Xerox Docuprint P8e Service Manual
2
1
3
3
4
6
7
5
8
9
10
14
13
12
16
17
11
15
20
26
21
27
22
23
29
18
19
26
24
28
25
20
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P8e_307a
Parts Lists
PL 9 Main Drive Motor
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
A)
127K30150
---------------------------------------------600K72020
Main Drive Motor Assembly {Includes Items 2 through 12}
Main Drive Motor
Motor bracket
Motor Drive Gear
Feed Drive Gear
Gear Bracket
Gear-Drive 1
Gear-Drive 2
Gear-Pulley
RCT-Belt Impeller
Hardware Kit
Parts Lists
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1
2
3
4
5
10
6
9
8
7
P8e_309a
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3-19
Parts Lists
PL 10 Electronics
Item
Part Number
Description
1)
2)
3)
160K60070
114E15570
160K60060
160K55520
--------------------160K55660
160K55510
007K11190
108E05380
108E05390
600K72020
High Voltage Power Supply PWB
AC Plug Assembly
Controller PWB (115 VAC)
Controller PWB (220 VAC)
SIMM 4MB
SIMM 8MB
SIMM 16MB
SIMM 32MB
Engine Controller PWB (115 VAC)
Engine Controller PWB (220 VAC)
Joint PWB
Fuse (115 VAC / T8A)
Fuse (220 VAC / T5A)
Hardware Kit
4)
5)
6)
7)
A)
Parts Lists
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1
6
7
2
3
5
4
P8e_310a
Xerox DocuPrint P8e Service Manual
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Parts Lists
Notes
Parts Lists
7/98
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Xerox Docuprint P8e Service Manual
Section 4
Repair Procedures
4
4.0 Overview.......................................................................................... 4-3
REP 4.1 Covers
REP 4.1.1 Face Up Cover ................................................................ 4-4
REP 4.1.2 Front Cover ..................................................................... 4-5
REP 4.1.3 Rear Cover ...................................................................... 4-6
REP 4.1.4 Top Cover ........................................................................ 4-7
REP 4.1.5 Left and Right Side Covers ............................................. 4-8
REP 4.2 Paper Feed
REP 4.2.1 Paper Feed Solenoid....................................................... 4-9
REP 4.2.2 Upper Frame Assembly................................................. 4-10
REP 4.2.3 Paper Feeder Assembly................................................ 4-12
REP 4.3 Paper Transportation and Sensing
REP 4.3.1 Pfeed Sensor................................................................. 4-14
REP 4.3.2 Paper Empty Sensor ..................................................... 4-15
Xerox DocuPrint P8e Service Manual
7/98
4-1
Repair Procedures
REP 4.4 Fuser
REP 4.4.1 Fuser Assembly............................................................. 4-16
REP 4.4.2 Fuser Pressure Roller ................................................... 4-18
REP 4.4.3 Halogen Lamp (Fuser Heat Rod) .................................. 4-19
REP 4.4.4 Fuser Thermistor ........................................................... 4-20
REP 4.5 Drive and Xerographic Modules
REP 4.5.1 Print Cartridge ............................................................... 4-21
REP 4.5.2 Gear Bracket ................................................................. 4-22
REP 4.5.3 Main Drive Motor Assembly .......................................... 4-23
REP 4.5.4 Transfer Roller ............................................................... 4-24
REP 4.5.5 DC Fan Motor ................................................................ 4-25
REP 4.5.5 DC Fan Motor
REP 4.6.1 Bottom Shield ................................................................ 4-26
REP 4.6.2 Engine Controller PWB ................................................. 4-27
REP 4.6.3 Controller PWB.............................................................. 4-29
REP 4.6.4 LSU (Laser) Assembly .................................................. 4-30
REP 4.6.5 HVPS (High Voltage Power Supply) PWB .................... 4-31
REP 4.6.6 Joint PWB...................................................................... 4-32
Repair Procedures
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Xerox DocuPrint P8e Service Manual
4.0 Overview
Locations given in the Repair Procedures are always referenced from the front of the printer as you are
facing the Control Panel. See figure 4.0.1.
Figure 4.0.1 Printer Orientation.
Left
Rear
Front
Right
P8e_300
The following notations apply:
•
Arrows in the illustrations show direction of movement.
•
Numbers in an illustration refer to the corresponding steps in the procedure being performed.
Example, REP 4.1.1, step 2 indicates to press on the two locking tabs. Notice that the two locking
tabs in the illustration are labeled 2.
•
At the bottom of each illustration is a number. In the illustration above the number is P8e_300. This
is the art number and is used by the developers for tracking and control of the art.
There are a number of steps you should follow each time before you begin a procedure:
1 Do not use force to remove or install printer components.
2 Use only the screw size and type designated in the REP. The wrong screw could easily damage
tapped holes.
3 Wear a wrist strap to dissipate static electricity, which may damage sensitive electronic parts, and
use a grounded mat when working with PWBs.
4 See Section 6 for the precise location of electrical connectors in the printer.
Xerox DocuPrint P8e Service Manual
7/98
4-3
Repair Procedures
REP 4.1 Covers
REP 4.1.1 Face Up Cover
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Press on the two locking tabs and open the cover (Figure 4.1.1a).
3 Carefully bend the cover in the middle until the hinge pin is free of the printer frame (Figure
4.1.1b).
4 Remove the Face Up Cover.
Figure 4.1.1a. Face Up Cover Locking Tabs.
2
P8e_257
Figure 4.1.1b. Face Up Cover Removal.
3
4
P8e_258
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Repair Procedures
7/98
4-4
Xerox DocuPrint P8e Service Manual
REP 4.1.2 Front Cover
Removal
1
2
3
4
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Panel Board Cover, the clear plastic lens, and the blue Online/Reset button. Allow
the Panel Board to remain connected to the harness (Figure 4.1.2a).
5 Carefully push the right side of the Front Cover out until it is free of the hinge pin. Remove the
Front Cover (Figure 4.1.2a).
6 Unplug the Control Panel connector.
Figure 4.1.2a. Front Cover Removal.
P8e_223
4
Left Side
5
P8e_210a
Right Side
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-5
Repair Procedures
REP 4.1.3 Rear Cover
Removal
1
2
3
4
Switch the printer power off and disconnect the AC power cord.
Remove the three screws that secure the Rear Cover (Figure 4.1.3a).
Release the two lock tabs that secure the bottom of the cover (Figure 4.1.3a).
Slide the cover up and remove.
Figure 4.1.3a. Rear Cover.
3
2
P8e_236
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Repair Procedures
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Xerox DocuPrint P8e Service Manual
REP 4.1.4 Top Cover
Removal
1
2
3
4
5
Switch the printer power off and disconnect the AC power cord.
Remove the Rear Cover (REP 4.1.3).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the two screws that secure the front of the Top Cover (Figure 4.1.4a).
Lift the Top Cover to remove (Figure 4.1.4a).
Figure 4.1.4a. Top Cover Removal.
4
P8e_315
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-7
Repair Procedures
REP 4.1.5 Left and Right Side Covers
Removal
1
2
3
4
5
6
7
8
9
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the screw securing the side cover (Figure 4.1.5a).
Release the locking tab located at the top of the side cover (Figure 4.1.5a).
Remove the side cover.
Figure 4.1.5a. Left and Right Side Cover Removal.
7
8
8
8
7
8
P8e_238
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Repair Procedures
7/98
4-8
Xerox DocuPrint P8e Service Manual
REP 4.2 Paper Feed
REP 4.2.1 Paper Feed Solenoid
Removal
1
2
3
4
5
6
7
8
9
10
11
12
13
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Covers (REP 4.1.5).
Remove the Bottom Shield (REP 4.6.1).
Remove the Gear Bracket (REP 4.5.2).
Remove the Controller PWB (REP 4.6.3).
Remove the Engine Controller PWB (REP 4.6.2).
Remove the solenoid connector from CN 402 of the Joint PWB.
Remove the two screws (and ground strap) that secure the Paper Feed Solenoid to the printer
frame (Figure 4.2.1a).
Figure 4.2.1a. Paper Feed Solenoid Removal.
13
P8e_311a
1
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-9
Repair Procedures
REP 4.2.2 Upper Frame Assembly
Removal
1
2
3
4
5
6
7
8
9
10
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Left and Right Side Covers (REP 4.1.5).
Remove the Gear Bracket (REP 4.5.2).
Remove the HVPS (REP 4.6.5).
Remove the two screws that secure the Paper Feed Solenoid to the printer frame (Figure
4.2.2a). Remove the solenoid from the frame but do not disconnect the solenoid harness.
11 Remove the six screws that secure the Upper Frame Assembly (Figure 4.2.2a).
12 Lift-up the left side of the Upper Frame Assembly approximately 12 mm (0.5 in). Lift-up the rear of
the right side of the Upper Frame Assembly. Move the Upper Frame Assembly to the right to
disconnect the front hinge pin and remove (Figure 4.2.2b).
Figure 4.2.2a. Upper Frame Assembly Removal.
11
10
P8e_244
Repair Procedures
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4-10
Xerox DocuPrint P8e Service Manual
Figure 4.2.2b. Upper Frame Assembly Removal.
12
P8e_245
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-11
Repair Procedures
REP 4.2.3 Paper Feeder Assembly
Removal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Left and Right Side Covers (REP 4.1.5).
Remove the Gear Bracket (REP 4.5.2).
Remove the HVPS (REP 4.6.5).
Remove the Upper Frame Assembly (REP 4.2.2).
Remove the screw that secures the earth (ground) strap to the left end of the paper feed shaft
(Figure 4.2.3a).
Pull out on the locking tab of the left bearing and rotate the bearing 45 degrees clockwise (Figure
4.2.3a).
Press the locking tab and remove the frame insert.
Remove the E-Ring that secures the drive gear and clutch to the right end of the paper feed shaft
(Figure 4.2.3a). remove the Gear and Clutch.
Move the left end of the Paper Feeder Assembly toward the front of the printer and remove the
assembly.
Figure 4.2.3a. Paper Feeder Assembly Removal.
15
12
11
14
14
P8e_314
Repair Procedures
7/98
4-12
Xerox DocuPrint P8e Service Manual
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-13
Repair Procedures
REP 4.3 Paper Transportation and Sensing
REP 4.3.1 Pfeed Sensor
Removal
1
2
3
4
5
6
7
8
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Rear Cover (REP 4.1.3).
Turn the printer up side down.
Remove the Bottom Shield (REP 4.6.1).
Remove the Engine Controller PWB (REP 4.6.2).
Disconnect CN401 from the Joint PWB (Figure 4.3.1a).
Remove the two screws that secure the Pfeed Sensor to the printer frame (Figure 4.3.1a).
Remove the Pfeed Sensor.
Figure 4.3.1a. Pfeed Sensor Removal.
8
7
P8e_318
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Repair Procedures
7/98
4-14
Xerox DocuPrint P8e Service Manual
REP 4.3.2 Paper Empty Sensor
Removal
1
2
3
4
5
6
7
8
9
10
11
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Rear Cover (REP 4.1.3).
Turn the printer up side down.
Remove the Bottom Shield (REP 4.6.1).
Remove the Engine Controller PWB (REP 4.6.2).
Remove the Controller PWB (REP 4.6.3).
Remove the Pfeed Sensor (REP 4.3.1).
Disconnect CN403 from the Engine Controller PWB (Figure 4.3.2a).
Remove the two screws that secure the Paper Empty Sensor to the printer frame (Figure 4.3.2a).
Lift the front end of the Sensor Assembly and move the assembly to free the three tabs (Figure
4.3.2a).
12 Move the assembly to the left and disconnect the drive shaft. Remove the Paper Empty Sensor
Assembly.
13 Press the lock tab and remove the Paper Empty Sensor from the assembly.
Figure 4.3.2a. Paper Empty Sensor Removal.
10
13
9
P8e_317
P8e_316
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-15
Repair Procedures
REP 4.4 Fuser
REP 4.4.1 Fuser Assembly
Removal
1
2
3
4
5
6
7
8
9
10
11
12
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Face Up Cover (REP 4.1.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the screw that secures the Wire Cap (Figure 4.4.1a). Remove the Wire Cap.
Disconnect the Fuser Harness from CN1 on the Engine Controller PWB (Figure 4.4.1a).
Remove the two screws that secure the AC power wires to the Fuser Assembly (Figure 4.4.1a).
Remove the two screws that secure the Fuser Assembly to the printer frame (Figure 4.4.1a).
Use a small screwdriver to carefully release the two locking tabs on the front of the Fuser
Assembly (Figure 4.4.1a).
13 Move the Fuser Assembly to the left until right hinge pin is free of the printer frame.
14 Lift the right end of the Fuser Assembly up approximately 25mm (1in.), and move the right end
toward the rear of the printer. (Figure 4.4.1a)
15 Continue to move the right end toward the rear of the printer until the left end is free of the printer
frame. Remove the Fuser Assembly.
Figure 4.4.1a. Fuser Assembly Removal.
14
12
11
8
10
Repair Procedures
9
12
P8e_225
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Xerox DocuPrint P8e Service Manual
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-17
Repair Procedures
REP 4.4.2 Fuser Pressure Roller
Removal
1
2
3
4
5
6
7
8
9
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Face Up Cover (REP 4.1.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the Fuser Assembly (REP 4.4.1).
Remove the Fuser Pressure Roller from the bearings (Figure 4.4.2a).
Figure 4.4.2a. Fuser Pressure Roller Removal.
P8e_313
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
Repair Procedures
7/98
4-18
Xerox DocuPrint P8e Service Manual
REP 4.4.3 Halogen Lamp (Fuser Heat Rod)
Removal
1
2
3
4
5
6
7
8
9
10
11
12
13
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Face Up Cover (REP 4.1.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the Fuser Assembly (REP 4.4.1).
Turn the Fuser Assembly up side down and remove the earth (ground) strap from the right end of
the Fuser (Figure 4.4.3a).
Remove the two screws that secure the Halogen Lamp to the AC Terminals (Figure 4.4.3a).
Carefully lift the Fuser Roll and bearings out of the Fuser Assembly.
Remove the Halogen Lamp and Fuser Drive Gear from the Fuser Roll (Figure 4.4.3a).
Remove the drive gear from the Halogen Lamp (Figure 4.4.3a).
Figure 4.4.3a. Halogen Lamp Removal.
10
12
9
10
P8e_319
13
Replacement
1 Assemble in reverse order.
2 Ensure the four Fuser Stripper Fingers are on top of the Fuser Roll.
3 Verify proper operation.
Xerox DocuPrint P8e Service Manual
7/98
4-19
Repair Procedures
REP 4.4.4 Fuser Thermistor
Removal
1
2
3
4
5
6
7
8
9
10
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Face Up Cover (REP 4.1.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the Fuser Assembly (REP 4.4.1).
Remove the Fuser Heat Roll (REP 4.4.3).
Remove the two screws that secure the Overheat Thermostat (Figure 4.4.4a). Remove the
Thermostat.
11 Release the six locking tabs (Figure 4.4.4a) and remove the Fuser Cover (the AC Electrodes are
attached to the bottom of the Fuser Cover).
12 Remove the screw that secures the Thermistor to the Fuser Assembly (Figure 4.4.4a). Remove
the Thermistor.
Figure 4.4.4a. Fuser Thermistor Removal.
11
10
12
P8e_320
Replacement
1 Assemble in reverse order.
2 Ensure the four Fuser Stripper Fingers are on top of the Fuser Roll.
3 Verify proper operation.
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REP 4.5 Drive and Xerographic Modules
REP 4.5.1 Print Cartridge
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Open the printer’s front cover.
3 Grasp the Print Cartridge Handle as shown in Figure 4.5.1a. Pull the Printer Cartridge up and out
of the printer.
Figure 4.5.1a. Printer Cartridge Removal.
3
2
P8e_268
4 If the Printer Cartridge will be out for longer then a few minutes, cover the Cartridge with several
sheets of paper to protect it from light.
Replacement
1 Assemble in reverse order.
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Repair Procedures
REP 4.5.2 Gear Bracket
Removal
1
2
3
4
5
6
7
8
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the six screws that secure the Gear Bracket to the printer frame (Figure 4.5.2a).
Figure 4.5.2a. Gear Bracket Removal.
9
8
P8e_200a
9 Lower the Gear Bracket to access the Drive Motor. Disconnect the Drive Motor Harness from the
Drive Motor (Figure 4.5.2a).
10 Remove the Gear Bracket.
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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REP 4.5.3 Main Drive Motor Assembly
Removal
1
2
3
4
5
6
7
8
9
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Cover (REP 4.1.5).
Remove the Gear Bracket (REP 4.5.2).
Remove the three screws that secure the Drive Motor Assembly to the Gear Bracket (Figure
4.5.3a).
Figure 4.5.3a. Drive Motor Assembly.
10
9
P8e_234a
10 Remove the two gears from the Drive Motor Assembly (Figure 4.5.3a).
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Repair Procedures
REP 4.5.4 Transfer Roller
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
NOTE: Wear rubber gloves when removing the Transfer Roller. Touching the rubber part of the roller
can cause print quality problems.
3 Press the locking tabs on the bushings on each end of the Transfer Roller. Remove the Transfer
Roller and the bushings.
Figure 4.5.4a. Transfer Roller Removal.
3
P8e_243
Replacement
1 If installing a new Transfer Roller, remove the gear and bushings from the old roller and place on
the new roller.
2 The high voltage contact for the roller is located in the left side frame. Slide the Transfer Roller to
the right and insert the left bushing and gear into position.
3 Slide the roller to the left against the high voltage contact and insert the right bushing.
4 Assemble remaining components in reverse order.
5 Verify proper operation.
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REP 4.5.5 DC Fan Motor
Removal
1
2
3
4
5
6
7
8
9
10
11
12
13
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Right Side Covers (REP 4.1.5).
Remove the Bottom Shield (REP 4.6.1).
Remove the Gear Bracket (REP 4.5.2).
Remove the Controller PWB (REP 4.6.3).
Remove the Engine Controller PWB (REP 4.6.2).
Remove the fan connector from CN 408 of the Joint PWB.
Remove the two screws securing the DC Fan Motor to the printer frame (Figure 4.5.5a).
Figure 4.5.5a. DC Fan Motor Removal.
13
P8e_400
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Repair Procedures
REP 4.6 Electrical Modules
REP 4.6.1 Bottom Shield
Removal
1
2
3
4
5
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Turn the printer up side down (Figure 4.6.1a).
Remove the three screws that secure the Shield to the bottom of the printer (Figure 4.6.1a).
Lift and remove the shield (Figure 4.6.1a).
Figure 4.6.1a. Bottom Shield.
4
5
P8e_239
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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REP 4.6.2 Engine Controller PWB
Removal
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
1
2
3
4
5
6
7
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Rear Cover (REP 4.1.3).
Turn the printer up side down.
Remove the Bottom Shield (REP 4.6.1).
Disconnect J5 from the Controller PWB (Figure 4.6.2a).
Remove the five screws that secure the Engine Controller PWB to the bottom of the printer
(Figure 4.6.2a).
8 Lift the edge of the Engine Controller PWB that is next to the Controller PWB approximately 40
mm (1.5 in.) and disconnect CN406 from the Joint PWB (Figure 4.6.2a).
9 Continue to lift the Engine Controller PWB and disconnect CN1, CN2, CN201, CN202, and the
AC inline connector (Figure 4.6.2a).
10 Remove the Engine Controller PWB.
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Repair Procedures
Figure 4.6.2a. Engine Controller Removal.
7
6
8
9
P8e_240
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REP 4.6.3 Controller PWB
Removal
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
1
2
3
4
5
6
7
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Rear Cover (REP 4.1.3).
Turn the printer up side down.
Remove the Bottom Shield (REP 4.6.1).
Disconnect J2 and J5 from the Controller PWB (Figure 4.6.3a).
Remove the four screws that secure the Controller PWB to the printer frame (Figure 4.6.3a).
Remove the Controller PWB.
Figure 4.6.3a. Controller PWB Removal.
6 6
7
7
7
7
P8e_312
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Repair Procedures
REP 4.6.4 LSU (Laser) Assembly
Removal
1
2
3
4
5
6
7
8
9
10
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Disconnect the harness connected to the left side of the Laser Assembly (Figure 4.6.4a).
Remove the screw that secures the ground wire to the Laser (Figure 4.6.4a).
Remove the four mounting screws that secure the Laser to the printer frame (Figure 4.6.4a).
Turn the Laser up side down and disconnect the harness connected to the right side of the Laser
(Figure 4.6.4a).
Figure 4.6.4a. Laser Assembly Removal.
9
8
7
10
P8e_231a
Replacement
1 Clean the Laser window.
1 Assemble in reverse order.
2 Verify proper operation.
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REP 4.6.5 HVPS (High Voltage Power Supply) PWB
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
Removal
1
2
3
4
5
6
7
8
9
10
Switch the printer power off and disconnect the AC power cord.
Remove the Face Up Cover (REP 4.1.1).
Remove the Print Cartridge (REP 4.5.1).
Remove the Front Cover (REP 4.1.2).
Remove the Rear Cover (REP 4.1.3).
Remove the Top Cover (REP 4.1.4).
Remove the Left Side Cover (REP 4.1.5).
Disconnect the following from the top of the HVPS PWB, CN2, CN3, and CN4 (Figure 4.6.5a).
Remove the five screws that secure the HVPS to the printer frame (Figure 4.6.5a).
Lower the HVPS PWB to access connector CN1. Disconnect CN1 from the HVPS PWB (Figure
4.6.5a).
NOTE: With the HVPS PWB removed, the four high voltage contacts can be removed. The three top
contacts are the same size. The bottom contact (transfer) is longer than the other three (Figure
4.6.5a).
Figure 4.6.5a. High Voltage Power Supply Removal.
9
7
P8e_227
8
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Repair Procedures
REP 4.6.6 Joint PWB
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
Removal
1
2
3
4
5
6
7
Switch the printer power off and disconnect the AC power cord.
Remove the Print Cartridge (REP 4.5.1).
Remove the Rear Cover (REP 4.1.3).
Turn the printer up side down.
Remove the Bottom Shield (REP 4.6.1).
Remove the Engine Controller PWB (REP 4.6.2).
Disconnect CN401, CN402, CN403, CN404, CN405, CN407 and CN408 from the Joint PWB
(Figure 4.6.6a).
8 Remove the three screws securing the Joint PWB to the Printer Frame (Figure 4.6.6a). Remove
the Joint PWB.
Figure 4.6.6a. Joint PWB Removal.
8
7
P8e_229
Replacement
1 Assemble in reverse order.
2 Verify proper operation.
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Xerox DocuPrint P8e Service Manual
Section 5
General Procedures and
Information
5
5.1 Precautions ..................................................................................... 5-3
5.1.1 General Safety Precautions..................................................... 5-3
5.1.2 Service Precautions................................................................. 5-3
5.1.3 ESD Precautions ..................................................................... 5-4
5.1.4 Laser Safety............................................................................. 5-4
5.2 Printer Operations .......................................................................... 5-5
5.2.1 Control Panel ........................................................................... 5-5
5.2.2 Printer Modes .......................................................................... 5-6
5.2.2.1 Ready Mode (Online)...................................................... 5-6
5.2.2.2 Test Mode ....................................................................... 5-6
5.2.3 Clearing Printer Memory.......................................................... 5-7
5.2.4 Print Cartridge Cleaning Procedure ......................................... 5-7
5.3 Printer Software .............................................................................. 5-7
5.3.1 Installing Software ................................................................... 5-8
5.3.1.1 Installing Printer Drivers.................................................. 5-8
5.3.1.2 Installing Status Monitor and Remote Control Panel ........ 585.3.2 The Status Monitor .......................................................... 5-9
5.3.3 Remote Control Panel (RCP) ................................................ 5-10
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General Procedures and Information
5.3.3.1 Total View Tab............................................................... 5-12
5.3.3.2 Printer Tab .................................................................... 5-13
5.3.3.3 Page Tab....................................................................... 5-14
5.3.3.4 Font Tab ........................................................................ 5-15
5.3.3.5 Quality Tab .................................................................... 5-16
5.3.3.6 Test Tab ........................................................................ 5-17
5.4 Diagnostic Control Unit (DCU) .................................................... 5-17
5.4.1 Connecting the DCU.............................................................. 5-18
5.4.2 The DCU’s Operating Modes................................................. 5-18
5.4.2.1 Status Mode.................................................................. 5-20
5.4.2.2 Diagnostic Mode ........................................................... 5-21
5.4.3 General Test Procedures ....................................................... 5-22
5.5 Engine Controller PWB ................................................................ 5-25
5.6 Installing Additional Memory....................................................... 5-25
5.7 EPROM Update Procedure .......................................................... 5-27
5.8 Supplemental Tools and Supplies .............................................. 5-29
5.8.1 Tools ...................................................................................... 5-29
5.8.2 Supplies ................................................................................. 5-29
5.9 Abbreviations................................................................................ 5-30
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5.1 Precautions
The three subsections below focus on three kinds of precautions important to service persons:
•
General safety precautions needed by everyone using or handling the printer.
•
Precautions needed by anyone servicing the printer.
•
Additional service precautions specifically related to Electrostatically Sensitive Devices (ESDs).
Read each of these precautions carefully.
5.1.1 General Safety Precautions
1 Do not use this printer near water, or where any kind of liquid can spill on it, and do not expose it
to inclement weather.
2 Make sure the printer is on a stable surface, and that the surface is large enough to keep the
printer from being accidentally knocked to the floor.
3 The printer's ventilation slots are designed to prevent overheating. Make sure these slots are not
covered or blocked. Don't put the printer in any enclosure that doesn't permit full ventilation.
4 Never insert objects of any kind into the printer through the ventilation slots. Such objects may
touch dangerous high voltage points, causing electric shock, a short circuit, or a fire.
5 Use only a grounded / earthed power source. If you are not sure of the type of power available,
consult your dealer or the local power company.
6 Make sure no one can trip on the power cord or communication cable, and that no weight is
placed on them.
7 Avoid touching the surface of the photo-sensitive drum. The surface is easily marked, and any
scratch or mark can affect print quality.
8 Don't expose the print cartridge to direct light for long periods.
9 Follow the directions in Section 2, “Paper Specifications,” on the proper choice of paper.
10 Before cleaning, disconnect the AC power. Use only a damp cloth for cleaning. Do not use liquid
cleaners or aerosol sprays.
5.1.2 Service Precautions
1 Before disassembly, disconnect the AC power.
2 Replace parts only with the same Xerox parts.
3 Pay attention to the proper orientation of parts when mounting or inserting them.
4 Pay particular attention to the Electrostatically Sensitive Device (ESD) precautions, since failure
to follow them can seriously damage the unit.
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General Procedures and Information
5.1.3 ESD Precautions
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
Semiconductor (solid state) devices that are easily damaged by static electricity are called
Electrostatically Sensitive Devices. Examples are integrated circuits (ICs), large-scale integrated circuits
(LSIs), semiconductor chip components, and some field-effect transistors.
The following techniques are designed to reduce the danger of damage to printer components as a
result of static electricity.
1 Check and observe all the safety and servicing precautions.
2 Before handling any circuit board or wiring assembly, perform the ESD procedures.
NOTE: to avoid the danger of shock, be sure to remove the wrist strap before powering up the unit under
test.
3 Place any sensitive assemblies on a conductive surface. This will prevent accumulation of static
electricity.
4 Do not use freon-propelled chemicals. These can generate enough static charge to damage
sensitive components.
5 Do not remove a replacement component from its protective package until you are ready to
install it. Most replacement components are packaged with leads that are electrically shorted
together by conductive foam, aluminum foil, or other conductive material.
6 Immediately before removing the protective material from the component, touch the protective
material to the printer chassis or the circuit assembly in which the device will be installed.
7 Minimize body motions when handling unpackaged replacement components. Even such simple
motions as clothes brushing together or a foot being lifted from a carpet can generate enough
static electricity to cause damage.
5.1.4 Laser Safety
The DocuPrint P8e laser printer contains a Class IIIb laser. All laser safety information is contained on
pages iii and iv in the front of this manual.
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5.2 Printer Operations
5.2.1 Control Panel
The Control Panel (Figure 5.2.1) is located on the right forward corner of the Front Cover Assembly. The
Control Panel includes a single On/Off-line button and three indicator LEDs.
The On/Off-line button has multiple functions that enable the user to select the desired operation.
The three Indicator LEDs: red (Error), amber (Paper), and green (Ready). These LEDs indicate the
printer’s status. (More detailed information about printer status is available through the Status Monitor
software utility.)
Figure 5.2.1 Control Panel.
Error LED
Paper LED
Ready LED
On/Off-line
Button
sm5_007a
The table below provides various LED conditions and describes their significance.
Indicator
Error LED (on)
Description
There is no print cartridge.
The cover is open.
There is a paper jam (if the Paper LED is on).
Other error condition.
Error LED (blink)
Printer memory is insufficient for print job.
Paper LED (on)
The paper tray is empty.
There is a paper jam (if Error LED is also on).
Paper LED (blink)
Ready LED (on)
Ready LED (blink)
The printer is on manual feed mode (push On/Off-line
button to feed paper from manual feeder).
The printer is ready to receive and process data.
The printer is receiving or processing data.
Ready LED (off)
The printer is offline
All LEDs (blink)
Possible printer failure.
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General Procedures and Information
5.2.2 Printer Modes
The DocuPrint P8e has two modes of operation, each with its own set of options.
1 Ready Mode (online)
2 Test Mode
5.2.2.1 Ready Mode (Online)
The Ready Mode (Online) is the printer’s normal operating mode. In this mode the printer is online and
ready to print. Ready Mode occurs automatically when the printer is switched on. The printer can be
taken Offline by pressing the On/Off-line button. When the button is pressed the Ready LED will go off.
Ready Mode may be restored by pressing the On/Off-line button again.
When the printer is in Ready Mode, the “Ready” LED on the Control Panel is lit. When the “Ready” LED
is blinking, the printer is receiving/processing data, or printing. When the Ready LED is OFF, the printer
is Offline.
5.2.2.2 Test Mode
In Test Mode, the printer is able to print a one page configuration sheet.
Local Test Mode
To initiate a printer self-test and print a configuration sheet, follow these steps:
1) Make sure the printer in on-line.
2) Press and hold the On/Off-line button until all three LEDs are blinking (approximately four
seconds), then release the button. The configuration sheet will be printed.
Remote Test Mode
The Remote Control Panel software can be used to tell the printer to print a one page printer
configuration sheet, although it cannot make the printer do a self-test.
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5.2.3 Clearing Printer Memory
This function resets the printer, restoring user default settings and clearing all data from the printer’s
memory except permanent fonts and macros.
To clear printer memory, while the “Ready” LED is OFF (the On/Off-line button has been pressed to take
the printer off line), press and hold the On/Off-line button until all three LED's are blinking. When the
button is released, all the LEDs except the Ready LED go out.
5.2.4 Print Cartridge Cleaning Procedure
This procedure is used to remove excess toner from the Print Cartridge.
To initiate this procedure, the “Ready” LED must be ON.
Press and Hold the On/Off-line button until all four LED’s remain lit (not blinking) and the Printer begins
to cycle up (starts the feed of the page).
The printer will produce one page. Depending on the contamination, the page may contain a heavy
concentration of background. More than one cleaning cycle may be required to remove contamination.
Replace Printer Cartridge if cleaning cycles do not resolve the print quality problem.
5.3 Printer Software
The customer has a choice of different software configurations depending upon their needs. The
DocuPrint P8e can be configured for Windows 3.1x, Windows 95/98 or Windows NT 4.0. The printer
software includes: Print Drivers, Remote Control Panel (RCP), and Status Monitor. This section
describes each of the software selections.
These programs enable the user to:
•
be alerted of any printer changes (Status Monitor)
•
configure the printer (driver) (RCP for DOS programs inside Windows)
•
set default parameters for the current print job (driver) (RCP for DOS programs inside Windows)
•
adjust toner usage (RCP)
•
print a configuration sheet, handle printer fonts and print a demo page (RCP)
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General Procedures and Information
5.3.1 Installing Software
To install the software, the printer does not need to be connected to the computer or be on. However, in
order to start the RCP or SM programs, the printer must be powered on and properly connected by a
IEEE-1284 compliant parallel printer cable.
5.3.1.1 Installing Printer Drivers
Installing the software for Windows 95/98
1 Start Windows. If Windows detects new hardware, click cancel.
2 Insert the disk labeled “Xerox DocuPrint P8e Driver Disk” into your computer’s floppy drive.
3 From the Start menu, select Run.
4 In the Run dialog box, type a:\setup (or b:\setup) and press Enter.
5 Follow the on-screen instructions to complete the installation.
6 Remove the diskette before restarting Windows.
7 Restart Windows, as prompted, when the installation is complete.
Installing the software for Windows 3.1x
1 Start Windows.
2 Insert the disk labeled “Xerox DocuPrint P8e Driver Disk” into your computer’s floppy drive.
3 From the Program Manager, select Run from the File menu.
4 In the Run dialog box, type a:\setup (or b:\setup) and press Enter.
5 Follow the on-screen instructions to complete the installation.
6 Remove the diskette before restarting Windows.
7 Restart Windows, as prompted, when the installation is complete.
Installing software for Windows NT 4.0
1 Start Windows.
2 Insert the disk labeled “Xerox DocuPrint P8e NT 4.0 Disk” into your computer’s floppy drive.
3 From the Windows NT 4.0 Start menu, select Settings, then Printers.
4 Double click on the Add Printer icon.
5 Click on My Computer and Next.
6 Select the port you are using, typically LPT1, then click on Next.
7 The computer will list different printer manufactures and models. Click on Have Disk.
8 In the Install from Disk dialog box, in the input box marked “Copy Manufacturer’s Files From:”,
make sure it says “a:\”. Click on OK
9 Xerox DocuPrint P8e will be listed. Click on Next.
10 Follow the on-screen instructions to complete the installation.
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5.3.1.2 Installing Status Monitor and Remote Control Panel
Installing the software for Windows 95/98
1 Insert the diskette labeled “Xerox DocuPrint P8e RCP and SM Disk” into your computer’s floppy
drive.
2 From the Start Menu, select Run.
3 Type A:\setup and press Enter. Follow the on-screen instructions to complete the installation.
Installing the software for Windows 3.1x
1 Insert the diskette labeled “Xerox DocuPrint P8e RCP and SM Disk” into your computer’s floppy
drive.
2 From the Program Manager, select File, Rum.
3 Type a:\setup and press Enter. Follow the on-screen instructions to complete the installation.
Installing software for Windows NT 4.0 (RCP only)
1 Insert the diskette labeled “Xerox DocuPrint P8e NT 4.0 Disk” into your computer’s floppy drive.
2 From the Start Menu, select Run.
3 Type A:\ntrcp\setup and press Enter. Follow the on-screen instructions to complete the
installation.
Installing software for DOS
1 Insert the diskette labeled “Xerox DocuPrint P8e RCP and SM Disk” into your computer's floppy
driver.
2 At the DOS prompt, enter the following commands:
> md dosrcp
> cd dosrcp
> copy a:\dosutil\*.*
> dosp8e.bat
5.3.2 Status Monitor
NOTE: The Status Monitor is not available with Windows NT 4.0.
The Status Monitor program runs in background mode. When selected, the Status Monitor automatically
displays messages from the printer on the computer screen whenever the printer's status changes.
NOTE: On some machines Window’s Print Manager must be disabled to get the Status Monitor to
operate correctly.
Status Monitor Messages
ON-LINE: The printer is in Ready Mode, online and is ready to receive print data. The printer may be in
standby mode or Power Save mode. When first turned on, the printer goes to this mode.
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General Procedures and Information
OFF-LINE: The printer is off-line and not ready to receive print data. The user needs to press the On/Offline button in order to go to ON-LINE mode.
Cover Open or Missing Cartridge: This message could either mean one or both of the following
conditions have occurred:
•
The printer's front cover is not closed properly
•
The image cartridge is not installed or installed improperly.
Can’t communicate with printer. Please check printer.: This error usually indicates some sort of
hardware-related problem such as:
•
The printer is turned off.
•
The printer cable is not connected or not connected properly.
•
The printer cable is defective.
•
The printer port and software driver settings don't match.
Technician’s Note: In the current release of the printer and software, sometimes this message pops up
for a few seconds and goes back down again when the printer is busy: i.e. printing a job or warming up
the fuser.
Paper Tray Open or Empty.: There is no paper either in the Multipurpose Paper Feeder or Manual
Feeder.
Paper jam near input feeder.: The printer had problems grabbing paper from either the Multipurpose
Paper Feeder or Manual Feeder. Paper should be pulled out, arranged carefully, and put back into the
feeder. If there are only a few sheets of paper in the MPF and/or the paper in there has excessive curl,
paper jams of this type will occur.
Paper jam near inside rear of printer.: The printer had a jam while feeding paper into the xerographic
area. To remedy the problem, the user should open the cover, remove the image cartridge, and paper
cleared.
Paper jam near front of printer.: The printer had a jam in the area from the fuser to face-up stacker or
fuser to face-down stacker. To remedy the problem, the user should clear any paper from the stackers,
open the cover, tear off any jammed paper, remove the image cartridge, and clear any remaining paper without using excessive force. If any paper is still jammed in the roller assembly to the face-down
stacker, this will clear when the printer cover is closed and the printer warmed-up.
Memory Full.: The printer is unable to print the current print job because of insufficient memory due to
the complexity of the print job or too many fonts. For this current release, this status error message is not
implemented but is planned for future releases.
Unknown Error.: A catastrophic printer failure such as a laser or fuser error has occurred. For this
current release, it is not known whether this error message has been implemented.
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5.3.3 Remote Control Panel (RCP)
The Remote Control Panel (RCP) has several different functions. As opposed to the driver which allows
the user to control how Windows applications drive the printer, the RCP is used to control printer defaults
for DOS applications run from inside Windows, i.e. MS-DOS Command Prompt. The RCP is also used to
set printer-specific features such as econo mode and Power Save time. These latter features are stored
in non-volatile memory in the printer. The RCP provides six different tabbed control panels:
•
Total View displays the current printer settings. NOTE: This view is not available in Windows NT.
•
Printer enables adjustment of general printing parameters.
•
Page enables choice of page layout, paper type, orientation, number of copies.
•
Font enables selection of fonts and symbol sets.
•
Quality enables adjustment of print density and use of Econo (toner) Saver Mode.
•
Test enables printing of a demonstration page and a configuration page. NOTE: This view is called
About/Test Printer in Windows NT.
To start the Remote Control Panel for Windows:
Windows 95/98 and Windows NT 4.0 - Select Program from the Start menu. Select Xerox DocuPrint
P8e, then Remote Control Panel from the drop down list.
Windows 3.1x - Double click the Xerox RCP folder in Program Manager. Double click the RCP&SM
icon.
The RCP window (shown on the next page) contains three main areas. The top area is a series of tabs
enabling the choice of any of five RCP views: Total View, Printer, Page, Font, Quality and Test. To select
a view, click on the appropriate tab. Beneath the row of tabs is the content for the current tab selection.
At the bottom of the screen is an array of six buttons: Send, Default, Reset, Form Feed, Status Monitor,
and Exit. These six selections appear in all six RCP views. Their uses are as follows:
Send: Works like the “Enter” command. When a parameter is changed, “Send” is boldfaced. Selecting it
writes the change in the Printers’ System Controller's non-volatile memory (NVM).
Default: Resets all printer parameters to factory default values.
Reset: Resets any changes in the RCP the user may have considered implementing but not yet sent to
the printer. Changes RCP to values older values - settings from the printer.
Form Feed: The program sends a form feed character to the printer. In most cases, the printer should
print a page with whatever was in printer memory. However, if the printer was accepting graphics
information before the RCP was started, the printer may interpret the form feed character to be data and
thus not eject a page.
Status Monitor: Displays the current printer status. NOTE: This button is not available in Windows NT.
Exit: Closes the Remote Control Panel.
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General Procedures and Information
5.3.3.1 Total View Tab
sm5_001
The Total View tab (shown above) displays the current printer parameters. The parameters are divided
into sub groups which correspond to the RCP tab selections. NOTE: this tab is not available in Windows
NT.
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5.3.3.2 Printer Tab
sm5_002
The Printer tab (shown above) enables the following printer settings:
Timeout: Sets how long after receiving data the printer waits before feeding paper. The default value is
20 seconds.
Power Save: While waiting for a printout, the printer is in standby mode (18W), but it can go into a sleep
mode with the fuser off (10W). The default time value to change from standby to Power Save mode is 30
minutes.
Emulation: Shows the current emulation. It will always display PCL 5e.
Paper Jam Recovery: If this is checked, the printer will reprint pages that were jammed in the printer.
This feature is only applicable when a jam occurs either in the input feeder area or xerographic area, i.e.
Status Monitor messages “Paper jam near input feeder” or “Paper jam near inside rear of printer.” If a
jam occurs near the output stackers, i.e. SM message “Paper jam near front of printer”, the printer will be
unable to reprint this page.
.
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5.3.3.3 Page Tab
Width:
Height:
sm5_003
The Page tab (shown above) enables the following printer settings:
Paper Size: Sets the default size of the image that will print on paper or envelope. The default value is
letter for 110 VAC operation and A4 for 220 VAC printers.
Lines Per Page: Sets the number of lines per page.
Copies: Sets number of copies to be printed.
Orientation: Determines the orientation of the image on the paper.
.
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5.3.3.4 Font Tab
sm5_004
The Font tab (shown above) enables the following printer settings:
Typeface: Shows the typeface of the current font.
Pitch: The pitch (horizontal spacing) of characters in a font may be selected when a fixed pitch outline
font is being used. Pitch selection is ignored by other fonts.
Symbol: Lists the various groups of font-specific characters and symbols.
Point Size: The point size (height) of a font may be selected when a proportionally spaced outline font is
being used. This selection is ignored by other fonts.
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General Procedures and Information
5.3.3.5 Quality Tab
.
Quality
sm5_005
The Quality tab (shown above) enables the following printer settings:
Density: Determines the overall density of the printed image.
Econo Mode: Determines the toner quantity to use when printing. If this mode is set to ON, the printer
conserves toner when printing (the printer uses roughly 50% less toner than usual). If the value is OFF, it
provides 100% usage. The default value is OFF.
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5.3.3.6 Test Tab
.
Configuration Sheet
Demonstration Page
sm5_006
The Test tab (shown above) contains the software copyright notice and version level. It also enables the
printing of the following test documents:
Configuration Sheet: Prints the printer’s current configuration.
Demonstration Page: Prints a demonstration page showing the main features of the printer.
Technician’s Note: The demonstration page states that standby mode uses “less than 18 Watts” of
power. The true value is 10 Watts.
5.4 The Diagnostic Control Unit (DCU)
The Diagnostic Control Unit (DCU) (600T80340) is a pocket-sized test instrument that enables a variety
of diagnostic tests and provides a coded digital readout which is used to monitor printer functions.
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General Procedures and Information
5.4.1 Connecting the DCU
Follow the instructions below to connect the DCU to the Engine Controller PWB.
1 Switch off the printer and disconnect the AC power cord. NEVER ATTEMPT TO CONNECT THE
DCU WHILE THE PRINTER POWER IS ON.
2 Remove the face up Cover.
3 Remove the front cover.
4 Remove the bottom panel.
5 Install the front cover.
6 Plug the DCU’s four-pin connector into CN3 on the Engine Controller PWB.
7 The Front Cover / Print Cartridge Interlock Switch must be actuated to perform the DCU
tests. The Print Cartridge must be in place and the Front Cover closed or the interlock cheated to
run the tests.
8 Reconnect AC power and switch on the printer.
5.4.2 The DCU’s Operating Modes
Operation of the DCU is simpler than it might appear from the variety of indicators and labels on the
DCU's face (see Figure 5.4.2a). Only some of them are involved at any given time, depending on the
DCU's current operating mode.
The DCU has two operating modes:
•
Status Mode
•
Diagnostic Mode
Two LEDs on the upper left of the DCU's face correspond to the two modes. One or the other will always
be lit to indicate the DCU's current mode.
In both Status and Diagnostic modes, double-digit numeric codes are displayed in the readout window
on the upper left. The meaning of any particular code depends on the DCU's current mode. The two
modes of operation and the associated codes are explained in the next two sections.
NOTE: If there is any discrepancy between the information here and labels on the DCU, ignore the DCU
labels and follow this information.
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Figure 5.4.2a Diagnostic Control Unit
SM5_012
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General Procedures and Information
5.4.2.1 Status Mode
When the printer is powered on after connecting the DCU, the DCU automatically enters the Status
Mode. The Status Mode monitors the status of printer functions during normal operations. As each
function is executed, its Status/Error Code is displayed. If any function fails, the Status/Error Code for
that function is displayed until the problem or error has been corrected. (A list of codes and status/error
parameters is in Table 5.4.3 on the following page.)
If the problem is resolved without disconnecting power, Status Mode removes the error code displayed
and resumes normal operation.
If power is disconnected, powering on once again causes Status Mode to repeat its status review until
another problem is detected, or the review is successfully completed.
Whenever Status Mode no longer detects any problem, the displayed Status Code will be one of the
three Ready codes (00, 01, 02), depending on which paper size has been selected.
Status Mode can be interrupted only by disconnecting power to the printer.
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Table 5.4.2 Status Mode Indications
Code
Indication
Code
Indication
00
Ready (legal)
47
Second feed sensor off
01
Ready (letter)
50
Paper Exit
02
Ready (A4)
60
Open fuser error
20
Print start
61
Warm up
21
Print start (manual)
62
Low heat error
23
Print start (second paper)?
64
Cover open sensor
30
Feed sensor 1st on
68
Overheating error
31
Feed sensor 1st off
70
No paper
33
Feed sensor 1st on (second paper)
71
Paper jam (between feeder and feed
sensor)
34
Feed sensor 1st off (second paper)
72
Jam1 (between feed sensor and exit
sensor
40
Second feed sensor on
73
Jam2 (at exit sensor)
43
Second feed sensor on (second paper)
90
Manual mode
95
LSU not ready
The Test Print Function
The Test Print Function is available in Status Mode when any of the three Ready codes (00, 01, 02) are
displayed. Pressing the Self-Test button (upper right) initiates the printing of a single page and checks all
functions required to produce a printed image. The Test Print is a page covered with vertical lines about
a quarter inch apart.
While the test print is being produced, the display changes as the Status monitor displays the codes for
each function involved in making the test print. If no problems occur during the Test Print operation the
DCU will again display one of the three Ready codes.
5.4.2.2 Diagnostic Mode
Diagnostic Mode enables the individual testing of thirteen different printer functions.
Diagnostic Mode is entered by simultaneously pressing three keys--DOWN, SHIFT, and STOP--at the
time the printer is switched on. If the printer is already connected and in the Status Mode, it is necessary
to switch off the printer, hold down the three keys, and switch on the printer.
When the DCU enters Diagnostic Mode, the readout window displays “00” and all LEDs on the printer's
Control Panel start to blink. The Control Panel LEDs continue to blink as long as the DCU is in
Diagnostic Mode.
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General Procedures and Information
The “00” readout is the Diagnostic Code for testing the main motor. The UP and SHIFT + DOWN keys
are used to scroll the Diagnostic Code list up and down in the readout window to select other diagnostic
tests.
5.4.3 General Test Procedures
As you read each of the paragraphs in this section, refer to the Diagnostic Test Table (Table 5.4.5b). This
will enable you to understand the similarities and differences among the thirteen test procedures. It will
also familiarize you with the use of the table as a guide while performing test procedures.
All thirteen main Diagnostic tests are started in the same way. After the Diagnostic test code has been
selected (see Column 1 in the table), the test is started by pressing the ENTER key (see Column 3).
Except for two, all the diagnostic tests are ended in the same way (see Column 6). After the test
procedure has been completed, the test is ended by pressing SHIFT + STOP. The exceptions are tests
11 and 12, which are ended by switching off the printer.
What happens between starting and stopping a test varies according to the type of test.
The four voltage tests (01-04) require use of a multimeter and probes. Test results are determined from
the multimeter readings (Column 3). Figure 5.4.5a illustrates the locations of the high voltage test points
and Table 5.4.5a indicates the voltage for each.
Table 5.4.5a
High Voltage Readings.
Figure 5.4.5a
High Voltage Test points.
All readings are Volts DC, +/- 5%
DCU Test
Test Point
Voltage
Reading on
High Voltage
PS
CN2
01
Charge
-1400
CN4
02
Metal end of
BTR Roller
-220 to
-550
CN3
HVPS PWB
CN1
03
Metal end of
BTR Roller
600 to 2800
SUPPLY
DEV
04
Bias Medium
Bias Dark
Bias
Bias
-300
-350
Bias Medium
Bias Dark
Supply
Supply
-500
-500
Supply
THV
MHV
Bias
Charge
13
Transfer Trigger
Transfer Duty
Transfer
Transfer
495
673
14
Transfer Duty
Transfer
673
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Transfer
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Xerox DocuPrint P8e Service Manual
Seven diagnostic tests (00, and 05 - 12) (Table 5.4.5b) require no additional equipment, and indicate
results in two ways: by LEDs (Column 5), and/or by obvious activity--sound or movement--as the printer
responds (Column 4).
The results of most tests are indicated by the three LEDs to the right of the readout window. Two of the
LEDs are labeled ON and OFF, and the third is unlabeled. However, these labels can be ignored when
reading results, since it is the pattern of lit LEDs which indicates test results.
For example, consider test 08, the test of the Feed and Exit Sensors. If the feed sensor circuit is working
properly, the “unlabeled” LED, and only that LED, will be lit when the Feed Sensor is actuated. If either of
the other two LEDs light, or if the “unlabeled” LED fails to light, the Feed Sensor circuit is not operating
properly.
Three of the thirteen tests (04, 05, and 10) are multiple tests. After the first test in the series is started by
pressing ENTER, the remaining tests in the series are initiated by pressing the UP key, once in
succession for each remaining test.
Three of the thirteen (07, 08, 09) are tests involving sensors. Pressing ENTER starts the tests. Manually
actuating and deactuating the sensor verifies the operation.
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General Procedures and Information
Table 5.4.5b DCU Test Procedures
Diagnostic
Code
Diagnostic
Test
To Conduct Test
00
Main Drive Motor
Press ENTER
Main Drive Motor Runs
Lit
Shift + Stop
01
Charge Voltage
Press ENTER
Voltage On
Lit
Shift + Stop
02
Transfer Negative
Press ENTER
Voltage On
Lit
Shift + Stop
03
Transfer Positive
Press ENTER
Voltage On
Lit
Shift + Stop
04
Developer Bias
Bias Medium
Bias Dark
Press ENTER
Press UP
Voltage On
Voltage On
Lit
Laser Assembly
Laser Diode & Motor ON
Press ENTER
Press up
Laser Motor On
Laser Diode On
Lit
05
Response
On
LEDs
Off
Lit
To End Test
___
Lit
Lit
Pressing Up stops
one test and starts
next
Shift + Stop
Shift + Stop
Lit
SM5_014
06
Pick-Up Solenoid
Press ENTER
Solenoid Activates
Lit
Shift + Stop
07
Paper Out Sensor
Press ENTER
Remove Paper
---------
Lit
Shift + Stop
Press ENTER
Actuate Feed Sensor
Actuate Exit Sensor
-------------
Press ENTER
Actuate Sensor
Deactuate Sensor
-------------
Fuser Circuit
Standby Heat
Print Heat
Overheating
Press ENTER
Press UP
Press UP
Fuser Warms
At Print Temp
Fuser Overheat
11
Continous Printing
Press ENTER
Prints test prints
Lit
Unplug Printer
12
Print Cartridge Cleaning
Cycle (continous)
Press ENTER
Cleaning Prints
Lit
Unplug Printer
13
Transfer
Transfer Trigger
Transfer Duty
Press ENTER
Automatically Switches
Voltage On
Voltage On
Lit
Lit
Transfer Duty
Press ENTER
Voltage On
Lit
08
09
10
14
Feed & Exit Sensor
Cover Open Sensor
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Lit
Lit
Shift + Stop
Lit
Shift + Stop
Lit
Lit
Lit
Shift + Stop
Lit
Lit
Shift + Stop
Shift + Stop
Xerox DocuPrint P8e Service Manual
5.5 Engine Controller PWB
The Engine Controller PWB:
•
Includes a motor driver that provides the signal necessary to turn the Main Motor.
•
Provides the control signal that energizes the paper pick-up solenoid.
•
Includes a temperature control circuit that monitors the fuser temperature and turns the heat rod on
and off.
•
Monitors the signal from the Cover Open Sensor. If the front cover is open or the Developer unit is
out of the machine or installed correctly the printer will not operate.
•
Provides the control signals necessary to operate the laser.
•
Identifies the installation of a new Print Cartridge.
The Engine Controller PWB monitors four paper sensors.
•
Feed Sensor: Located before the transfer process. Senses if paper is feeding and starts the
process of sending image data to the laser.
•
Exit Sensor: The Exit Sensor is located next to the fuser and monitors paper travel in the fuser
area.
•
Paper Detect Sensor: This sensor senses if there are papers in the Multipurpose Paper Feeder.
•
Paper Width Sensor: Located on the side of the paper path, this sensor is used to detect narrow
paper.
5.6 Installing Additional Memory
The printer is equipped with 4Mb of resident base memory which is expandable to a total of 36Mb. The
base memory may be expanded by installing an additional Single Inline Memory Module (SIMM). By
doing this, the size of the receive buffer and the size of the font download buffer are increased. This also
enables the printing of more complex pages.
On the Controller PWB, there is only one SIMM slot dedicated to increase the printer memory. There are
four available SIMM options to increase the printer memory up to a total of 36Mb. All SIMMs are industry
standard EDO 72 pin 32-bit memory (no parity, 60 ns or faster), and are available in sizes of 4, 8, 16, or
32MB. When the SIMM is installed, the Controller PWB will automatically detect the memory and
increase the printer buffer size.
To install an additional memory module:
1 Switch off printer and disconnect the AC power.
2 Disconnect all cables from the back of the printer.
3 Open the front cover and remove the Print Cartridge.
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General Procedures and Information
4 Turn the printer upside down and remove all the screws securing the shield cover. Remove the
shield cover.
5 If you are replacing a SIMM, push out on the metal clips at each end of the SIMM connector and
pull the SIMM toward you and lift it out.
sm5_010
6 Hold the SIMM with the connection points pointing toward the control board and insert the SIMM
all the way into the connector at a 45 degree angle.
7 Push the SIMM away from you until it snaps into place.
Make sure both metal clips on the connector are fastened and the two pins on the connector are
pushed through the holes on the SIMM.
Step 6
Step 7
sm5_009
sm5_008
8 Replace the shield cover.
9 Turn the printer back over and replace the image cartridge.
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5.7 EPROM Update Procedure
There are two components in the P8e printer that may be upgraded in the field, a Flash EPROM and an
EPROM. The Flash EPROM contains the OS Version and PCL5e Version. The Flash EPROM can be
upgraded without any physical work on the printer. The EPROM, on the other hand, must be upgraded
by physically changing a chip on a circuit board. The EPROM contains the Engine Version. The two work
together, you can not mix and match different version numbers.
The update procedure works in the following environments:
•
MS-DOS version 6.22
•
Windows 95, F8 Command Prompt Only boot
•
Windows 95, MS-DOS Command Prompt
•
Windows 95, Shutdown - Restart computer in MS-DOS mode
•
Windows 3.1, Exit Windows and go to plain DOS version 6.22
NOTE: This procedure does not work with the Windows NT Version 4.0 MS-DOS Command Prompt.
The procedure requires two zipped files which contain the following files:
•
fprt.exe
•
xerox-lt.110 (if default paper size is letter)
or xerox-a4.220 (if default paper size is A4)
•
rom.XXX (XXX represents the version level, i.e. 103 for version 1.03)
•
boot.XXX (XXX represents the version level, i.e. 103 for version 1.03)
The computer’s parallel port should be assigned as standard LPT1 (hex 378) before beginning the
procedure.
Procedure
1 Unzip the files to a temporary directory.
2 Make sure the printer is powered off and the parallel cable is IEEE-1284 compliant and
connected properly.
3 Hold the On/Off-line button and switch on the printer. Continue holding the button for 3-4 seconds
until the LEDs are scrolling in this fashion: error, paper, ready, error, paper, error. Release the On/
Off-Line button.
4 At the C> prompt, type: fprt boot.XXX lpt1 (XXX represents the version level, i.e. 103 for version
1.03).
5 When all the LEDs are blinking simultaneously, approximately 10 seconds, switch off the printer.
6 Hold the On/Off-line button and switch on the printer. Continue holding the button for 3-4 seconds
until the LEDs are scrolling in this fashion: error, paper, ready, error, paper, error. Release the On/
Off-Line button.
7 At the C> prompt, type: fprt rom.XXX lpt1 (XXX represents the version level, i.e. 103 for version
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General Procedures and Information
1.03).
8 Wait approximately 1-2 minutes until the message “The printing is completed!” is displayed and
the LED’s are blinking simultaneously. Switch off the printer.
9 Switch the printer back on. The printer should go to an on-line condition with the ready LED on.
10 At the C> prompt, type: fprt xerox-lt.XXX lpt1 (XXX represents the version level, i.e. 103 for
version 1.03). This tests 115 VAC systems with a default for letter size paper
OR
At the C> prompt, type: fprt xerox-a4.XXX lpt1 (XXX represents the A4letter size paper.
The ready LED should stay on.
11 Switch off the printer and then switch it back on.
12 Print a configuration sheet by holding the On/Off-line button down for about 5 seconds until all
the LEDs are blinking, then release the button.
13 The configuration sheet should list a OS version that corresponds with the version you have just
installed.
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5.8 Supplemental Tools and Supplies
5.8.1 Tools/Kits
Item
Part Number
Anacom G80
600T80138
Diagnostic Control Unit
600T80340
High Voltage Probe
600T1653
5.8.2 Supplies
Item
Cleaning Cloth (treated)
Part Number
35P1538
Cleaning Pads
600S4372
Cotton Swabs
35P2162
Disposable Gloves
99P3082
Disposable Plastic Bags
99P3023
Drop Cloth
5P1737
Film Remover
43P45
Formula A Cleaner
43P48
Glue Capsule
63P560
Polyurethane Pads
600S4653
Towel (heavy duty)
35P3191
Xerox Europe (XE)
Cleaner
Cleaning Pad Kit
Cloth
Fuser Cleaning Solvent Pads
8R90175
600S4372
8R90019
43P83
General Cleaning Solvent
8R90176
Lens Cleaner
8R90177
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General Procedures and Information
5.9 Abbreviations
Abbreviation
Stands for
BCR
Bias Charge Roll
BIOS
Basic Input/Output System
BPS
Bits Per Second
BTR
Bias Transfer Roll
Abbreviation
Stands for
INTR
Interrupt Request
I/O
Input and Output
lb
LDON
CBUSY
Command busy
LED
CCLK
Command clock
lin
Pound(s)
Laser Diode On
Light Emitting Diode
linearity
clk
clock
LSU
Laser Scanner Unit
cm
centimeter(s)
MHV
Main High Voltage
CMOS
CMSG
Complementary Metal Oxide
motor_pa
Motor phase A
Semiconductor
motor_pb
Motor phase B
Command message
MPU
Micro Processor Unit
CON
connector
NC
No Connection
CPU
Central Processing Unit
neg
negative
DCU
Diagnostic Control Unit
OSC
oscillator
DMA
Direct Memory Access
PCU
Printer Control Unit
Direct Memory Access Controller
PPM
Pages Per Minute
DMAC
DOS
DPI
DRAM
DS
DVM
EBUSY
EEPROM
EMSG
HSYNC
INT
INTA
Disk Operating System
PRINT
Dots Per Inch
psync
Dynamic Random Access Memory
Data Strobe
pwr
RAM
Digital Voltmeter
READY
Print command
page synchronization
power
Random Access Memory
Engine ready to print
Engine Status Busy
ROM
Read Only Memory
Electrically Erasable Programmable
SCC
Serial Comm. Controller
Read Only Memory
THV
Transfer High Voltage
Engine Status message
Vcc
Horizontal sync
VCU
Interrupt
VDI
Interrupt Acknowledge
VDO
Image Cartridge
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collector supply voltage (dc)
Video Control Unit
Video data from controller
Video data output
Print Cartridge
Xerox DocuPrint P8e Service Manual
Section 6
Wiring Data
6
6.1 Introduction..................................................................................... 6-2
6.2 Connection and Wiring Diagrams ................................................. 6-3
6.2.1 Master Connection and Wiring Diagram ................................... 6-3
6.3 Circuit Board Layout ...................................................................... 6-4
6.3.1 Controller PWB ......................................................................... 6-4
6.3.2 Joint PWB ................................................................................. 6-6
6.3.3 Engine Controller PWB ............................................................. 6-8
6.3.4 HVPS ...................................................................................... 6-10
6.3.5 Control Panel PWB ................................................................. 6-12
6.3.6 PFeed PWB ............................................................................ 6-12
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Wiring Data
6.1 Introduction
This wiring section contains the master connection diagram, the circuit board layouts, and the circuit
board wiring diagrams.
The master connection and wiring diagram illustrates all the circuit boards and electrical components
and how they are connected.
The circuit board layout section contains the circuit board layouts and the wiring connectors. The circuit
board illustrations show the locations of the connectors and any sensors located on the board. Each
connector has an arrow that indicates the position of pin one for that connector.
The wiring diagrams illustrate the wiring connections between the circuit boards and between circuit
boards and components.
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6.2 Connection and Wiring Diagrams
6.2.1 Master Connection and Wiring Diagram
Engine
Controller
PWB
Ac in
On/off
Switch
Joint PWB
Cn403
Paper Empty
Sensor
Cn401
Pfeed Sensor
Cn404
Developer Fuse
Cn407
Pretransfer Lamp
Cn405
Drive Motor
Cn402
Paper Feed
Solenoid
Cn201
Halogen Lamp
Fuser Heat Rod
Fuser
Thermister
Cn202
Cn1
Hvps
Cn1
Cover Open
Interlock
Cn2
Laser PWB
Cn4
Laser Motor
Cn2
Cn4
Cn3
Transfer Roller
Thv
Charge
Mhv
Developer Bias
Dev
Supply Voltage
Supply
Cn408
Cn5
Cn3
Cn406
DC Fan
Motor
J5
Parallel
Connector
Control
Panel
J1
J7
J2
J8
Controller
PWB
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Master_a
Wiring Data
6.3 Circuit Board Layout
6.3.1 Controller PWB
J1 PARALLEL CONNECTOR
J8
J7
J2
J5
Control
Wiring Data
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Engine
Controller
PWB
CN5 2
1
4
3
6
5
8
7
10
9
12
11
14
13
16
15
18
17
20
19
22
21
24
23
WHT
BLK
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
1 J5
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Controller
PWB
J2 1
2
3
4
5
6
7
ORN
WHT
WHT
WHT
WHT
WHT
WHT
1
2
3
4
5
6
7
Control
Panel
J8 1
2
3
4
Simm
Connector
J7
J1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Parallel
Interface
Connector
WIR001
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Wiring Data
6.3.2 Joint PWB
Cn405
Cn408
Cn402
Cn403
Cn401
Cn406
Cn404
Cn407
Joint_a
Wiring Data
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Xerox DocuPrint P8e Service Manual
CN4 2
1
4
3
6
5
8
7
Engine
10
Controller
9
PWB
12
11
14
13
16
15
18
17
20
19
WHT
BLK
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
1 CN406
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Joint PWB
Cn405 1
2
3
4
5
6
BLK
RED
RED
RED
RED
RED
1
2
BLK
BLK
Clutch
Cn404 1
2
RED
BLK
Developer
Fuse
CN403 1
2
3
BLK
RED
WHT
1
CN401 2
3
4
BLK
RED
BLU
WHT
CN407 1
2
BLK
RED
Cn402
CN408 1
2
3
Drive
Motor
Paper Empty
Sensor
Pfeed Sensor
Pretransfer
Lamp
BLU
RED
DC Fan
Motor
WIR002a
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Wiring Data
6.3.3 Engine Controller PWB
AC POWER
INLINE
CONNECTOR
CN202
F1
CN201
CN2
CN5
CN4
CN1
EXIT
SENSOR
CN3
LVPS
Wiring Data
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CN1 2
1
4
3
6
5
8
7
10
9
12
11
HVPS
14
PWB
13
16
15
18
17
20
19
22
21
24
23
J5
Controller
PWB
2
1
4
3
6
5
8
7
10
9
12
11
14
13
16
15
18
17
20
19
22
21
24
23
BLK
RED
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
CN2
BLK
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
CN5
CN3
Engine
Controller
PWB
1
2
3
4
Diagnostic Control
Unit Connector
CN202
1
2
WHT
WHT
Fuser Heat
Rod
CN1
1
2
WHT
WHT
Fuser
Thermister
CN4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
BLK
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
CN
201
2 CN406
1
4
3
6
5
8
7
10
9
12
11
14
13
16
15
18
17
20
19
Joint
PWB
1
3
OFF/ON
Switch
Black
White
Green
Printer
Power
Connector
AC Line
Wir010
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Wiring Data
6.3.4 HVPS
CN2
CN4
HVPS PWB
CN3
CN1
SUPPLY
DEV
THV
MHV
HVPS
Wiring Data
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CN2 2
1
4
3
6
5
8
7
10
ENGINE
9
CONTROLLER
12
PWB
11
14
13
16
15
18
17
20
19
22
21
24
23
RED
BLK
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
TRANSFER ROLLER
CHARGE
DEVELOPER BIAS
SUPPLY VOLTAGE
CN1
CN4
HVPS
CN3
CN2
1
2
3
4
5
6
BLK
RED
RED
RED
RED
RED
LASER PWB
1
2
3
4
5
BLK
RED
RED
RED
RED
LASER MOTOR
1
2
WHT
WHT
COVER OPEN
INTERLOCK
THV
MHV
DEV
Supply
WIR004
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Wiring Data
6.3.5 Control Panel PWB
LED2
LED3
LED1
CN1
SW1
CONTROL
BLU
WHT
RED
BLK
6.3.6 PFeed PWB
NARROW
S (2)
PFEED SW
PFEED
Wiring Data
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Xerox DocuPrint P8e Service Manual
Section 7
Repair Analysis Procedures
7
RAP 7.1 Using RAPs ............................................................................ 7-2
RAP 7.2 Entry Level RAP ..................................................................... 7-3
RAP 7.3 Main Drive Motor .................................................................... 7-6
RAP 7.4 Control Panel.......................................................................... 7-8
RAP 7.5 Paper Feed.............................................................................. 7-9
RAP 7.6 Paper Jam ............................................................................. 7-10
RAP 7.7 Printer Problem .................................................................... 7-11
RAP 7.8 Image Quality Problems ...................................................... 7-12
7.0.1 Image Quality Defect Definitions, Causes and Solutions ...... 7-12
RAP 7.9 Communications RAP ......................................................... 7-16
RAP 7.10 SIMM Check-Out Procedure.............................................. 7-17
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Repair Analysis Procedures (RAP)
RAP 7.1 Using RAPs
In each of the following repair analysis procedures you are instructed to perform certain actions and
make observations. The instruction is followed by a statement. If your response to the statement is yes,
perform the action following the “Y”. If your response to the question is no, perform the action following
the “N.”
In addition, keep the following points in mind while performing any RAP:
1 RAPs use the following notation when referring to printer connections:
• P/J XX – indicates Plug/Jack XX is connected to a component.
• CN XX – indicates connector XX is connected to a component.
• P XX – refers to the plug of P/J XX (except for connectors soldered directly to the board).
• J XX – refers to the jack of P/J XX (except for connectors soldered directly to the board).
CAUTION!
Use an Electrostatic Discharge Kit (ESD) when handling sensitive electrical
components.
2 When you take a voltage reading at a P/J location, the notation “P/J3-5 and P/J 2-6” indicates
that you should place the red probe (+) of the voltmeter on pin 5 of P/J 3, and place the black
probe (-) of the voltmeter on pin 6 of P/J 2. In most cases the second P/J pin in the notation is a
Return (RTN), Frame Ground (FG), or Signal Ground (SG).
3 When a RAP tells you to take a voltage reading between P/J X and P/J Y, with no pin numbers
given, refer to the Wiring and Connection Diagrams in Section 6 and take readings on ALL pins.
4 Unless otherwise instructed by a RAP, take all voltage readings with the Print Cartridge/Front
Cover Interlock cheated, AC power applied, and the printer power switched on.
5 Voltage values stated in RAPs are approximate. Actual voltages you get may differ slightly. A
small difference in voltage is acceptable.
6 Refer to the appropriate Repair Procedures if you must remove, replace or reinstall a component.
7 The term replace means the named part or parts could be the cause of the initial problem.
Example: the phrase “replace the Fuser Assembly” means to remove the current Fuser
Assembly and replace with a new Fuser Assembly.
Image Quality Problems
Use A4 or letter-size paper when troubleshooting an image quality problem. Use the local Test Print
Mode to determine whether an image quality problem is being caused by the printer or by the PC. If the
test prints are normal, but in the online mode the prints have a image quality problem, the problem may
be in the Controller PWB, Interface Cable, or with the Host Computer.
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
RAP 7.2 Entry Level RAP
If the Status Monitor is displaying a fault message, or there is an obvious failure or fault, go immediately
to the appropriate Repair Procedure or Repair Analysis Procedure. If you are not sure where to begin,
continue troubleshooting using the following steps. If the printer exhibits intermittent operation and/or
inconsistent failure symptoms, the problem may be due to electrical noise.
1 Perform the following:
— Switch the AC power off
— Check the printer paper path for jammed paper or other obstacles
— Ensure that the Multipurpose Paper Feeder has a good supply of fresh paper
— Ensure the Print Cartridge is properly installed
— Ensure that all covers are properly closed.
2 Switch the AC power on. The Main Drive Motor runs.
Y
|
N
Go to RAP 7.3.
3 The Ready LED illuminates and all other LEDs are off.
Y
|
N
If all three LEDs are flashing, go to RAP 7.7, otherwise go to RAP 7.4.
4 The Main Drive Motor stops.
Y
|
N
Replace the Engine Controller PWB (PL 10).
5 Press and hold the On Line/Reset Key for approximately 5 seconds. All LEDs flash.
Y
|
N
Replace in order: Controller PWB (PL 10), Control Panel (PL 2).
6 Release the On Line/Reset Key. All LEDs go out and the Ready LED flashes.
Y
|
N
Replace in order: Controller PWB (PL 10), Control Panel (PL 2).
NOTE: If during steps 7 through 13, all LEDs begin to flash, go to RAP 7.7.
7 Paper is fed from the Multipurpose Paper Feeder.
Y
|
N
Go to RAP 7.5.
8 The Error LED and Paper LED remain off.
Y
|
N
Go to RAP 7.6.
9 The Configuration sheet is delivered to the output tray.
Y
|
N
Remove the Main Cover and verify the operation of the Exit Roll Assembly and drive gears.
Repair or replace as necessary.
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Repair Analysis Procedures (RAP)
10 All printed pages are undamaged (no wrinkles, folded corners, rips, etc.).
Y
|
N
Check the paper path for obstructions, damaged or out of place components, gears, or
rollers.
11 The print quality is acceptable.
Y
|
N
Perform procedure 5.2.4 (Print Cartridge Cleaning Procedure), then go to RAP 7.8.
12 Press and hold the Front Panel Key until the LEDs flash. Release the key. During the printing of
the configuration sheet, the Exit Fan impeller blades rotate.
Y
|
N
Replace the Exit Fan (PL 9).
13 Ask the customer to enter the Remote Control Panel, select the Test Menu, and print a
configuration sheet. The configuration sheet prints successfully.
Y
|
N
Go to RAP 7.9.
14 Ask the customer to select the Page Menu. Change the “Copies” selection to a different number;
example: if the number is 1, change it to 3; if the number is 3, change it to 4. Select send. Select
the Test Menu and print a configuration sheet. The selected parameter is change is indicated on
the configuration sheet.
Y
|
N
Replace the Controller PWB (PL 10).
15 Ask the customer to print a document from an application program. The document prints
successfully.
Y
|
N
Have the customer validate the application and printer setup.
16 The customer has indicated a problem with the memory SIMM.
Y
|
N
The printer appears to be functioning properly. If the customer reported a Status Monitor
Fault / Message that has not been corrected, see Table 7.2. Status Monitor Fault / Message
Table.
17 Go to RAP 7.10.
Repair Analysis Procedures (RAP)
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Table 7.2. Status Monitor Fault / Message Table.
Status Monitor Message
Corrective Action
On Line
Normal Operation, no action required.
Off line
Press the Front Panel Key to go Online. The Ready LED is illuminated.
Warming Up
Paper Tray Open or Empty
Cover Open or Missing
Print Cartridge
Normal Operation, fuser is warming to operating temperature.
Place paper in the paper tray. Ensure that the paper tray is fully inserted into the
printer. Verify that the paper empty actuator moves freely. Replace the Engine
Controller PWB (PL 10).
Verify that the Print Cartridge is properly installed. Verify that the Front Cover is
properly closed. Verify that the Print Cartridge/front cover interlock actuator moves
freely. Replace the Engine Controller PWB (PL 10).
Paper Jam 0
Go to RAP 7.6.
Paper Jam 1
Go to RAP 7.6.
Paper Jam 2
Go to RAP 7.6.
Scanner Error (LASER)
Replace the LASER Assembly (PL 6).
Fuser Error
Replace the Halogen Lamp (PL 8). Replace the Fuser Assembly (PL 8). Replace
Engine Controller PWB (PL 10).
Input/Output (I/O) Error
Inspect printer cable for damage and for proper connection, replace if necessary.
Cable supports bi-directional operation. Verify settings of host computer match
printer settings. Replace the Controller PWB (PL 10).
Memory Full
Print job too large for printer memory. Add additional memory to printer or reduce
the page complexity.
Band Error
Print job too large for printer memory. Add additional memory to printer or reduce
the page complexity.
Port Not Available
Unknown Status
Communications problem, go to RAP 7.9.
Using the DCU, verify the Laser and Fuser operation, replace if necessary (Laser
PL 6 or Fuser PL 8).
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Repair Analysis Procedures (RAP)
RAP 7.3 Main Drive Motor
1 The Error LED on the Control Panel is illuminated.
Y
|
N
Go to step 5.
2 Switch the AC power off. Connect the DCU and switch the AC power on. The DCU displays the
error code 64.
Y
|
N
Replace the Engine Controller PWB (PL 10).
3 Using the DCU, enter the diagnostic mode and run diagnostic code 09. Test the Print Cartridge/
Front Cover Interlock Sensor. The sensor functions normally.
Y
|
N
Verify the mechanical operation of the Print Cartridge/Front Cover Interlock Sensor
Actuator. If functioning normally, replace the Print Cartridge/Front Cover Interlock Sensor
(PL 6).
4 Replace the Engine Controller PWB (PL 10).
5 Remove the Gear Bracket AssemblyREP 4.5.2. The Main Drive Motor Assembly Harness is
properly connected to the Main Drive Motor.
Y
|
N
Properly reconnect the harness, repair, or replace as necessary (PL 9).
6 With the Main Drive Motor Assembly Harness properly connected lay the Gear Bracket and Main
Drive Motor Assembly on the table next to the printer. Cheat the Front Cover Interlock. Switch the
AC power on. The Main Drive Motor Assembly runs normally.
Y
|
N
Go to step 10.
7 Switch the AC power off. Rotate the Paper Feeder Assembly gears. The gears rotate freely.
Y
|
N
Check the gears for obstructions. Repair or replace the Paper Feeder Assembly as
necessary (PL 4).
8 Rotate the Fuser Drive Gears. The Fuser Drive and Exit Drive Gears rotate freely.
Y
|
N
Check the gears for obstructions. Repair or replace the Fuser Assembly as necessary (PL
8).
9 Replace the Print Cartridge (PL 1). If problem persists, replace the Main Drive Motor (PL 9).
10 With AC power applied, Print Cartridge/Front Cover Interlock closed, and the Main Drive Motor
not running, measure the voltage on the Main Drive Motor harness connector. The voltage
between pin 3 and frame ground and between pin 4 and frame ground is +24.0 +/- 2.0 VDC on
both pins.
Y
|
N
Replace the following one at a time; the Engine Controller PWB (PL 10), then the Joint
PWB (PL 10).
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
11 With AC power applied and the Main Drive Motor not running, measure the voltage between pins
1, 2, 5, & 6 and frame ground. The voltage is +24.0 +/- 2.0 VDC on all pins.
Y
|
N
Replace the Main Drive Motor Assembly (PL 9).
12 Replace the following one at a time; the Joint PWB (PL 10), then the Engine Controller PWB (PL
10).
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Repair Analysis Procedures (RAP)
RAP 7.4 Control Panel
1 Switch the AC Power off. After 10 seconds, switch the AC Power on. All the LEDs are off.
Y
|
N
Go to step 8.
2 Remove the Control Panel Cover and measure the voltage from CN1 pin 7 to pin 6. The voltage
is +5.0 +/- 0.5 VDC.
Y
|
N
Go to step 4.
3 Replace in the following order: Controller PWB (PL 10), the Control Panel (PL 2).
4 Measure the voltage on the Controller PWB between J2 pin 7 and frame ground. The voltage is
5.0 +/- 0.5 VDC.
Y
|
N
Go to step 6.
5 Replace the Control Panel (PL 2).
6 Measure the voltage on the Controller PWB between J5 pin 15 and frame ground. The voltage is
5.0 +/- 0.5 VDC.
Y
|
N
Verify the harness between the Controller PWB and the Engine Controller PWB. Repair or
replace as necessary. If harness is OK, replace the Engine Controller PWB (PL 10).
7 Replace the Controller PWB (PL 10).
8 Use Table 7.4 to isolate the problem.
Table 7.4. Control Panel LEDs.
Control Panel LEDs
All three LEDs blink.
Possible Cause
Solution
Defective Laser
Defective Fuser
Go to RAP 7.7.
No Print Cartridge
Open Front Cover
Defective Front Cover Actuator
Engine Controller PWB
Properly reinstall or replace Print Cartridge.
Close Front Cover.
Verify / replace Front Cover Actuator (PL 6).
Replace the Engine Controller PWB (PL 10).
No paper
Low Paper Sensor Actuator
Engine Controller PWB
Add paper or properly adjust paper in tray.
Verify / replace Low Paper Actuator (PL 5).
Replace the Engine Controller PWB (PL 10).
Error and Paper LEDs
are illuminated
Paper Jam 0, 1, or 2
Go to RAP 7.6.
Error and On-line blink
Complex job
Add memory.
Reduce to 300 X 300 DPI.
Set to Raster graphics.
Error LED only is
illuminated.
Flashing Paper LED.
Repair Analysis Procedures (RAP)
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RAP 7.5 Paper Feed
1 Switch the AC power off. Connect the DCU to the printer (see section 5). Perform the Pick-up
Solenoid test. The solenoid energizes.
Y
|
N
Go to step 6.
2 Perform the Feed and Exit Sensor Test. The Feed Sensor test indications are correct.
Y
|
N
Replace in order: Pfeed Sensor (PL 7), Joint PWB (PL 10), Engine Controller PWB (PL
10).
3 The Exit Sensor test indications are correct.
Y
|
N
Verify the operation of the Exit Sensor Actuator. If OK, replace the Engine Controller PWB
(PL 10).
4 Remove the Right Side Cover. Perform the Main Drive Motor test. With the Main Drive Motor
rotating, manually actuate the Paper Feed Solenoid. The Pick Up Roller rotates one complete
revolution each time the solenoid is actuated.
Y
|
N
Replace the Paper Feed Solenoid (PL 6).
5 Clean or replace as necessary: the Pick-up Roll (PL 4), the Pick-up Roll Assembly (PL 4).
6 Disconnect CN402 from the Joint PWB. Measure the resistance between pins 1 & 2 of the
disconnected plug. The resistance is less than 100 ohms.
Y
|
N
Replace the Paper Feed Solenoid (PL 6).
7 Replace in order: Joint PWB (PL 10), Engine Controller PWB (PL 10).
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Repair Analysis Procedures (RAP)
RAP 7.6 Paper Jam
1 Visually inspect the paper for folded corners, lead edge damage, rips, or tears. The paper is free
of damage.
Y
|
N
Check paper path for obstructions, components out of place, damp or improperly installed
paper.
2 Check paper path for obstructions. Check Transfer Roller for binding and for proper operation.
Check for defective Print Cartridge. All items check OK.
Y
|
N
Repair or replace as necessary.
3 Disconnect the AC power. Connect the DCU and reconnect the AC power. Run a test print. The
DCU indicates a jam. Use Table 7.6 to isolate the problem.
Table 7.6. Paper Jams.
Indication
Possible Cause
Solution
Paper Jam 0.
Paper Feed / Registration
Sensor or Sensor Actuator
Use DCU test 08 to verify sensor. If OK replace the Engine
Controller PWB (PL 10).
Paper Jam 01
Paper Feed / Registration
Sensor or Sensor Actuator
Use DCU test 08 to verify sensor. If OK replace the Engine
Controller PWB (PL 10).
Fuser Assembly
Verify Fuser Assembly is operational. Remove or replace as
necessary (PL 8).
Inspect Exit Sensor Actuator. Repair of replace as
necessary (PL 8).
Using DCU test 08, verify Fuser Exit Sensor is operational.
If OK, replace the Engine Controller PWB (PL 10)
Exit Drive Assembly
Inspect Exit Assembly. Repair or replace as necessary (PL
8).
Fuser Assembly
Verify Fuser Assembly is operational. Remove or replace as
necessary (PL 8).
Inspect Exit Sensor Actuator. Repair of replace as
necessary (PL 8).
Using DCU test 08, verify Fuser Exit Sensor is operational.
If OK, replace the Engine Controller PWB (PL 10).
Paper Jam 02
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
RAP 7.7 Printer Problem
A printer problem is indicated by all three LEDs flashing. If the customer has Status Monitor running, an
Unknown Status, Laser Error, or Fuser Error indication will be displayed.
1 Switch the AC power off, then on. Wait for 60 seconds. All three LEDs are flashing.
Y
|
N
Return to the Entry Level RAP and continue.
2 Switch the AC power off. Connect the DCU and switch the AC power on. After 60 seconds
compare the code displayed on the DCU with Table 7.7.
Table 7.7. DCU Codes.
DCU Code
Status
Solution
00
Ready (Legal Paper)
Normal Operation, no action required.
01
Ready (Letter Paper)
Normal Operation, no action required.
02
Ready (A4 Paper)
Normal Operation, no action required.
60
Open Fuser Error
Go to step 3.
61
Warm Up
Normal Operation, No action required.
62
Low Heat Error
Go to step 3.
68
Over Heat Error
Go to step 3.
95
Laser Ready Error
Go to step 6.
3 Switch the AC power off. Remove the Left Side Cover REP 4.1.5 and the Fuser Wire Cap.
Remove one of the screws that secure the AC wire to the Fuser Assembly. Measure the
resistance between the two AC terminals on the Fuser. The resistance is less than 5 ohms.
Y
|
N
Replace the Halogen Lamp (REP 4.4.3) (PL 8).
4 Disconnect CN1 (Fuser Thermister) from the Engine Controller PWB. Measure the resistance
between pins 1 and 2 on the disconnected plug. The resistance is between 4K ohms and 200K
ohms.
Y
|
N
Replace the Thermister (PL 8).
5 Replace the Engine Controller PWB (PL 10).
6 Disconnect the AC power. Remove the Laser Assembly and verify proper connection of both
Laser harness connectors. Both connectors are properly connected and the harnesses are
undamaged.
Y
|
N
Properly connect, repair, or replace as necessary (PL).
7 Replace in order: Laser Assembly (PL 6), Engine Controller PWB (PL 10), HVPS PWB (PL 10).
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Repair Analysis Procedures (RAP)
RAP 7.8 Image Quality Problems
This section contains image quality repair procedures to assist in correcting image quality defects. These
procedures provide definitions, causes and solutions.
Throughout these procedures, the term “vertical” refers to the process direction (the direction paper
travels through the printer); the term “horizontal” refers to the scanning direction (the direction the laser
beam scans across the page).
7.0.1 Image Quality Defect Definitions, Causes and Solutions
Defect Definitions
Possible Causes
Solutions
NON-UNIFORM IMAGE
QUALITY: The line darkness and
solid area density image vary
across the print.
1.
2.
3.
4.
5.
Print Cartridge.
Print Cartridge ground.
Unstable high voltage output.
BTR contamination.
LSU Laser window
contamination.
1. Inspect drum for deterioration or contamination.
If defective, replace the Print Cartridge.
2. Verify Print Cartridge ground. Check continuity
between cartridge contact and the Controller
PWB metal cover. Ensure that the drum contact
is clean and undamaged.
3. Verify that all high voltage outputs are to
specification (refer to section 5, DCU operation).
4. Inspect Transfer Roller spring tension and
bearings. Remove the Transfer Roller and clean
(dust off). Replace Transfer Roller if necessary
(PL 7).
5. Remove the LSU (Laser) Assembly, clean or
replace as necessary (PL 6).
BLACK PRINTS: the print is
completely covered with toner
and has no visible image.
1.
2.
3.
4.
5.
Controller PWB.
Incorrect charge voltage.
Print Cartridge.
Engine Controller PWB.
Laser on all the time.
1. Using the DCU, print a DCU test print. If the test
print is OK, replace the Controller PWB. If test
print is black, continue.
2. Verify charge voltage output. Charge voltage
equals - 1.3 KVDC +/- 100 VDC. If not replace
the HVPS PWB.
3. Replace Print Cartridge (PL 1).
4. Replace Engine Controller PWB (PL 10).
5. Replace LSU (LASER) Assembly (PL 6).
HORIZONTAL DELETIONS:
There are areas of the image that
are extremely light or missing
entirely. These missing areas
form wide bands that run
horizontally across the page in
the direction of scanning.
1. Controller PWB.
2. Print Cartridge grounding
problem.
3. Print Cartridge.
4. Transfer Roller.
5. Laser Assembly
6. Engine Controller PWB.
7. Fuser Assembly.
1. Using the DCU, print a DCU test print. If the test
print is OK, replace the Controller PWB (PL 10).
2. Verify Print Cartridge ground. Check continuity
between cartridge contact and the Controller
PWB metal cover. Ensure that the drum contact
is clean and undamaged.
3. If deletion repeats every:
94.3 mm (3.8in) - Drum defect
37.7 mm (1.5in) - Charge Roll
40.0 mm (1.2in) - Supply Roll
46.1 mm (1.8in) - Developer Roll
Replace the Print Cartridge (PL 1).
4. If deletion repeats every 47.1 mm (1.9 in.),
replace the Transfer Roller (PL 7).
5. Replace Laser Assembly (PL 6).
6. Replace Engine Controller PWB (PL 10).
7. If deletion repeats every 56.1 mm (2.2 in) Heat
Roll or 56.2 mm (2.2in) Pressure Roll, replace
the Fuser Assembly (PL 8)
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
Defect Definitions
Possible Causes
Solutions
1. Replace the Print Cartridge (PL 1).
2. Inspect the LSU (LASER) beam path for
contamination. Clean as necessary.
3. Inspect fuser rolls for damage and replace as
necessary.
4. Inspect Transfer Roller spring tension and
bearings. Remove the Transfer Roller and clean
(dust off). Replace Transfer Roller if necessary
(PL 7).
VERTICAL DELETIONS: There
are areas of the image that are
extremely light or missing
entirely. These missing areas
form wide bands that run
vertically along the page in the
direction of paper movement.
1.
2.
3.
4.
Print Cartridge.
Laser Assembly.
Fuser Assembly.
Transfer Roller.
SPOT DELETIONS: Solid areas
are marked with irregular white
areas.
1. Print Cartridge.
2. Transfer Roller.
3. Damp Paper.
1. Deletions repeat every 94.3 mm (3.7 in.).
Replace Print Cartridge.
2. Remove the Transfer Roller and clean (dust off).
If deletion repeats every 47.1 mm (1.9 in.),
replace the Transfer Roller (PL 7).
3. Replace paper.
LIGHT PRINTS:
1. Remote Control Panel (RCP)
settings.
2. Print Cartridge not installed
correctly.
3. Incorrect high voltage output.
4. Low toner in cartridge.
1. Verify the RCP print quality settings.
2. Re-install the Print Cartridge.
3. Verify that all high voltage outputs are to
specification (refer to section 5, DCU operation).
4. Remove the Print Cartridge and shake to
redistribute toner. Replace Print Cartridge if
necessary (PL 1).
BLANK PRINTS: Prints with
no visible image.
1. Seal tape not removed from
Print Cartridge.
2. Defective ground on Print
Cartridge.
3. Controller PWB.
4. Incorrect high voltage output.
5. Defective LASER.
6. Transfer Roller pressure
7. Paper
1. Inspect cartridge for removal of seal tape.
2. Verify Print Cartridge ground. Check continuity
between cartridge contact and the Controller
PWB metal cover. Ensure that the Print
Cartridge ground contact is clean and
undamaged.
3. Using the DCU, print a DCU test print. If the test
print is OK, replace the Controller PWB.
4. Verify that all high voltage outputs are to
specification (refer to section 5, DCU operation).
5. Using the DCU, verify the Laser operation.
Replace the LSU (LASER) Assembly (PL 6) if
necessary.
6. Inspect Transfer Roller spring tension and
bearings. Remove the Transfer Roller and clean
(dust off). Replace Transfer Roller if necessary
(PL 7).
7. Install fresh paper in the Multipurpose Feeder.
EXTRANEOUS MARKS:
Horizontal or vertical bands, or
other marks that are print defects
caused by bad or incorrect font
data, print drivers, electrical
noise or other causes not directly
related to the
electrophotographic process.
1. Defective font download.
2. Loose / defective cables,
cables out of specification (too
long, etc.).
3. Electromagnetic interference.
4. Controller PWB.
5. Engine Controller PWB.
1. Customer may have recently changed/modified
host software or drivers. Reconfigure if
necessary.
2. Inspect cable connections for proper installation
and for damage. Parallel cable must be a good
quality and comply with the IEEE 1284 bidirectional specification.
3. Relocate printer to another location or to another
power outlet.
4. Replace the Controller PWB (PL 10).
5. Replace the Engine Controller PWB (PL 10).
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Repair Analysis Procedures (RAP)
Defect Definitions
Possible Causes
Solutions
CHARACTER DEFECTS:
Garbled print, missing, repeating,
or scrambled characters are
problems relating to font data or
character generation. These are
print defects not related to the
electrophotographic process.
1. Defective font download.
2. Loose / defective cables,
cables out of specification (too
long, etc.).
3. Electromagnetic interference.
4. Defective SIMM.
5. Controller PWB.
6. Engine Controller PWB.
1. Customer may have recently changed/modified
host software or drivers. Reconfigure if
necessary.
2. Inspect cable connections for proper installation
and for damage. Parallel cable must be a good
quality and comply with the IEEE 1284 bidirectional specification.
3. Relocate printer to another location or to another
power outlet.
4. Replace the SIMM (PL 10).
5. Replace the Controller PWB (PL 10).
6. Replace the Engine Controller PWB (PL 10).
SPOTS: There are spots of
1.
2.
3.
4.
5.
Paper.
Paper path contaminated.
Print Cartridge
Fuser Assembly.
Transfer Roller.
1.
2.
3.
4.
UNFUSED IMAGE: part of or all
of the image is unfused.
1.
2.
3.
4.
5.
Damp paper.
Paper quality.
Light image density
Fuser Assembly.
Engine Controller PWB.
1. Replace paper from a fresh unopened ream.
2. Be sure that the paper is not extremely rough,
heavily textured, or of a high rag content.
3. Check Remote Control Panel print quality
settings.
4. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
5. Replace the Engine Controller PWB (PL 10).
STREAKS: Extraneous dark
lines/bands in or across the
process direction. These are
Engine Controller defects not
related to the Controller PWB or
Host Data.
1.
2.
3.
4.
Print Cartridge.
Fuser Assembly.
Transfer Roller.
Contaminated paper path.
1. Inspect drum surface for scratches or bands. If
defective, replace the Print Cartridge (PL 1).
2. Inspect fuser rollers for scratches or
contamination. If defective, replace the Fuser
Assembly (PL 8).
3. Inspect Transfer Roller. If defective, replace the
Transfer Roller (PL 7).
4. Clean the paper path.
RESIDUAL IMAGES: The image
from a previous print, which was
not removed during the cleaning
process, has been developed on
the current print.
1.
2.
3.
4.
Print Cartridge.
Fuser Assembly.
Erase Lamps.
High Voltage Contacts
1. Replace Printer cartage (PL 1).
2. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
3. Remove the Print Cartridge, attach the DCU and
perform diagnostic test 04. Verify operation of
the Erase Lamps. Replace as necessary.
4. Verify that all high voltage outputs are to
specification (refer to section 5, DCU operation).
Clean all high voltage contacts.
BACKGROUND: Uniform toner
contamination in non image
areas.
1. Print Density.
2. High voltage output.
3. Print Cartridge.
toner on the page.
Repair Analysis Procedures (RAP)
Replace paper from a fresh unopened ream.
Clean paper path.
Replace Print Cartridge (PL 1).
Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
5. If spot repeats every 47.1 mm (1.9 in.), replace
the Transfer Roller (PL 7).
1. Verify print quality setting in the Remote Control
Panel.
2. Verify that all high voltage outputs are to
specification (refer to section 5, DCU operation).
Clean all high voltage contacts.
3. Replace the Print Cartridge (PL 1).
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Xerox DocuPrint P8e Service Manual
Defect Definitions
Possible Causes
Solutions
DAMAGED PRINTS: Creases,
wrinkles, excessive curl, cuts,
folds or embossed marks.
1. Paper
2. Paper source and
transportation.
3. Fuser Assembl.y
4. Print Cartridge.
1. Properly install fresh paper into the Multipurpose
Paper Feeder.
2. Inspect paper transportation system for proper
operation. Replace worn parts.
3. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
4. Replace Print Cartridge (PL 1).
SKIPS / SMEARS: Skips, loss,
or stretching of the image in
bands across the process
direction.
Smear-The distortion of the
image in bands across the
process direction that cause it to
appear to be blurred or
compressed.
1.
2.
3.
4.
1. Inspect paper transportation system for proper
operation. Replace worn parts.
2. Inspect Main Drive Motor Assembly for damaged
or worn gears. Replace as necessary.
3. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
4. Replace Print Cartridge (PL 1).
Skewed Image: Angular
displacement of the image from
its intended position on the print.
The printed image is not parallel
with the sides of the page.
1. Paper Feed.
2. Paper transportation.
3. Fuser Assembly.
Paper transportation.
Main Drive Motor Assembly.
Fuser Assembly.
Print Cartridge
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1. Inspect Multipurpose Paper Feeder for damage.
Replace parts as necessary. Properly install
fresh paper in the paper tray.
2. Inspect paper transportation system for proper
operation. Replace worn parts.
3. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
Repair Analysis Procedures (RAP)
RAP 7.9 Communications RAP
You were directed to this RAP because a problem exists where the customer is unable to communicate
to the printer from the host computer.
NOTE: If you have access to another PC, verify that the printer does not operate.
1 Connect the Anacom G80 or similar interface test box to the parallel port and generate a test
print. The test print completes successfully. NOTE: You may have to remove the back cover to
attach the plug.
Y
|
N
Replace the Controller PWB (PL 10).
2 Disconnect the Anacom G80 or similar interface test box from the parallel port and perform the
following:
• Inspect for any visual signs of damage to the host interface cable. Replace interface cable if
necessary (customer purchased item)
• Reconnect the host interface cable to the parallel interface port
• If using MSWindows, have the customer check printer setup. Also check the setup in the
application the customer is using.
• Have customer send a print job using another application.
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
RAP 7.10 SIMM Check-Out Procedure
1 Remove and reinstall the SIMM. Print a Status Report. The RAM size indicated on the Status
Report matches the memory actually installed in the printer.
Y
|
N
Go to step 3.
2 Return to the Entry Level RAP and continue.
3 Replace the Controller PWB (PL 10). Print a configuration sheet. The RAM size indicated on the
Status Report matches the memory actually installed in the printer.
Y
|
N
Inform the customer that the SIMM appears defective or is not compatible with the printer.
A compatible SIMM is a EDO, 72 pin, 60 ns or faster, 32 bit, no parity.
4 Problem is resolved. Return to the Entry Level RAP and continue.
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Repair Analysis Procedures (RAP)
Notes
Repair Analysis Procedures (RAP)
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Xerox DocuPrint P8e Service Manual
Section 8
P8ex Addendum
1
1
2
Introduction........................................................................................... 8-3
PCL 6 Emulation ................................................................................... 8-4
Universal Serial Bus (USB) .................................................................. 8-5
REP 4.6.3A Controller PWB (P8ex) ..................................................... 8-6
Parts List ............................................................................................. 8-10
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Introduction
The purpose of this addendum is to provide the necessary information to support the DocuPrint P8ex
printer.
All procedures and technical information in the DocuPrint P8e Service Manual apply to the DocuPrint
P8ex printer with the exception of the information provided in this addendum.
The differences are mostly software related, however there are some changes to the hardware.
The DocuPrint P8ex hardware related changes are as follows:
•
New Controller PWB with Universal Serial Bus (USB) Port
— The Controller PWB can be accessed from the rear of the printer by removing two screws and
pulling the Controller out.
— The Rear cover and frame has been changed to accommodate the Controller PWB.
•
The Front cover was changed to display the product name DocuPrint P8ex.
The DocuPrint P8ex software related changes are as follows:
•
The software allows 1200 dpi image quality using image quality enhancement techniques
•
The CD-ROM contains the software required to operate the DocuPrint P8ex printer along with
useful printer utilities and a complete reference guide. If the customers PC is not equipped with a
CD-ROM drive, the customer can obtain software installation files on floppy diskettes from Xerox
software support.f
The addendum consist of the following information:
1) A description of the PCL 6 emulation
2) A description of the Universal Serial Bus (USB)
3) A new Repair Procedure for the Controller PWB, REP 4.6.3A Controller PWB (P8ex)
— Accessing the Controller Board now provides easy access to the Memory SIMM
4) P8ex Parts List.
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Addendum
PCL 6 Emulation
PCL 6 is a raster based printer language. PCL 6 allows the P8ex to use memory more efficiently.
However, there is no way to get a legible print file to view or edit with PCL 6. The PLC 6 emulation will
not allow printing from DOS, unless there is a PCL 6 DOS driver made for an application, (this is unlikely
to happen). This is why PCL 5e emulation is also available on the P8ex printer. Refer to table 1.
Table 1. Printer Driver Features
Setting
Usage/Description
Number of copies
Select 1-99 copies.
•
•
Page orientation
Select portrait or landscape.
•
•
Paper size
Select from supported paper sizes
(see “Printer Specifications” in the User Guide).
•
•
Paper source
Select printing from multipurpose paper feeder or
manual feeder.
•
•
Graphic quality
Select enhancement for graphical and/or text
printing.
•
•
Graphic mode
Select vector or raster mode.
•
•
*
True Type fonts
Select font printing.
•
•
*
EconoMode
Select draft mode printing capability.
•
•
*
Overlays
Include overlays in printed documents.
•
•
*
Multiple images (N-Up)
Select 1-9 images per physical page.
•
Watermarks
Create and use watermarks on documents.
•
PCL 6
PCL 5e
* This setting is not available in the Windows NT 4.0 version of the PCL 5e driver.
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Universal Serial Bus (USB)
The Universal Serial Bus (USB) is a new interface that connects to peripheral devices. P8ex USB is only
supported when Windows 98 is loaded on the PC. (NOTE: USB printing from iMAC is not supported).
In order to use the USB, the customer must install the USB port driver on a PC which has Windows 98
and USB hardware. When the USB port driver is installed, a port called SSUSB is created. The SSUSB
port allows jobs to print to the P8ex.
Connecting the USB Port
NOTE: The USB port requires USB v1.0 compliant cable.
1 Make sure that the printer and PC are turned off.
2 Plug the USB cable into the connector on the rear of the printer (Figure 1).
Figure 1. Connecting the USB
Rearview
of P8ex Printer
USB Cable
3 Connect the other end of the cable to the USB port on the customer’s computer.
Installing the USB Port Driver
The USB driver must be installed in order to print to the P8ex using a USB connection. Currently, USB
printing is only available using Windows 98.
1 Insert the DocuPrint P8ex CD into the CD-ROM drive.
2 If the CD starts automatically, go to step 4. Otherwise select Run from the Start menu.
3 Click Browse, select the CD-ROM drive, then double-click on setup.exe.
4 Select the appropriate language.
5 Select the USB Port Driver installation.
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Addendum
REP 4.6.3A Controller PWB (P8ex)
Removal
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
The printer has been upgraded to allow easy access to the Controller PWB. The Controller PWB is
accessed by removing two screws from the rear of the printer and pulling the board out of the printer.
Memory can be upgraded or the Controller PWB can be replaced.
Removing the Controller PWB
1 Turn off the printer and unplug the power cord.
2 Disconnect all cables from the rear of the printer.
3 Remove the two screws from the Controller PWB (Figure 2).
4 Pull the Controller PWB out of the printer (Figure 2).
Figure 2. Removing the Controller PWB
Video Controller PWB
5 Disconnect J2 and J5 from the Controller PWB.
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Xerox DocuPrint P8ex Service Manual
Installing Additional Memory
There is only one SIMM slot on the Controller PWB that is dedicated to increase the printer memory.
There are four available SIMM options available which increase the printer memory up to a total of
36Mb. All SIMMs must be industry standard EDO 72 pin 32-bit memory (no parity, 60 ns or faster), and
are available in sizes of 4, 8, 16, or 32MB. When the SIMM is installed, the Controller PWB will
automatically detect the memory and increase the printer’s buffer size.
To install an additional memory module:
1 Turn off the printer and disconnect the AC power.
2 Disconnect all cables from the rear of the printer.
3 Remove the two screws from the Controller PWB. Refer to figure 2.
4 Pull the Controller PWB out of the printer. Refer to figure 2.
5 Hold the SIMM with the connection points pointing toward the control board and insert the SIMM
all the way into the connector at a 45 degree angle (Figure 3).
Figure 3. Installing the SIMM
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Addendum
6 Push the SIMM down until it snaps into place (Figure 4).
Make sure both metal clips on the connector are fastened and the two pins on the connector are
pushed through the holes on the SIMM (Figure 4).
Figure 4. Installing the SIMM
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Xerox DocuPrint P8ex Service Manual
7 If you are replacing a SIMM, push out on the metal clips at each end of the SIMM connector and
rotate the SIMM up to lift it out (Figure 5).
Figure 5. Removing the SIMM
Replacement
1 Assemble in reverse order.
2 Print a Status Page to verify memory has been installed correctly and system recognizes the
installation of additional memroy.
3 Verify proper operation.
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Addendum
Parts List
PL 1 Covers
Item
Part Number
Description
1)
2)
-----802E00400
802E18660
---------------802E00380
802E19230
-----113R00296
600K72020
Top Cover}
Rear Cover (P8e)
Rear Cover (P8ex)
Right Side Cover
Bottom Cover
Face Up Cover
Front Cover (P8e)
Front Cover (P8ex)
Left Side Cover
Print Cartridge
Hardware Kit
3)
4)
5)
6)
7)
8)
A)
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7
8
6
2
3
P8e_308
5
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Addendum
PL 2 Front Cover
Item
Part Number
Description
1)
2)
3)
4)
5)
--------------------802E00380
802E19230
----------3E50440
107E16960
101E19680
-----802E00390
600K72020
Front Cover {Includes Items 2 through 7}
Stacker Extender
Stacker
Duct
Front Cover (P8e)
Front Cover (P8ex)
Stacker Guide
Stopper
Key
LED
Control Panel
Control Panel Cover
Face Up Exit Cover
Hardware Kit
6)
7)
8)
9)
10)
11)
12)
A)
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1
3
2
7
6
4
5
9
10
12
8
11
P8e_301a
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Addendum
PL 3 Paper Trays
Item
Part Number
Description
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
------------------------------------------------------------50E15050
802E00400
802E18660
600K72020
Media (Paper) Tray {Includes Items 2 through 12}
Gear Adjust Rack, Left
Gear Adjust Rack, Right
Pinion Gear
Auto Tray Adjust, Right
Manual Tray Adjust, Right
Film Guide Sheet
Manual Tray Adjust, Left
Manual Paper Tray
Auto Tray Adjust, Left
Paper Guide Plate
Rear Cover Assembly {Includes Items 13 & 14}
Tray Extender
Rear Cover (P8e)
Rear Cover (P8ex)
Hardware Kit
A)
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Xerox DocuPrint P8ex Service Manual
1
11
2
10
9
4
8
7
3
5
6
12
Rear panel of P8ex
13
13
14
14
P8_302A
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Addendum
PL 10 Electronics
Item
Part Number
Description
1)
2)
3)
160K60070
114E15570
160K60060
160K55520
160K65260
160K65270
--------------------160K55660
160K55510
007K11190
108E05380
108E05390
600K72020
High Voltage Power Supply PWB
AC Plug Assembly
Controller PWB (115 VAC) (P8e)
Controller PWB (220 VAC) (P8e)
Controller PWB (115 VAC) (P8ex)
Controller PWB (220 VAC) (P8ex)
SIMM 4MB
SIMM 8MB
SIMM 16MB
SIMM 32MB
Engine Controller PWB (115 VAC)
Engine Controller PWB (220 VAC)
Joint PWB
Fuse (115 VAC / T8A)
Fuse (220 VAC / T5A)
Hardware Kit
4)
5)
6)
7)
A)
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1
Rear view of P8ex
6
7
2
5
3
3
4
P8e_310b
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