SERVICE BULLETIN

Date Issued: 12 May 2008

SB 768
FAILS ON FIRST TILT
Product: Phaser 8400, 8500, 8550, 8560, 8860, C2424,
8560MFP, 8860MFP When the printhead fails to tilt forward on the first tilt, it is often due to
something physically interfering with the printhead movement:
Operational Groups: OPB, NADC
1. On rare occasions, you may find the printhead appears to be
stuck to the wiper blade. This can occur if the printer was
Troubleshooting the 7,010.43 error code improperly shut down while performing a printhead cleaning
cycle.
The 7,010.43 error code indicates the printer is having difficulty tilting
the printhead forward from the parked position to the print position.
There are several printer systems involved in tilting the printhead so
troubleshooting the error can be challenging. The printer does not
directly sense the printhead's tilting position. Instead it applies drive
current to the process drive motor, and monitors the motion of the
motor's rotation encoder for "following error". For a particular drive
voltage the encoder should rotate at a particular rate as the printhead
(driven thru the process drive, the DM camshaft, and the head tilt gear
train) tilts forward. If the printer does not see the expected encoder
readings it assumes a tilt failure.

These instructions are also useful for troubleshooting the less common
7,007.49, 7,008,41, and 7,009.42 error codes.

• When you encounter a 7,010.43 error, determine when the

7,010.43 fault occurs.
• Does it occur during boot-up the first time the printer
attempts to tilt the printhead forward? If so, go to topic
"Fails on First Tilt". 2. In this case:
a. Allow the printhead to heat up to soften the ink.
• Does it occur later in the boot process after successfully
b. Gently separate the printhead from the wiper.
tilting a few times but failing when it begins to start a
c. Manually lower the wiper (by rotating the wiper drive
cleaning cycle? If so go to "Fails on Subsequent Tilt".
gear) and set the printhead into the print position next
to the drum.
d. Restart the printer.

Copyright © 2008 Xerox Corporation. All rights reserved. XEROX®, the stylized X®, and Phaser®
trademarks of Xerox Corporation in the United States and/or other countries.
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3. Is the printhead being centered by the X-axis motor? Does it
stay centered? Watch the left-right motion of the printhead.
Also watch for smooth left-right movement; if the nose-cone
threads are stripped, the printhead movement may be jerky
and irregular. When the printhead is tilted forward in the print
position, the X-axis nosecone is always in contact with the
printhead's stub shaft. When the printhead is tilted backwards
into its parked position, the X-axis nose cone is retracted away
from the printhead (no contact).
4. At the left side of the printer verify that the printhead X-axis
The printhead should travel all the way to the left (home) and
then halfway back to be centered to the drum. Once centered,
the printhead can then tilt forward. If the printhead does not
move left-right:
5. Verify that the process drive assembly is correctly timed as
a. Check for ink in the roll block (from an ink overflow).
If you find ink in the roll block, power the printer up in
Service Diagnostics and run the Exercise Heaters: All
Heaters On test. This will soften the ink and allow you
to remove the ink block (it will be hot!) to clean it.
Check for ink in Roll block and bias spring
the roll block
X-axis return spring hook
b. Does the X-axis motor rotate? If the printhead is not
pushed right-left, remove the x-axis motor and restart
the printer.
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c. Does the motor rotate? If not either the motor is bad
and must be replaced or the motor drivers in the
electronics module are bad and the electronics module
must be replaced.
d. Does the X-axis motor hold the printhead in the
centered positioned? If it does not, either the motor is
failing or the motor drivers (in the electronics module)
are bad.
return spring hook is correctly located in the printhead's left-
end stub shaft at the center of the roll block (shown in the
photo above). Ensure the spring and spring hook are not
obstructed or interfering with the printer frame.
described in the topic "Homing the Process Drive Train" in the
service manual and Service Bulletin 714.
Broken process drive
mounting post
Ensure none of the process drive mounting posts are broken. If
you encounter a broken post, repair it using the 604K55230
Broken Post Repair Kit. Refer to Service Bulletin 766. In
Europe you can optionally use repair kit 604K54910.
6. Is one of the printhead restraints cracked? It may be necessary 8. Is each printhead restraint lock arm lowering when the wiper
to remove the restraints to verify whether cracks are present. assembly is lowered? Verify that the printhead is centered and
not in contact with the lock arms. If the spring-loaded lock
arms do not freely move, replace the printhead restraint.

Check the printhead

restraints for cracks
Lock arm properly
lowered

7. Inspect the gray printhead data cable. Has the data cable choke
coil fallen behind the printhead? The choke coil should be
attached by Velcro. Also verify that the printhead heater
wiring harness, next to the gray ribbon cable, is also properly
dressed and restrained.

Lock arm stuck in

raised positioned

Printhead data cable choke

coil in correct location

Printhead heater wiring

harness in restraint

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9. Check for ink spills or shards in the roll block and under the
printhead. At the left side of the printer examine the roll block
and printhead stub shaft for evidence of ink. Remove the
waste tray and examine the area under the printhead for ink
accumulations. Also look for ink shards under the DMU.
10. If there is evidence of ink under the printhead, there could be
ink in the printhead tilt gear train. Remove the printhead and
inspect the tilt gear train for shards of ink.

Tilt gears
(printhead
Look for shards of removed)
ink in the waste tray
cavity

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 11. Inspect the drum maintenance (DM) cams for cracks. Most
often it is the right cam that cracks. Remove the DMU and lift
the pivot plate out of the way to inspect the right cam. Note: It
is possible to have a cracked cam that still functions normally.
Even so, replace a cracked DM camshaft when you find one.
Check for cracked DM
cams
12. If the DM camshaft was previously removed it is possible that
the left-end bushing fell out of place from the inside of the left-
side frame. Verify the bushing is in place. If the bushing falls
out of place, it usually ends up under the Y-axis motor body.
FAILS ON SUBSEQUENT TILT
When the printhead fails on a subsequent tilt, it is usually caused by
something adding more drag or friction into the tilt drive system. The
printhead tilts forward at certain times during power–up but faults while
making the precise positioning needed for a printhead clean cycle.
Was a new Drum Maintenance Unit recently installed? The oil roller of
new DMU may be stiff, especially if cold. During the printhead tilt cycle
the DMU is lifted against the drum. If it is too stiff it may exert extra
drag into the system.
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Break in the new roller by doing the following:
a. Turn off the printer
b. Remove the left and right covers.
c. Manually raise the DMU into contact with the drum by
lifting it by its handle. Hold it against the drum.
d. Rotate the drum for about 50 revolutions by turning the
drum pulley on the left end of the drum.
e. Reassemble the printer and test.
2. Inspect the DM cams for cracks. (Illustrated in Step 11 of
previous topic.) Most often it is the right end cam that cracks.
Remove the DMU and lift the pivot plate out of the way to
inspect the cam. Note: It is possible to have a cracked cam that
still functions normally if the cam has not spun out of position
on the shaft. If a cam is cracked, replace the camshaft
assembly.
3. If the drum maintenance camshaft was replaced, it is possible
the right side ground plane was bent or bulged-out. This
ground plane bulge can force the right end bushing and DM
gear against the process drive gear train adding friction load
into the system.
The ground plane should
be flush against the
black side frame
Note for removing a bushing from a ground plane: Use a
rotating, twisting motion on the bushing instead of pulling it.
4. Check the action of the printhead overload spring. When the
printhead is tilted back it presses down against the overload
spring. As the printhead tilts forward the spring pushes up
against the printhead. If the spring is dragging against another
object such as the X-axis return spring or the printer frame that
can change the load on the tilt system and the printer may
declare a fault. Inspect the overload spring for interference and
a smooth lift action.
5. A lack of grease on drum maintenance cams-to-pivot plate
contacts points could induce more drag into the system.
Remove the paper preheater to inspect the contact points.
Grease if necessary (use Nye Rheolube 368, part number
070E00890). You will need to remove the Y-axis motor to
access the left end of the pivot plate if greasing the contact
points is needed.

Printhead X-axis return

spring

Ensure the printhead

overload spring moves Ensure the points where
freely and does not the drum maintenance
interfere with the X-axis cams contact the pivot
return spring plate are lubricated

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CHECK THE HEAD TILT ENGAGE MECHANISM
1. Verify the head tilt engage mechanism engages and
disengages. When the head tilt has been reset (by manually
rotating the drum maintenance camshaft one revolution) the
two arrows on the left side of the printer frame point at each
other indicating head tilt is disengaged. (This is described in
the Adjustments and Calibrations chapter of the service manual.)
The arrows point to each
other when the tilt
mechanism is disengaged. Head tilt solenoid
Remember: the printhead must be centered to the drum prior to
rotating the drum maintenance cam to reset printhead tilt
engagement. If the printhead is not centered use a small flat-
blade screwdriver to turn the X-axis motor shaft to center the
printhead.
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2. All printers except the 8400 feature the head tilt solenoid.
Verify that when the head tilt solenoid fires the head tilt
mechanism is engaged. If necessary, use service diagnostics
Exercise Menu: Tilt Solenoid. When tilt is engaged, the
indicator arrows will not then point at each other. For the 8400
slightly raising the printhead wiper will engage the head tilt
mechanism.
3. Verify that the wiper is not misaligned (left end too high
relative the right end) and prematurely engaging head tilt.
Wiper alignment is described in the service manual under the
topic Wiper Alignment.
4. As a very last resort if all other troubleshooting does not resolve
the problem, then perform a PS and PE NVRAM reset. Restart
the printer in service diagnostics mode as described in the
service manual. Navigate to the Function Menu and execute
the Clear PS NVRAM and Clear PE NVRAM functions. This
erases all the printer's stored network and engine settings.
Then run the Set PE NVRAM to Defaults function before
exiting diagnostics mode.
TME
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