SERVICE FLASH

Date Issued: 28 Sept 2009 Serial number range of printers suspected of containing electronic
modules with suspect triacs are listed below. The bounds are
SF 231 conservative; many printers inside the serial number ranges are not
suspect:
Product: Phaser 8560, 8560MFP, 8860, 8860MFP
Start End
Operational Groups: OPB, NADC
8560 FBT264468 FBT284041
8560_WDN FBT631183 FBT632824
DEFECTIVE TRIACS CAUSING MACHINE FAILURES 8560MFP CXF340702 CXF342023
8560MFPM - -
Defective triacs have been discovered in recent production of solid ink 8860 HAV040895 HAV043985
8860MFP HBB034416 HBB034849
printers. The triacs, found in the electronic module's power supply,
normally conduct AC electricity under processor control to the various
The end of the serial number range is the point at which printers began
printer heaters.
being built with screened triac parts. Following the ending printer
serial number, no triacs from suspected lots were used in Xerox
Failure analysis by the triac component vendor and Xerox engineers
printers. These ranges are subject to change as further information
has determined that micro cracks are forming in the triac's
becomes available.
semiconductor die. Thermal cycling propagates the cracks which
creates leakage currents. The leakage currents cause the triacs to self-
excite and conduct AC current without control. Excessive current flow SPARE PART FRU ELECTRONIC MODULES
leads to 13,xxx.4x thermistor faults, 37,0xx.4x heater PEST fault codes, Electronic modules in spare part stocks have been screened.
and actual burnt-out heaters.
8560 p.n. 137E24444
The failure mode appears to be exacerbated in printers operating in 8560MFP p.n. 084K35871
240 VAC environments. Failures usually occur within one to two 8860 p.n. 084K36551
months of initial printer installation and often within 2,000 prints or 8860MFP p.n. 084K36561
less. At the time of this flash release, triac failures in the 110 VAC
environments have not been seen. We will continue to test and If you examine an electronic module's serial number, any module with
monitor field service data to determine the scale of the failures. a date code less than the code listed below is believed to be a good part.
For example: -904xxxxxx is the suspect date. 819673604-852652452 is
This is not a safety issue and it does not present a hazard to our GOOD, 891673604-905785123 is SUSPECT)
customers. The printer's safety enclosure will contain any failure
although smoke may be emitted by a heater failure. At this time, we Below is Good Between is suspect Above is Good
do not anticipate a need to rework all printers nor are we 8560 -904000936 - -933000000
recommending doing field replacements pre-emptively on printers 8560MFP -907000024 - -933000000
within the affected serial number range. Therefore, we would not 8860 -906000402 - -933000000
advise you to replace parts on printers until a failure is noted. 8860MFP -902000250 - -933000000

Copyright © 2009 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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 Replace electronic module. Test printhead
jetstack heaters, replace printhead if bad. If
WHAT TO DO Replace Electronic you do not replace the printhead and the error
13,136.4x Module re-occurs, replace the printhead.
Follow the service guidance provided in the following table for the Replace electronic module. Test printhead
relevant error code or condition. jetstack heaters, replace printhead if readings
Replace Electronic bad. If you do not replace the printhead and
13,200.4x Module the error re-occurs, replace the printhead.
Fault Action Notes Replace electronic module. Test printhead
Replace Electronic reservoir heaters, replace if bad. If you do not
No Power Module Replace electronic module. Replace Electronic replace the printhead and the error re-occurs,
Replace Electronic 13,264.4x Module replace the printhead.
Module & test Replace electronic module. Test printhead Replace electronic module. Test inkloader's
37,002.4x Printhead jetstack heaters, replace printhead if bad. heaters, replace if bad. If you do not replace
Replace Electronic Replace Electronic the inkloader and the error re-occurs, replace
Module & test Replace electronic module. Test printhead 13,328.4x Module the inkloader.
37,003.4x Printhead jetstack heaters, replace printhead if bad. Replace electronic module. Test inkloader's
Replace Electronic heaters, replace if bad. If you do not replace
Module & test Replace electronic module. Test printhead Replace Electronic the inkloader and the error re-occurs, replace
37,004.4x Printhead reservoir heaters, replace if bad. 13,392.4x Module the inkloader.
Replace Electronic Replace electronic module. Test inkloader's
Module & test Replace electronic module. Test printhead heaters, replace if bad. If you do not replace
37,005.4x Printhead reservoir heaters, replace if bad. Replace Electronic the inkloader and the error re-occurs, replace
Replace Electronic 13,456.4x Module the inkloader.
Module and test Replace electronic module. Test drum's Replace electronic module. Test inkloader's
37,006.4x Drum Assembly heater, replace if bad. heaters, replace if bad. If you do not replace
Replace Electronic Replace Electronic the inkloader and the error re-occurs, replace
Module and test Replace electronic module. Test preheater's 13,520.4x Module the inkloader.
37,008.4x Preheater Assembly heater, replace if bad.
Replace Electronic
Module and test Replace electronic module. Test inkloader's
37,009.4x Inkloader Assembly heaters, replace if bad.
Replace Electronic
Module and test Replace electronic module. Test inkloader's
37,010.4x Inkloader Assembly heaters, replace if bad.
Replace Electronic
Module and test Replace electronic module. Test inkloader's
37,011.4x Inkloader Assembly heaters, replace if bad.
Replace Electronic
Module and test Replace electronic module. Test inkloader's
37,012.4x Inkloader Assembly heaters, replace if bad.
Replace Electronic
Module and test Replace electronic module. Test inkloader's
37,013.4x Inkloader Assembly heaters, replace if bad.
Replace electronic module. Test drum's
heater, replace if bad. If you do not replace
Replace Electronic the drum and the error re-occurs, replace the
13,008.4x Module drum. Check left side cover for warping.

Page 2 of 4
CHECKING HEATERS
1. Turn printer off. Check heater
2. Unplug power cord. resistance at
connector
Drum and Paper Preheater check at electronic module. Disconnect
the 4-wire J4AC harness from the right side of the electronics module (by
the power switch).
• At the harness, measure the yellow-black preheater circuit; you
should measure ~51 ohms.
• Measure the white-black drum heater circuit; you should measure
~18 ohms (the two drum heater elements in parallel). This check
will also include the drum fuse located on the paper preheater
assembly.
Paper Preheater. Check the paper preheater element for proper
resistance. Remove the paper preheater assembly form the printer.
• Measure the resistance from J0720 Pin 2 to 4; you should measure
Check heater
resistance at ~51 ohms. (Green ground wire is Pin 4.)
connector • Inspect the printed heater element on the underside of the
assembly. If you see burn marks or bubbles, replace the paper
preheater.

Check heater for

burns and
bubbles

Drum. Check the drum heater elements for proper resistance.

Disconnect the 3-wire drum heater harness from the relay board.
Measure the red-black circuit and the white-black circuit. Each heater
element in the circuit should measure ~36 ohms.
Check heater
resistance at
connector

Page 3 of 4
Inkloader. Check the inkloader elements for proper resistance. Remove
the ink loader from the printer. Measure the resistance of the inkloader's
4-wire AC wiring harness J1AC.
• Measure the heater element circuits red-white (magenta melter),
yellow-white (yellow melter), blue-white (cyan melter), black-
white (black melter). Each should measure ~100 ohms.
Printhead. Check the printhead's heater elements for proper resistance.
Remove the ink loader to expose the printhead's 7-wire AC wiring
harness J2AC.
• Jetstack: Measure the Pin 1-5, red-red circuit and the Pin 1-6 red-
yellow circuit. Each should measure ~2.5 kohms
• Reservoir: Measure the Pin 1-3, red-white circuit and the Pin 2-4
yellow-white circuit. Each should measure ~50 ohms.

Check heater
resistance at Check heater
connector resistance at
connector

• Inspect the printed heater element on the face of the melters. If

you see burn marks or bubbles, replace the ink loader.

Check heaters
for burns and
bubbles
TME

Pub. No.:

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