XEROX

Xerox DocuPrint P8e / P8ex

Service Manual

P8e_100

720P41711
3/99
This Service Manual contains information that Copyright 1998 Xerox Corporation. All rights
applies to the Xerox DocuPrint P8e Electronic reserved.
Laser Printer.
Copyright protection claimed includes all forms of
NOTICE matters of copyrightable materials and information
now allowed by statutory or judicial law or
This manual is for use by Xerox Technicians and hereinafter granted, including without limitation,
Xerox trained technicians only. material generated from the software programs
which are displayed on the screen such as styles,
NOTICE templates, icons, screen displays, looks, etc.
While every care has been taken in the Xerox, Xerox Europe (XE), and all product names
preparation of this manual, no liability will be and product numbers mentioned in this
accepted by Xerox arising out of any inaccuracies publication are trademarks.
or omissions.
PCL 5e, HP LaserJet, and Intellifont are
All service documentation is supplied to Xerox trademarks of Hewlett-Packard Company. IBM is
external customers for informational purposes a trademark of International Business Machines
only. Xerox service documentation is intended for Corporation. Microsoft, Microsoft Windows,
use by certified, product trained service personnel Microsoft Word, MS, and MS-DOS are trademarks
only. Xerox does not warrant or represent that of Microsoft Corporation. Univers is a trademark
such documentation is complete. Nor does Xerox of Linotype AG or its subsidiaries. WordPerfect is
represent or warrant that it will notify or provide to a trademark of WordPerfect Corporation.
such customer any future changes to this Centronics is a trademark of Centronics
documentation. Customer’s service of equipment, Corporation. Macintosh and TrueType are
or modules, components, or parts of such trademarks of Apple Computer, Incorporated. All
equipment may void any otherwise applicable other product names are trademarks/tradenames
Xerox warranties. If Customer services such of their respective owners.
equipment, modules, components, or parts
thereof, Customer releases Xerox from any and The Xerox DocuPrint P8e uses PCL 5e emulation.
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. PCL and PCL 5e are trademarks of Hewlett
Packard Company. These printers contain an
Prepared by: emulation of the Hewlett Packard PCL 5e
Xerox Corporation command language, recognizes HP PCL PCL 5e
PSD&E and commands, and processes these commands
Mail Stop: ESM1-058 in a manner compatible with Hewlett Packard
701 S. Aviation Blvd. LaserJet printer products.
El Segundo, CA. 90245

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.

3/99
Copyright Information ii Xerox DocuPrint P8e Service Manual
 Warning The laser and output of the laser scanner unit
produces a beam that, if looked into, could cause
This equipment complies with the eye damage. Service procedures must be
requirements in Part 15 of FCC rules for a followed exactly as written without change.
class A computing device. Operation of the
equipment in a residential area may cause When servicing the machine or laser module,
unacceptable interference to radio and TV follow the procedures specified in the manual and
reception, requiring the operator to take there will be no hazards from the laser.
whatever steps are necessary to correct the
interference. Laser (FDA): Any laser label visible to service
must be reproduced in the service manual with
Product Safety location shown or indicated. Safe working
procedures and clear warnings concerning
Electrostatic Discharge precautions to avoid possible exposure must also
be included.
This caution indicates that there are components
which are sensitive to damage caused by The Laser contained in the DocuPrint P8e meets
electrostatic discharge. the following standard: Laser class 3B, maximum
5mW, wavelength 780nm.
CAUTION The following LASER symbol will be displayed at
These components are susceptible the start of any procedure where possible
to electrostatic discharge. Observe
all ESD procedures to avoid
exposure to the laser beam exists.
damage.

Shock Hazard
DP8_006
This symbol indicates the presence of potentially
hazardous voltages. LUOKAN 1 LASERLAITE

KLASS 1 LASER APPARAT

Each P8e laser printer has the following laser

DP8_001 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

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Xerox DocuPrint 4508 Service Manual 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

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Product Safety iv Xerox DocuPrint P8e Service Manual
Table of Contents Introduction
Title Page The Xerox DocuPrint P8e Service Manual is the
primary document used for repairing and
Introduction .............................................. v maintaining the P8e Laser Printers.
Organization ............................................ vi This manual contains Service Call Procedures,
Diagnostic Procedures, General Information,
Service Call Procedures .......................1-1 Repair Analysis Procedures, Copy Quality
Analysis Procedures, Wiring Data, and Parts Lists
Printer Specifications ...........................2-1
that will enable the Service Representative to
Parts Lists ..............................................3-1 repair P8e failures.

Repair Procedures ................................4-1 NOTE: In some of the DocuPrint P8e

documentation the Print Cartridge is
General Procedures ..............................5-1 referred to as the Image Cartridge. Print
Cartridge is the correct term.
Wiring Data ............................................6-1

Repair Analysis Procedures.................7-1

P8ex Addendum ....................................8-1

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Xerox DocuPrint P8e Service Manual v Contents
Organization Section 8 - P8ex Addendum

This manual is divided into seven sections. The All procedures and technical information in the
title and description of each section of the manual DocuPrint P8e Service Manual apply to the
is as follows: DocuPrint P8ex printer with the exception of the
Section 1 - SERVICE CALL PROCEDURES information provided in the P8ex addendum. The
P8ex Addendum contains the following
This section is used to identify a suspected informatiom:
problem. It contains Call Flow, Initial Actions, and
Final Actions. This part of the service manual 1) A description of the PCL 6 emulation
should always be used to start the service call. 2) A description of the Universal Serial Bus
(USB)
Section 2 - PRINTER SPECIFICATIONS 3) A new Repair Procedure for the Controller
PWB, REP 4.6.3A Controller PWB (P8ex)
This section contains all the specifications for the
P8e / P8ex printers. — Accessing the Controller Board now
provides easy access to the Memory
Section 3 - PARTS LISTS
SIMM
This section contains illustrations of disassembled 4) P8ex Parts List.
subsystems and a listing of the spared parts.
— This section contains illustrations of
Part names are listed in this section of the manual disassembled subsystems and a listing
even if the part itself is not spared. All the parts of the spared parts for the DocuPrint
that are spared will have the part number listed. P8ex.
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.

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Contents vi Xerox DocuPrint P8e Service Manual
 Product Manual Title Part Number
P8e Laser Printer Xerox DocuPrint P8e Service Manual 720P41711

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Xerox DocuPrint P8e Service Manual vii Revision Control List
 Product Manual Title Part Number
P8e Laser Printer Xerox DocuPrint P8e Service Manual 720P41711

Page Date Page Date Page Date Page Date

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Revision Control List viii 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

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Xerox DocuPrint P8e Service Manual 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 Repair Procedures

Wiring Data General Procedures

Final Actions Correct Any

Image Quality Secondary Problems

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Service Call Procedures 1-2 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 volt-
age.
• 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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Xerox DocuPrint P8e Service Manual 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.

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Service Call Procedures 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

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Xerox DocuPrint P8e Service Manual 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 Line Voltage Frequency Frequency Running Power Power

Voltage Tolerance Tolerance Consumption 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.

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Printer Specifications 2-2 Xerox DocuPrint P8e Service Manual
2.2 Physical Location

224 mm
8.8 in

367 mm
14.36 in
345 mm P8e_100
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 Resolution - dpi
(pages per minute) (Dots per inch)
From Sleep mode to From Standby mode 8 ppm True 600 x 600 dpi
Standby mode 20 seconds
under 30 seconds From Power save mode
30 seconds

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Xerox DocuPrint P8e Service Manual 2-3 Printer Specifications
2.4 Environment

Temperature Humidity Noise Level

Operating 10o - 32o C 20 - 80% RH Sleep (Power Saver) - Background Within 5o
50o - 90.5o F Standby - Under 29 dB
Printing - Under 47 dB

Shipping -20o - 40o C 10 - 95% RH ------ ------

-4o - 104o F

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.

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Printer Specifications 2-4 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) 150
COM10
#9
C5
D5
DL

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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Xerox DocuPrint P8e Service Manual 2-5 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) Error Light
2) Paper light
3) On-Line light
4) 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.

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Printer Specifications 2-6 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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Xerox DocuPrint P8e Service Manual 3-1 Parts Lists
PL 1 Covers
Item Part Number Description
1) ------ Top Cover}
2) 802E00400 Rear Cover
3) ------ Right Side Cover
4) ------ Bottom Cover
5) ------ Face Up Cover
6) 802E00380 Front Cover
7) ------ Left Side Cover
8) 113R00296 Print Cartridge
A) 600K72020 Hardware Kit

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Parts Lists 3-2 Xerox Docuprint P8e Service Manual
 1

6
2

P8e_308

4
5

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Xerox DocuPrint P8e Service Manual 3-3 Parts Lists
PL 2 Front Cover
Item Part Number Description
1) ------ Front Cover {Includes Items 2 through 7}
2) ------ Stacker Extender
3) ------ Stacker
4) ------ Duct
5) 802E00380 Front Cover
6) ------ Stacker Guide
7) ------ Stopper
8) 3E50440 Key
9) 107E16960 LED
10) 101E19680 Control Panel
11) ------ Control Panel Cover
12) 802E00390 Face Up Exit Cover
A) 600K72020 Hardware Kit

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Parts Lists 3-4 Xerox Docuprint P8e Service Manual
 1

2 3

9
10
12
8

11

P8e_301a

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Xerox DocuPrint P8e Service Manual 3-5 Parts Lists
PL 3 Paper Trays
Item Part Number Description
1) ------ Media (Paper) Tray {Includes Items 2 through 12}
2) ------ Gear Adjust Rack, Left
3) ------ Gear Adjust Rack, Right
4) ------ Pinion Gear
5) ------ Auto Tray Adjust, Right
6) ------ Manual Tray Adjust, Right
7) ------ Film Guide Sheet
8) ------ Manual Tray Adjust, Left
9) ------ Manual Paper Tray
10) ------ Auto Tray Adjust, Left
11) ------ Paper Guide Plate
12) ------ Rear Cover Assembly {Includes Items 13 & 14}
13) 50E15050 Tray Extender
14) 802E00400 Rear Cover
A) 600K72020 Hardware Kit

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Parts Lists 3-6 Xerox DocuPrint P8e Service Manual
 1

11 2

10

9 3
4

8
5

7
6

12

13

14

P8e_302

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Xerox DocuPrint P8e Service Manual 3-7 Parts Lists
PL 4 Feeder
Item Part Number Description
1) 19K04760 Paper Separator Unit {Includes Items 2 & 3}
2) ------ Separator Pad
3) ------ Separator Holder
4) 809E18310 Knock Up Spring
5) 19K04770 Knock Up Spring Holder Assembly {Includes Items 6 & 7}
6) ------ Knock Up Spring Holder
7) ------ Knock Up Ground
8) ------ Separator Spring
9) 15K39950 Media Unit Knock Up Assembly {Includes Items 10 through 13}
10) ------ Knock Up Holder, Right
11) ------ Knock Up Pad
12) ------ Knock Up Holder, Left
13) ------ Knock Up Plate
14) ------ Extension Spring
15) 7K10890 Media Unit Clutch {Includes Items 16 through 19}
16) ------ Clutch Hub
17) ------ Clutch Spring
18) ------ Clutch Collar
19) ------ Pick Up Gear
20) ------ Media Unit Pick Up Assembly {Includes Items 21 through 31}
21) ------ Knock Up Cam
22) ------ Paper Guide Roll
23) ------ E-Ring
24) 32E14350 Paper Feed Guide
25) 130E09080 Pick Up Rubber
26) ------ Pick Up Housing
27) ------ Knock Up Cam, Right
28) ------ Pick Up Shaft Pin
29) ------ Feed Idler Shaft
30) 22E23240 Feed Roller, Left
31) ------ Pick Up Shaft
32) ------ Shaft Lock Bushing
A) 600K72020 Hardware Kit

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Parts Lists 3-8 Xerox DocuPrint P8e Service Manual
 5
1

3 6
12
4
13 2

14
32
21
22 24 7

23 8
22
11
25

26
28
22 24 9
30
29
22 10
20 27
23
16 14
28
17
18
30 19
29 28
31
15

P8e_303

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Xerox DocuPrint P8e Service Manual 3-9 Parts Lists
PL 5 Paper Transport
Item Part Number Description
1) 22K64020 Media Frame Support Unit {Includes Items 2 through 6}
2) ------ Feed Rubber
3) ------ Idler Feed Shaft
4) ------ Feed Shaft Bearing
5) ------ Feed Spring
6) ------ Feed Support Frame
7) ------ Media Feed Gear Unit
8) 120E19120 Paper Empty Actuator
9) 695E58680 Paper Separator
10) 130K64640 Paper Empty Assembly
A) 600K72020 Hardware Kit

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Parts Lists 3-10 Xerox Docuprint P8e Service Manual
 1

2
3

4
2

10

P8e_304

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Xerox DocuPrint P8e Service Manual 3-11 Parts Lists
PL 6 Frame Assembly (1 of 2)
Item Part Number Description
1) 62K09270 LSU (Laser) Unit
2) 001K72470 Upper Frame Unit
3) ------ Cover Open Actuator Spring
4) ------ Cover Open Actuator
5) ------ Cover Open Micro Switch
6) ------ Developer Plate, Left
7) ------ Developer Plate Spring
8) ------ Developer Plate, Right
9) ------ Cover Open Sensor Cover
10) ------ Upper Frame
11) 121E15480 Paper Feed Solenoid
A) 600K72020 Hardware Kit

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Parts Lists 3-12 Xerox Docuprint P8e Service Manual
 1

4
9

5 10

7
8

P8e_305
11

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Xerox DocuPrint P8e Service Manual 3-13 Parts Lists
PL 7 Frame Assembly (2 of 2)
Item Part Number Description
1) 22E23250 Transfer Roller
2) 19K04780 Transfer Unit Holder {Includes Items 3, 4, & 5}
3) ------ Transfer Roller Bushing
4) ------ Transfer Roller Spring
5) ------ Transfer Roller Holder
6) ------ Media Unit Operator, Left {Includes Items 7 & 8}
7) ------ Pad Holder, Left
8) ------ Separator Pad, Left
9) ------ Media Unit Operator, Right {Includes Items 10 & 11}
10) ------ Separator Pad, Right
11) ------ Pad Holder, Right
12) 007E59210 Transfer Gear
13) 15K39960 Lower Frame Unit
14) ------ Base Frame
15) ------
16) ------
17) ------
18) ------
19) ------ Rubber Foot
20) ------
21) ------ Saw Plate
22) ------ Saw Plate Holder
23) 130E09090 Feed Sensor Assembly
24) 120E19130 Exit Actuator
25) 101E19690 Fuser Cover
26) ------ Transfer Roller Terminal Unit {Includes Items 27 & 28}
27) ------ High Voltage Shaft, Large
28) ------ High Voltage Spring, Large
29) ------ High Voltage Terminal Unit
30) ------ High Voltage Shaft, Small
31) ------ Developer Unit Fuse {Includes Items 32, 33, & 34}
32) 108K00690 Developer Unit Fuse Contact, Upper
33) ------ Developer Unit Fuse Plate
34) ------ Developer Unit Fuse Contact, Lower
35) ------ Off / On Switch
36) 38K12830 ELA Unit-PTL
37) ------
38) ------
39) ------
40) 127E12600 DC Fan Motor
A) 600K72020 Hardware Kit

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Parts Lists 3-14 Xerox Docuprint P8e Service Manual
 3
12
1
4
2
5
2

39 3
36
4
37
8 5
38 7
6
9
35
10
31
32 22 11
33 21
29 34
26 30
28
27 13

25

14

15

24 16

20 17
18

19
23

40
P8e_306a

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Xerox DocuPrint P8e Service Manual 3-15 Parts Lists
PL 8 Fuser
Item Part Number Description
1) 126K12920 Fuser Unit Assembly (115 VAC) {Includes Items 2 through 19}
126K12970 Fuser Unit Assembly (220 VAC) {Includes Items 2 through 19}
2) ------ Rubber Exit Roller
3) ------ Exit Bearing
4) ------ Exit Gear
5) ------ Roller
6) ------ Fuser Cover
7) ------ AC Electrode, Left
8) ------ AC Electrode, Right
9) ------ Thermostat
10) ------ Fuser Frame
11) ------ Bracket
12) 130E09100 Thermistor
13) ------ Bracket
14) ------ Exit Spring
15) 122E02490 Halogen Lamp (115 VAC)
122E02480 Halogen Lamp (220 VAC)
16) ------ Heat Roll Bearing, Left
17) ------ Heat Roller
18) ------ Heat Roll Bearing, Right
19) ------ Fuser Gear
20) 9K01910 Pressure Roller Holder Assembly {Includes Items 21, 22, & 23}
21) ------ Pressure Roller Bearing
22) ------ Pressure Roller Bearing Holder
23) ------ Pressure Roller Bearing Spring
24) 126K12890 Pressure Roller
25) 17E09150 Exit Roller Assembly {Includes Items 26, 27, 28, & 29}
26) ------ Rubber Exit Roll F/Up
27) ------ Exit Shaft F/Up
28) ------ Exit Gear
29) 115E06360 Exit Shaft Bushing - TX
A) 600K72020 Hardware Kit

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Parts Lists 3-16 Xerox Docuprint P8e Service Manual
 2
1
3

3
4
6
7
5

9
8

14 10

13

12

16
17
11
15
20 21
26 27
22
23
18
19
26
29 24

28
25

20
P8e_307a

7/98
Xerox DocuPrint P8e Service Manual 3-17 Parts Lists
PL 9 Main Drive Motor
Item Part Number Description
1) 127K30150 Main Drive Motor Assembly {Includes Items 2 through 12}
2) ------ Main Drive Motor
3) ------ Motor bracket
4) ------ Motor Drive Gear
5) ------ Feed Drive Gear
6) ------ Gear Bracket
7) ------ Gear-Drive 1
8) ------ Gear-Drive 2
9) ------ Gear-Pulley
10) ------ RCT-Belt Impeller
A) 600K72020 Hardware Kit

7/98
Parts Lists 3-18 Xerox Docuprint P8e Service Manual
 1

10
6

P8e_309a

7/98
Xerox DocuPrint P8e Service Manual 3-19 Parts Lists
PL 10 Electronics
Item Part Number Description
1) 160K60070 High Voltage Power Supply PWB
2) 114E15570 AC Plug Assembly
3) 160K60060 Controller PWB (115 VAC)
160K55520 Controller PWB (220 VAC)
4) ------ SIMM 4MB
------ SIMM 8MB
------ SIMM 16MB
------ SIMM 32MB
5) 160K55660 Engine Controller PWB (115 VAC)
160K55510 Engine Controller PWB (220 VAC)
6) 007K11190 Joint PWB
7) 108E05380 Fuse (115 VAC / T8A)
108E05390 Fuse (220 VAC / T5A)
A) 600K72020 Hardware Kit

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Parts Lists 3-20 Xerox Docuprint P8e Service Manual
 1

P8e_310a

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Xerox DocuPrint P8e Service Manual 3-21 Parts Lists
Notes

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Parts Lists 3-22 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

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Xerox DocuPrint P8e Service Manual 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

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Repair Procedures 4-2 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.

7/98
Xerox DocuPrint P8e Service Manual 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.

P8e_257

Figure 4.1.1b. Face Up Cover Removal.

P8e_258

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Repair Procedures 4-4 Xerox DocuPrint P8e Service Manual
REP 4.1.2 Front Cover
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 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

P8e_210a

Right Side

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Xerox DocuPrint P8e Service Manual 4-5 Repair Procedures
REP 4.1.3 Rear Cover
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the three screws that secure the Rear Cover (Figure 4.1.3a).
3 Release the two lock tabs that secure the bottom of the cover (Figure 4.1.3a).
4 Slide the cover up and remove.

Figure 4.1.3a. Rear Cover.

2
P8e_236

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Repair Procedures 4-6 Xerox DocuPrint P8e Service Manual
REP 4.1.4 Top Cover
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Rear Cover (REP 4.1.3).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the two screws that secure the front of the Top Cover (Figure 4.1.4a).
5 Lift the Top Cover to remove (Figure 4.1.4a).

Figure 4.1.4a. Top Cover Removal.

P8e_315

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Xerox DocuPrint P8e Service Manual 4-7 Repair Procedures
REP 4.1.5 Left and Right Side Covers
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the screw securing the side cover (Figure 4.1.5a).
8 Release the locking tab located at the top of the side cover (Figure 4.1.5a).
9 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.

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Repair Procedures 4-8 Xerox DocuPrint P8e Service Manual
REP 4.2 Paper Feed
REP 4.2.1 Paper Feed Solenoid
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Covers (REP 4.1.5).
8 Remove the Bottom Shield (REP 4.6.1).
9 Remove the Gear Bracket (REP 4.5.2).
10 Remove the Controller PWB (REP 4.6.3).
11 Remove the Engine Controller PWB (REP 4.6.2).
12 Remove the solenoid connector from CN 402 of the Joint PWB.
13 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.

7/98
Xerox DocuPrint P8e Service Manual 4-9 Repair Procedures
REP 4.2.2 Upper Frame Assembly
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Left and Right Side Covers (REP 4.1.5).
8 Remove the Gear Bracket (REP 4.5.2).
9 Remove the HVPS (REP 4.6.5).
10 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

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Repair Procedures 4-10 Xerox DocuPrint P8e Service Manual
 Figure 4.2.2b. Upper Frame Assembly Removal.

P8e_245 12

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

7/98
Xerox DocuPrint P8e Service Manual 4-11 Repair Procedures
REP 4.2.3 Paper Feeder Assembly
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Left and Right Side Covers (REP 4.1.5).
8 Remove the Gear Bracket (REP 4.5.2).
9 Remove the HVPS (REP 4.6.5).
10 Remove the Upper Frame Assembly (REP 4.2.2).
11 Remove the screw that secures the earth (ground) strap to the left end of the paper feed shaft
(Figure 4.2.3a).
12 Pull out on the locking tab of the left bearing and rotate the bearing 45 degrees clockwise (Figure
4.2.3a).
13 Press the locking tab and remove the frame insert.
14 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.
15 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

P8e_314 14

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Repair Procedures 4-12 Xerox DocuPrint P8e Service Manual
Replacement
1 Assemble in reverse order.
2 Verify proper operation.

7/98
Xerox DocuPrint P8e Service Manual 4-13 Repair Procedures
REP 4.3 Paper Transportation and Sensing
REP 4.3.1 Pfeed Sensor
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Rear Cover (REP 4.1.3).
4 Turn the printer up side down.
5 Remove the Bottom Shield (REP 4.6.1).
6 Remove the Engine Controller PWB (REP 4.6.2).
7 Disconnect CN401 from the Joint PWB (Figure 4.3.1a).
8 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

P8e_318

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

7/98
Repair Procedures 4-14 Xerox DocuPrint P8e Service Manual
REP 4.3.2 Paper Empty Sensor
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Rear Cover (REP 4.1.3).
4 Turn the printer up side down.
5 Remove the Bottom Shield (REP 4.6.1).
6 Remove the Engine Controller PWB (REP 4.6.2).
7 Remove the Controller PWB (REP 4.6.3).
8 Remove the Pfeed Sensor (REP 4.3.1).
9 Disconnect CN403 from the Engine Controller PWB (Figure 4.3.2a).
10 Remove the two screws that secure the Paper Empty Sensor to the printer frame (Figure 4.3.2a).
11 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

P8e_317

P8e_316

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

7/98
Xerox DocuPrint P8e Service Manual 4-15 Repair Procedures
REP 4.4 Fuser
REP 4.4.1 Fuser Assembly
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Face Up Cover (REP 4.1.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the screw that secures the Wire Cap (Figure 4.4.1a). Remove the Wire Cap.
9 Disconnect the Fuser Harness from CN1 on the Engine Controller PWB (Figure 4.4.1a).
10 Remove the two screws that secure the AC power wires to the Fuser Assembly (Figure 4.4.1a).
11 Remove the two screws that secure the Fuser Assembly to the printer frame (Figure 4.4.1a).
12 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

8 11

10 12
9
P8e_225

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Repair Procedures 4-16 Xerox DocuPrint P8e Service Manual
Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Xerox DocuPrint P8e Service Manual 4-17 Repair Procedures
REP 4.4.2 Fuser Pressure Roller
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Face Up Cover (REP 4.1.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the Fuser Assembly (REP 4.4.1).
9 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.

7/98
Repair Procedures 4-18 Xerox DocuPrint P8e Service Manual
REP 4.4.3 Halogen Lamp (Fuser Heat Rod)
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Face Up Cover (REP 4.1.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the Fuser Assembly (REP 4.4.1).
9 Turn the Fuser Assembly up side down and remove the earth (ground) strap from the right end of
the Fuser (Figure 4.4.3a).
10 Remove the two screws that secure the Halogen Lamp to the AC Terminals (Figure 4.4.3a).
11 Carefully lift the Fuser Roll and bearings out of the Fuser Assembly.
12 Remove the Halogen Lamp and Fuser Drive Gear from the Fuser Roll (Figure 4.4.3a).
13 Remove the drive gear from the Halogen Lamp (Figure 4.4.3a).

Figure 4.4.3a. Halogen Lamp Removal.

10
12

10
13
P8e_319

Replacement
1 Assemble in reverse order.
2 Ensure the four Fuser Stripper Fingers are on top of the Fuser Roll.
3 Verify proper operation.

7/98
Xerox DocuPrint P8e Service Manual 4-19 Repair Procedures
REP 4.4.4 Fuser Thermistor
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Face Up Cover (REP 4.1.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the Fuser Assembly (REP 4.4.1).
9 Remove the Fuser Heat Roll (REP 4.4.3).
10 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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Repair Procedures 4-20 Xerox DocuPrint P8e Service Manual
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

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.

7/98
Xerox DocuPrint P8e Service Manual 4-21 Repair Procedures
REP 4.5.2 Gear Bracket
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the six screws that secure the Gear Bracket to the printer frame (Figure 4.5.2a).

Figure 4.5.2a. Gear Bracket Removal.

P8e_200a
8

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.

7/98
Repair Procedures 4-22 Xerox DocuPrint P8e Service Manual
REP 4.5.3 Main Drive Motor Assembly
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Cover (REP 4.1.5).
8 Remove the Gear Bracket (REP 4.5.2).
9 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

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.

7/98
Xerox DocuPrint P8e Service Manual 4-23 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.

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.

7/98
Repair Procedures 4-24 Xerox DocuPrint P8e Service Manual
REP 4.5.5 DC Fan Motor
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Open the Front Cover and remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Right Side Covers (REP 4.1.5).
8 Remove the Bottom Shield (REP 4.6.1).
9 Remove the Gear Bracket (REP 4.5.2).
10 Remove the Controller PWB (REP 4.6.3).
11 Remove the Engine Controller PWB (REP 4.6.2).
12 Remove the fan connector from CN 408 of the Joint PWB.
13 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.

P8e_400 13

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

7/98
Xerox DocuPrint P8e Service Manual 4-25 Repair Procedures
REP 4.6 Electrical Modules
REP 4.6.1 Bottom Shield
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Turn the printer up side down (Figure 4.6.1a).
4 Remove the three screws that secure the Shield to the bottom of the printer (Figure 4.6.1a).
5 Lift and remove the shield (Figure 4.6.1a).

Figure 4.6.1a. Bottom Shield.

4

P8e_239

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Repair Procedures 4-26 Xerox DocuPrint P8e Service Manual
REP 4.6.2 Engine Controller PWB
Removal

CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.

1Switch the printer power off and disconnect the AC power cord.
2Remove the Print Cartridge (REP 4.5.1).
3Remove the Rear Cover (REP 4.1.3).
4Turn the printer up side down.
5Remove the Bottom Shield (REP 4.6.1).
6Disconnect J5 from the Controller PWB (Figure 4.6.2a).
7Remove 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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Xerox DocuPrint P8e Service Manual 4-27 Repair Procedures
 Figure 4.6.2a. Engine Controller Removal.
7

8
9

P8e_240

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Repair Procedures 4-28 Xerox DocuPrint P8e Service Manual
REP 4.6.3 Controller PWB
Removal

CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.

1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Rear Cover (REP 4.1.3).
4 Turn the printer up side down.
5 Remove the Bottom Shield (REP 4.6.1).
6 Disconnect J2 and J5 from the Controller PWB (Figure 4.6.3a).
7 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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Xerox DocuPrint P8e Service Manual 4-29 Repair Procedures
REP 4.6.4 LSU (Laser) Assembly
Removal
1 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Disconnect the harness connected to the left side of the Laser Assembly (Figure 4.6.4a).
8 Remove the screw that secures the ground wire to the Laser (Figure 4.6.4a).
9 Remove the four mounting screws that secure the Laser to the printer frame (Figure 4.6.4a).
10 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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Repair Procedures 4-30 Xerox DocuPrint P8e Service Manual
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 Switch the printer power off and disconnect the AC power cord.
2 Remove the Face Up Cover (REP 4.1.1).
3 Remove the Print Cartridge (REP 4.5.1).
4 Remove the Front Cover (REP 4.1.2).
5 Remove the Rear Cover (REP 4.1.3).
6 Remove the Top Cover (REP 4.1.4).
7 Remove the Left Side Cover (REP 4.1.5).
8 Disconnect the following from the top of the HVPS PWB, CN2, CN3, and CN4 (Figure 4.6.5a).
9 Remove the five screws that secure the HVPS to the printer frame (Figure 4.6.5a).
10 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.

P8e_227
8

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Xerox DocuPrint P8e Service Manual 4-31 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 Switch the printer power off and disconnect the AC power cord.
2 Remove the Print Cartridge (REP 4.5.1).
3 Remove the Rear Cover (REP 4.1.3).
4 Turn the printer up side down.
5 Remove the Bottom Shield (REP 4.6.1).
6 Remove the Engine Controller PWB (REP 4.6.2).
7 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

P8e_229

Replacement
1 Assemble in reverse order.
2 Verify proper operation.

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Repair Procedures 4-32 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 ........ 5-
85.3.2 The Status Monitor .......................................................... 5-9
5.3.3 Remote Control Panel (RCP) ................................................ 5-10

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Xerox DocuPrint P8e Service Manual 5-1 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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General Procedures and Information 5-2 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-3 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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General Procedures and Information 5-4 Xerox DocuPrint P8e Service Manual
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 Description

Error LED (on) 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) The printer is on manual feed mode (push On/Off-line
button to feed paper from manual feeder).

Ready LED (on) The printer is ready to receive and process data.

Ready LED (blink) The printer is receiving or processing data.

Ready LED (off) The printer is offline

All LEDs (blink) Possible printer failure.

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Xerox DocuPrint P8e Service Manual 5-5 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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General Procedures and Information 5-6 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-7 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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General Procedures and Information 5-8 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-9 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/Off-
line 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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General Procedures and Information 5-10 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-11 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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General Procedures and Information 5-12 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-13 General Procedures and Information
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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General Procedures and Information 5-14 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-15 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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General Procedures and Information 5-16 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-17 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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General Procedures and Information 5-18 Xerox DocuPrint P8e Service Manual
 Figure 5.4.2a Diagnostic Control Unit

SM5_012

7/98
Xerox DocuPrint P8e Service Manual 5-19 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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General Procedures and Information 5-20 Xerox DocuPrint P8e Service Manual
 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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Xerox DocuPrint P8e Service Manual 5-21 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
CN4
01 Charge -1400
HVPS PWB
02 Metal end of -220 to
CN3
BTR Roller -550
CN1
03 Metal end of 600 to 2800
BTR Roller SUPPLY
DEV
04
Bias Medium Bias -300
Supply THV
Bias Dark Bias -350 MHV
Bias Transfer
Bias Medium Supply -500
Bias Dark Supply -500
sm5_020
Charge
13
Transfer Trigger Transfer 495
Transfer Duty Transfer 673

14
Transfer Duty Transfer 673

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General Procedures and Information 5-22 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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Xerox DocuPrint P8e Service Manual 5-23 General Procedures and Information
 Table 5.4.5b DCU Test Procedures

Diagnostic Diagnostic To Conduct Test Response LEDs To End Test

Code Test On Off ___

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 Pressing Up stops

Bias Medium Press ENTER Voltage On Lit one test and starts
Bias Dark Press UP Voltage On Lit Lit next
Shift + Stop

05 Laser Assembly Press ENTER Laser Motor On Lit Shift + Stop

Laser Diode & Motor ON Press up Laser Diode On Lit 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

08 Feed & Exit Sensor Press ENTER -----

Actuate Feed Sensor ----- Lit
Actuate Exit Sensor ----- Lit Shift + Stop

09 Cover Open Sensor Press ENTER -----

Actuate Sensor -----
Deactuate Sensor ----- Lit Shift + Stop

10 Fuser Circuit
Standby Heat Press ENTER Fuser Warms Lit
Print Heat Press UP At Print Temp Lit
Overheating Press UP Fuser Overheat Lit Shift + Stop

11 Continous Printing Press ENTER Prints test prints Lit Unplug Printer

12 Print Cartridge Cleaning Press ENTER Cleaning Prints Lit Unplug Printer
Cycle (continous)

13 Transfer
Transfer Trigger Press ENTER Voltage On Lit Lit Lit
Transfer Duty Automatically Switches Voltage On Lit Shift + Stop

14 Transfer Duty Press ENTER Voltage On Lit Shift + Stop

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General Procedures and Information 5-24 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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Xerox DocuPrint P8e Service Manual 5-25 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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General Procedures and Information 5-26 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 5-27 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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General Procedures and Information 5-28 Xerox DocuPrint P8e Service Manual
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 Part Number
Cleaning Cloth (treated) 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 8R90175
Cleaning Pad Kit 600S4372
Cloth 8R90019
Fuser Cleaning Solvent Pads 43P83
General Cleaning Solvent 8R90176
Lens Cleaner 8R90177

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Xerox DocuPrint P8e Service Manual 5-29 General Procedures and Information
5.9 Abbreviations
Abbreviation Stands for Abbreviation Stands for
BCR Bias Charge Roll INTR Interrupt Request
BIOS Basic Input/Output System I/O Input and Output
BPS Bits Per Second lb Pound(s)
BTR Bias Transfer Roll LDON Laser Diode On
CBUSY Command busy LED Light Emitting Diode
CCLK Command clock lin linearity
clk clock LSU Laser Scanner Unit
cm centimeter(s) MHV Main High Voltage
CMOS Complementary Metal Oxide motor_pa Motor phase A
Semiconductor motor_pb Motor phase B
CMSG 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
DMAC Direct Memory Access Controller PPM Pages Per Minute
DOS Disk Operating System PRINT Print command
DPI Dots Per Inch psync page synchronization
DRAM Dynamic Random Access Memory pwr power
DS Data Strobe RAM Random Access Memory
DVM Digital Voltmeter READY Engine ready to print
EBUSY Engine Status Busy ROM Read Only Memory
EEPROM Electrically Erasable Programmable SCC Serial Comm. Controller
Read Only Memory THV Transfer High Voltage
EMSG Engine Status message Vcc collector supply voltage (dc)
HSYNC Horizontal sync VCU Video Control Unit
INT Interrupt VDI Video data from controller
INTA Interrupt Acknowledge VDO Video data output
Image Cartridge Print Cartridge

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General Procedures and Information 5-30 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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Xerox DocuPrint P8e Service Manual 6-1 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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Wiring Data 6-2 Xerox DocuPrint P8e Service Manual
6.2 Connection and Wiring Diagrams
6.2.1 Master Connection and Wiring Diagram

Ac in Engine Joint PWB

Controller Paper Empty
PWB Cn403
Sensor
On/off
Switch Cn401 Pfeed Sensor
Cn201
Cn404 Developer Fuse
Halogen Lamp Cn202
Fuser Heat Rod
Cn407 Pretransfer Lamp
Fuser Cn1
Thermister
Cn405 Drive Motor
Hvps
Cn402 Paper Feed
Cn1 Cn2
Solenoid
Cover Open
Cn2
Interlock
Cn4 Cn406
Laser PWB Cn4 Cn3
Cn408 DC Fan
Cn5 Motor
Laser Motor Cn3

Transfer Roller Thv

Charge Mhv
Developer Bias Dev J5
Supply Voltage Supply

Parallel
Connector J1 J7

Control J2
Panel

J8

Master_a
Controller
PWB

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Xerox DocuPrint P8e Service Manual 6-3 Wiring Data
6.3 Circuit Board Layout
6.3.1 Controller PWB

J1 PARALLEL CONNECTOR

J8

J7

J2

J5

Control

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Wiring Data 6-4 Xerox DocuPrint P8e Service Manual
 CN5 2 WHT 1 J5 J2 1 ORN 1
1 BLK 2 2 WHT 2
4 WHT 3 3 WHT 3
WHT WHT Control
3 4 Controller 4 4 Panel
6 WHT 5 5 WHT 5
PWB
5 WHT 6 6 WHT 6
8 WHT 7 7 WHT 7
7 WHT 8
WHT 9
10 J8 1
9 WHT 10 2
Engine WHT 11
12 3
Controller 11 WHT 12 4
PWB 14 WHT 13
13 WHT 14 J1
16 WHT 15
WHT 1
15 16 2
18 WHT 17
WHT 3
17 18 Simm
WHT 4
20 19 Connector 5
19 WHT 20
WHT 6
22 21 J7 7
21 WHT 22
WHT 8
24 23 9
23 WHT 24 10 Parallel
11
Interface
12
13 Connector
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
WIR001

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Xerox DocuPrint P8e Service Manual 6-5 Wiring Data
6.3.2 Joint PWB

Cn405 Cn408 Cn402

Cn403

Cn401

Cn406

Cn407 Cn404

Joint_a

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Wiring Data 6-6 Xerox DocuPrint P8e Service Manual
 WHT BLK
CN4 2 1 CN406 Cn405 1
1 BLK 2 2 RED
4 WHT 3 3 RED Drive
3 WHT 4 4 RED Motor
6 WHT 5 5 RED
5 WHT 6 6 RED
WHT Joint PWB
8 7
WHT 1 BLK
7 8 Cn402 Clutch
WHT 2 BLK
Engine 10 9
Controller 9 WHT 10
PWB WHT RED
12 11 Cn404 1 Developer
WHT 2 BLK Fuse
11 12
14 WHT 13
WHT BLK
13 14 CN403 1 Paper Empty
16 WHT 15 2 RED
Sensor
15 WHT 16 3 WHT
18 WHT 17
17 WHT 18
WHT 1 BLK
20 19 RED
19 WHT 20
CN401 2
3 BLU Pfeed Sensor
4 WHT

BLK
CN407 1 Pretransfer
2 RED Lamp

BLU
CN408 1 DC Fan
2 Motor
3 RED

WIR002a

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Xerox DocuPrint P8e Service Manual 6-7 Wiring Data
6.3.3 Engine Controller PWB

AC POWER

INLINE
CONNECTOR

CN202

F1

CN201

CN2

CN5

CN4

EXIT
SENSOR
CN1
CN3

LVPS

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Wiring Data 6-8 Xerox DocuPrint P8e Service Manual
 CN1 2 BLK 1 1
CN2 CN3
RED 2 2 Diagnostic Control
1
4 WHT 3 3 Unit Connector
WHT 4 4
3
6 WHT 5
5 WHT 6
1 WHT
8 WHT 7 CN202 Fuser Heat
Engine 2 WHT Rod
WHT 8
7 Controller
10 WHT 9 PWB 1 WHT
WHT 10 CN1 Fuser
9 WHT
WHT 2 Thermister
12 11
WHT 12
HVPS 11
WHT 1 BLK 2 CN406
PWB 14 13 CN4
WHT 2 WHT 1
13 14
WHT 3 WHT 4
16 15
WHT 4 WHT 3
15 16
WHT 5 WHT 6
18 17
WHT 6 WHT 5
17 18
WHT 7 WHT 8
20 19
WHT 8 WHT 7
19 20
WHT 9 WHT 10
22 21
WHT 10 WHT Joint
21 22 9
WHT PWB
24 WHT 23 11 12
WHT 12 WHT 11
23 24
13 WHT 14
14 WHT 13
BLK 15 WHT 16
J5 2 1 CN5
WHT 16 WHT 15
1 2
WHT 17 WHT 18
4 3
WHT 18 WHT 17
3 4
WHT 19 WHT 20
6 5
WHT 20 WHT 19
5 6
8 WHT 7
WHT 8
7 CN 1
10 WHT 9 201 3
WHT 10
9
12 WHT 11
WHT 12
Controller 11
PWB WHT 13 OFF/ON
14
WHT Switch
13 14
16 WHT 15
WHT 16
15
WHT Black
18 17
WHT White
17 18
WHT Green
20 19
WHT 20
19 Printer
22 WHT 21 Power AC Line
WHT 22 Connector
21
24 WHT 23
WHT 24
23

Wir010

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Xerox DocuPrint P8e Service Manual 6-9 Wiring Data
6.3.4 HVPS

CN2

CN4

HVPS PWB

CN3

CN1

SUPPLY

DEV

THV

MHV

HVPS

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Wiring Data 6-10 Xerox DocuPrint P8e Service Manual
 CN2 2 RED 1 1 BLK
CN1 CN4
BLK 2 2 RED
1
WHT 3 RED
4 3 HVPS LASER PWB
WHT 4 4 RED
3
6 WHT 5 5 RED
WHT 6 6 RED
5
8 WHT 7
WHT 8
7 BLK
10 WHT 9 CN3 1
ENGINE WHT 2 RED
9 10
CONTROLLER WHT 3 RED LASER MOTOR
12 11
PWB WHT 4 RED
11 12
WHT 5 RED
14 13
WHT 14
13
16 WHT 15
WHT 16
15
18 WHT 17 1 WHT
COVER OPEN
WHT CN2 WHT
17 18 2 INTERLOCK
20 WHT 19
WHT 20
19
22 WHT 21
21 WHT 22
24 WHT 23
23 WHT 24

THV
TRANSFER ROLLER

MHV
CHARGE

DEV
DEVELOPER BIAS

Supply
SUPPLY VOLTAGE

WIR004

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Xerox DocuPrint P8e Service Manual 6-11 Wiring Data
6.3.5 Control Panel PWB

LED2

LED3

LED1

CN1

SW1

CONTROL

6.3.6 PFeed PWB

WHT
RED
BLU

BLK

NARROW
S (2) PFEED SW

PFEED

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Wiring Data 6-12 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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Xerox DocuPrint P8e Service Manual 7-1 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.

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Repair Analysis Procedures (RAP) 7-2 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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Xerox DocuPrint P8e Service Manual 7-3 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.

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Repair Analysis Procedures (RAP) 7-4 Xerox DocuPrint P8e Service Manual
 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 Normal Operation, fuser is warming to operating temperature.

Paper Tray Open or Empty 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).

Cover Open or Missing Verify that the Print Cartridge is properly installed. Verify that the Front Cover is
Print Cartridge 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 Communications problem, go to RAP 7.9.

Unknown Status Using the DCU, verify the Laser and Fuser operation, replace if necessary (Laser
PL 6 or Fuser PL 8).

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Xerox DocuPrint P8e Service Manual 7-5 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).

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Repair Analysis Procedures (RAP) 7-6 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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Xerox DocuPrint P8e Service Manual 7-7 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 Possible Cause Solution

All three LEDs blink. Defective Laser Go to RAP 7.7.

Defective Fuser

Error LED only is No Print Cartridge Properly reinstall or replace Print Cartridge.
illuminated. Open Front Cover Close Front Cover.
Defective Front Cover Actuator Verify / replace Front Cover Actuator (PL 6).
Engine Controller PWB Replace the Engine Controller PWB (PL 10).

Flashing Paper LED. No paper Add paper or properly adjust paper in tray.
Low Paper Sensor Actuator Verify / replace Low Paper Actuator (PL 5).
Engine Controller PWB Replace the Engine Controller PWB (PL 10).

Error and Paper LEDs Paper Jam 0, 1, or 2 Go to RAP 7.6.

are illuminated

Error and On-line blink Complex job Add memory.

Reduce to 300 X 300 DPI.
Set to Raster graphics.

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Repair Analysis Procedures (RAP) 7-8 Xerox DocuPrint P8e Service Manual
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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Xerox DocuPrint P8e Service Manual 7-9 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 Use DCU test 08 to verify sensor. If OK replace the Engine
Sensor or Sensor Actuator Controller PWB (PL 10).

Paper Jam 01 Paper Feed / Registration Use DCU test 08 to verify sensor. If OK replace the Engine
Sensor or Sensor Actuator 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)

Paper Jam 02 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).

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Repair Analysis Procedures (RAP) 7-10 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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Xerox DocuPrint P8e Service Manual 7-11 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 1. Print Cartridge. 1. Inspect drum for deterioration or contamination.

QUALITY: The line darkness and 2. Print Cartridge ground. If defective, replace the Print Cartridge.
solid area density image vary 3. Unstable high voltage output. 2. Verify Print Cartridge ground. Check continuity
across the print. 4. BTR contamination. between cartridge contact and the Controller
5. LSU Laser window PWB metal cover. Ensure that the drum contact
contamination. 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 1. Controller PWB. 1. Using the DCU, print a DCU test print. If the test
completely covered with toner 2. Incorrect charge voltage. print is OK, replace the Controller PWB. If test
and has no visible image. 3. Print Cartridge. print is black, continue.
4. Engine Controller PWB. 2. Verify charge voltage output. Charge voltage
5. Laser on all the time. 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: 1. Controller PWB. 1. Using the DCU, print a DCU test print. If the test
There are areas of the image that 2. Print Cartridge grounding print is OK, replace the Controller PWB (PL 10).
are extremely light or missing problem. 2. Verify Print Cartridge ground. Check continuity
entirely. These missing areas 3. Print Cartridge. between cartridge contact and the Controller
form wide bands that run 4. Transfer Roller. PWB metal cover. Ensure that the drum contact
horizontally across the page in 5. Laser Assembly is clean and undamaged.
the direction of scanning. 6. Engine Controller PWB. 3. If deletion repeats every:
7. Fuser Assembly. 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)

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Repair Analysis Procedures (RAP) 7-12 Xerox DocuPrint P8e Service Manual
 Defect Definitions Possible Causes Solutions

VERTICAL DELETIONS: There 1. Print Cartridge. 1. Replace the Print Cartridge (PL 1).
are areas of the image that are 2. Laser Assembly. 2. Inspect the LSU (LASER) beam path for
extremely light or missing 3. Fuser Assembly. contamination. Clean as necessary.
entirely. These missing areas 4. Transfer Roller. 3. Inspect fuser rolls for damage and replace as
form wide bands that run necessary.
vertically along the page in the 4. Inspect Transfer Roller spring tension and
direction of paper movement. bearings. Remove the Transfer Roller and clean
(dust off). Replace Transfer Roller if necessary
(PL 7).

SPOT DELETIONS: Solid areas 1. Print Cartridge. 1. Deletions repeat every 94.3 mm (3.7 in.).
are marked with irregular white 2. Transfer Roller. Replace Print Cartridge.
areas. 3. Damp Paper. 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) 1. Verify the RCP print quality settings.
settings. 2. Re-install the Print Cartridge.
2. Print Cartridge not installed 3. Verify that all high voltage outputs are to
correctly. specification (refer to section 5, DCU operation).
3. Incorrect high voltage output. 4. Remove the Print Cartridge and shake to
4. Low toner in cartridge. redistribute toner. Replace Print Cartridge if
necessary (PL 1).

BLANK PRINTS: Prints with 1. Seal tape not removed from 1. Inspect cartridge for removal of seal tape.
no visible image. Print Cartridge. 2. Verify Print Cartridge ground. Check continuity
2. Defective ground on Print between cartridge contact and the Controller
Cartridge. PWB metal cover. Ensure that the Print
3. Controller PWB. Cartridge ground contact is clean and
4. Incorrect high voltage output. undamaged.
5. Defective LASER. 3. Using the DCU, print a DCU test print. If the test
6. Transfer Roller pressure print is OK, replace the Controller PWB.
7. Paper 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: 1. Defective font download. 1. Customer may have recently changed/modified
Horizontal or vertical bands, or 2. Loose / defective cables, host software or drivers. Reconfigure if
other marks that are print defects cables out of specification (too necessary.
caused by bad or incorrect font long, etc.). 2. Inspect cable connections for proper installation
data, print drivers, electrical 3. Electromagnetic interference. and for damage. Parallel cable must be a good
noise or other causes not directly 4. Controller PWB. quality and comply with the IEEE 1284 bi-
related to the 5. Engine Controller PWB. directional specification.
electrophotographic process. 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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Xerox DocuPrint P8e Service Manual 7-13 Repair Analysis Procedures (RAP)
 Defect Definitions Possible Causes Solutions

CHARACTER DEFECTS: 1. Defective font download. 1. Customer may have recently changed/modified
Garbled print, missing, repeating, 2. Loose / defective cables, host software or drivers. Reconfigure if
or scrambled characters are cables out of specification (too necessary.
problems relating to font data or long, etc.). 2. Inspect cable connections for proper installation
character generation. These are 3. Electromagnetic interference. and for damage. Parallel cable must be a good
print defects not related to the 4. Defective SIMM. quality and comply with the IEEE 1284 bi-
electrophotographic process. 5. Controller PWB. directional specification.
6. Engine Controller PWB. 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. Paper. 1. Replace paper from a fresh unopened ream.
toner on the page. 2. Paper path contaminated. 2. Clean paper path.
3. Print Cartridge 3. Replace Print Cartridge (PL 1).
4. Fuser Assembly. 4. Inspect/clean/replace Fuser Assembly as
5. Transfer Roller. necessary (PL 8).
5. If spot repeats every 47.1 mm (1.9 in.), replace
the Transfer Roller (PL 7).

UNFUSED IMAGE: part of or all 1. Damp paper. 1. Replace paper from a fresh unopened ream.
of the image is unfused. 2. Paper quality. 2. Be sure that the paper is not extremely rough,
3. Light image density heavily textured, or of a high rag content.
4. Fuser Assembly. 3. Check Remote Control Panel print quality
5. Engine Controller PWB. settings.
4. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
5. Replace the Engine Controller PWB (PL 10).

STREAKS: Extraneous dark 1. Print Cartridge. 1. Inspect drum surface for scratches or bands. If
lines/bands in or across the 2. Fuser Assembly. defective, replace the Print Cartridge (PL 1).
process direction. These are 3. Transfer Roller. 2. Inspect fuser rollers for scratches or
Engine Controller defects not 4. Contaminated paper path. contamination. If defective, replace the Fuser
related to the Controller PWB or Assembly (PL 8).
Host Data. 3. Inspect Transfer Roller. If defective, replace the
Transfer Roller (PL 7).
4. Clean the paper path.

RESIDUAL IMAGES: The image 1. Print Cartridge. 1. Replace Printer cartage (PL 1).
from a previous print, which was 2. Fuser Assembly. 2. Inspect/clean/replace Fuser Assembly as
not removed during the cleaning 3. Erase Lamps. necessary (PL 8).
process, has been developed on 4. High Voltage Contacts 3. Remove the Print Cartridge, attach the DCU and
the current print. 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 1. Print Density. 1. Verify print quality setting in the Remote Control
contamination in non image 2. High voltage output. Panel.
areas. 3. Print Cartridge. 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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Repair Analysis Procedures (RAP) 7-14 Xerox DocuPrint P8e Service Manual
 Defect Definitions Possible Causes Solutions

DAMAGED PRINTS: Creases, 1. Paper 1. Properly install fresh paper into the Multipurpose
wrinkles, excessive curl, cuts, 2. Paper source and Paper Feeder.
folds or embossed marks. transportation. 2. Inspect paper transportation system for proper
3. Fuser Assembl.y operation. Replace worn parts.
4. Print Cartridge. 3. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).
4. Replace Print Cartridge (PL 1).

SKIPS / SMEARS: Skips, loss, 1. Paper transportation. 1. Inspect paper transportation system for proper
or stretching of the image in 2. Main Drive Motor Assembly. operation. Replace worn parts.
bands across the process 3. Fuser Assembly. 2. Inspect Main Drive Motor Assembly for damaged
direction. 4. Print Cartridge or worn gears. Replace as necessary.
Smear-The distortion of the 3. Inspect/clean/replace Fuser Assembly as
image in bands across the necessary (PL 8).
process direction that cause it to 4. Replace Print Cartridge (PL 1).
appear to be blurred or
compressed.

Skewed Image: Angular 1. Paper Feed. 1. Inspect Multipurpose Paper Feeder for damage.
displacement of the image from 2. Paper transportation. Replace parts as necessary. Properly install
its intended position on the print. 3. Fuser Assembly. fresh paper in the paper tray.
The printed image is not parallel 2. Inspect paper transportation system for proper
with the sides of the page. operation. Replace worn parts.
3. Inspect/clean/replace Fuser Assembly as
necessary (PL 8).

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Xerox DocuPrint P8e Service Manual 7-15 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.

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Repair Analysis Procedures (RAP) 7-16 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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Xerox DocuPrint P8e Service Manual 7-17 Repair Analysis Procedures (RAP)
Notes

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Repair Analysis Procedures (RAP) 7-18 Xerox DocuPrint P8e Service Manual
 Section 8 1

P8ex Addendum 1

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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Xerox DocuPrint P8ex Service Manual 8-1 Addendum
 This Page intentionally left blank

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Addendum 8-2 Xerox DocuPrint P8ex Service Manual
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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Xerox DocuPrint P8ex Service Manual 8-3 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 PCL 6 PCL 5e

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. •
* This setting is not available in the Windows NT 4.0 version of the PCL 5e driver.

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Addendum 8-4 Xerox DocuPrint P8ex Service Manual
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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Xerox DocuPrint P8ex Service Manual 8-5 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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Addendum 8-6 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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Xerox DocuPrint P8ex Service Manual 8-7 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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Addendum 8-8 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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Xerox DocuPrint P8ex Service Manual 8-9 Addendum
Parts List

PL 1 Covers
Item Part Number Description
1) ------ Top Cover}
2) 802E00400 Rear Cover (P8e)
802E18660 Rear Cover (P8ex)
3) ------ Right Side Cover
4) ------ Bottom Cover
5) ------ Face Up Cover
6) 802E00380 Front Cover (P8e)
802E19230 Front Cover (P8ex)
7) ------ Left Side Cover
8) 113R00296 Print Cartridge
A) 600K72020 Hardware Kit

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Addendum 8-10 Xerox DocuPrint P8ex Service Manual
 1

6
2

P8e_308

4
5

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Xerox DocuPrint P8ex Service Manual 8-11 Addendum
PL 2 Front Cover
Item Part Number Description
1) ------ Front Cover {Includes Items 2 through 7}
2) ------ Stacker Extender
3) ------ Stacker
4) ------ Duct
5) 802E00380 Front Cover (P8e)
802E19230 Front Cover (P8ex)
6) ------ Stacker Guide
7) ------ Stopper
8) 3E50440 Key
9) 107E16960 LED
10) 101E19680 Control Panel
11) ------ Control Panel Cover
12) 802E00390 Face Up Exit Cover
A) 600K72020 Hardware Kit

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Addendum 8-12 Xerox DocuPrint P8ex Service Manual
 1

2 3

9
10
12
8

11

P8e_301a

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Xerox DocuPrint P8ex Service Manual 8-13 Addendum
PL 3 Paper Trays
Item Part Number Description
1) ------ Media (Paper) Tray {Includes Items 2 through 12}
2) ------ Gear Adjust Rack, Left
3) ------ Gear Adjust Rack, Right
4) ------ Pinion Gear
5) ------ Auto Tray Adjust, Right
6) ------ Manual Tray Adjust, Right
7) ------ Film Guide Sheet
8) ------ Manual Tray Adjust, Left
9) ------ Manual Paper Tray
10) ------ Auto Tray Adjust, Left
11) ------ Paper Guide Plate
12) ------ Rear Cover Assembly {Includes Items 13 & 14}
13) 50E15050 Tray Extender
14) 802E00400 Rear Cover (P8e)
802E18660 Rear Cover (P8ex)
A) 600K72020 Hardware Kit

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Addendum 8-14 Xerox DocuPrint P8ex Service Manual
 1
11 2
10

9 3
4

8
5

7
6

12

Rear panel of P8ex

13
13

14
14

P8_302A

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Xerox DocuPrint P8ex Service Manual 8-15 Addendum
PL 10 Electronics
Item Part Number Description
1) 160K60070 High Voltage Power Supply PWB
2) 114E15570 AC Plug Assembly
3) 160K60060 Controller PWB (115 VAC) (P8e)
160K55520 Controller PWB (220 VAC) (P8e)
160K65260 Controller PWB (115 VAC) (P8ex)
160K65270 Controller PWB (220 VAC) (P8ex)
4) ------ SIMM 4MB
------ SIMM 8MB
------ SIMM 16MB
------ SIMM 32MB
5) 160K55660 Engine Controller PWB (115 VAC)
160K55510 Engine Controller PWB (220 VAC)
6) 007K11190 Joint PWB
7) 108E05380 Fuse (115 VAC / T8A)
108E05390 Fuse (220 VAC / T5A)
A) 600K72020 Hardware Kit

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Addendum 8-16 Xerox DocuPrint P8ex Service Manual
 1

Rear view of P8ex

2
5
3

P8e_310b

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Xerox DocuPrint P8ex Service Manual 8-17 Addendum
 This Page Intentionally Left Blank

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Addendum 8-18 Xerox DocuPrint P8ex Service Manual
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