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09/2007

4-53

Phaser 8860/8860MFP Service Manual

REP 4.0.7

Repairs and Adjustments

Initial Issue

Figure 1 Removing the Process Drive and Process Drive Gear Alignment

8.

Remove the Process Drive from the chassis.

9.

Disconnect the Process Drive from the harness.

Replacement

CAUTION

Before tightening the Process Drive mounting screws, align the holes in the Process Drive
flange with the mounting bosses on the frame, seat the gears, and press the Process Drive
tightly against the frame. Next, seat all three screws before torquing the screws to a final tight-
ness of 12 in-lbs. Tightening the screws individually before seating all three can put undue
strain on the mounting bosses. Do not use the screws to pull the Process Drive into alignment.

Perform the Head Tilt Gear (

ADJ 4.13.1

), and Process Drive Alignment (

ADJ 4.7.1

) adjust-

ments before restoring system power.

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Summary of Contents for Phaser 8860

Page 1: ...705P01205 September 2007 Phaser 8860 8860MFP Service Documentation...

Page 2: ...Xerox service technicians and service partners only and are not for resale These materials may not be distributed copied or otherwise reproduced without prior written consent from Xerox Corporation X...

Page 3: ...Safety Summary iv Moving the System vi Symbology and Nomenclature vii Electrostatic Discharge Precautions ix Regulatory Specifications ix Phaser 8860 8860MFP Overview x System Configurations xi Parts...

Page 4: ...09 2007 iv Phaser 8860 8860MFP Service Manual Initial Issue Introduction...

Page 5: ...ostic aids for troubleshooting that include Power On Self Test POST Built in Self Tests BIST and Fault Code error procedures Section 3 Image Quality This section contains the diagnostic aids for troub...

Page 6: ...afety Use the Power Cord supplied with the system Plug the Power Cord directly into a properly grounded electrical outlet Do not use a ground adapter plug to connect the system to an electrical outlet...

Page 7: ...erson capable of rendering first aid or resuscitation is present Use care when servicing with power Dangerous voltages may exist at several points in this product To avoid personal injury do not touch...

Page 8: ...rd or using a power strip with an on off switch For the 8860MFP lock the scanhead shipping restraint before removing the scanner por tion for shippment Moving the scanner with the scanhead unlocked ca...

Page 9: ...t sur Marche ou avec le cordon d alimentation branch The following sections have additional specific warning information WARNING A Warning is used whenever an operating or maintenance procedure a prac...

Page 10: ...ed in order to prevent additional damage when circuit boards are returned for repair The instructions for using the ESD Field Service Kit can be found in ESD Field Service Kit Usage in the General Pro...

Page 11: ...ectricity to damage an electro statically sensitive device Handle IC s and EPROM s carefully to avoid bending pins Pay attention to the direction of parts when mounting or inserting them on Printed Ci...

Page 12: ...The Phaser 8860 in either the printer 8860 or multifunction 8860MFP configuration uses a Printhead and a new formulation of solid ink sticks with an image processor supporting Post Script 3 and PCL5c...

Page 13: ...ng a unique factory supplied 4 digit PIN Once set to Metered operation the con trol software performs the following 1 The Mode and PIN entered values in Engine Control Board NVRAM are set 2 The Contro...

Page 14: ...1 Tray 4 optional 2 Tray 3 optional 3 Tray 2 4 Tray 1 MPT 5 Output Tray 6 Exit Cover 7 Control Panel 8 Duplex Automatic Document Feeder DADF Front Cover 9 DADF 10 Interface Cover 11 Drum Maintenance K...

Page 15: ...rd 9 RJ 11 Fax Modem Connection Back View Electronics Module The system s main electronics and power supply are enclosed in a metal case called the Elec tronics Module The Electronics Module s rear pa...

Page 16: ...ects black and white or color for copy or scan jobs 2 Document Type selects the type of document photo graphic mixed text and graphics or text only for copy or scan jobs 3 Output Quality selects the o...

Page 17: ...n or fax Yellow indicates a warning condition The system continues the operation Red indicates a startup or operational error condition Blinking indicates a warm up or busy condition Control Panel Rig...

Page 18: ...de View with Interface Connections 1 Drum Maintenance Kit 2 Waste Tray 3 AC Power Cord Connection 4 Power Switch 5 USB Connection 6 Configuration Card 7 Ethernet Connection Back View Electronics Modul...

Page 19: ...se 8860 8860MFP uses a unique Drum Mainte nance Kit See Section 5 for the correct replacement part Figure 4 Routine Maintenance Items and Consumables Consumables CAUTION Phaser 8860 8860MFP products u...

Page 20: ...el Shortcuts Table 1 Short Cuts Mode or Menu Press These Buttons Service Tools Menu From any menu press and hold the Up Arrow then press OK Hidden Service Menu From the Service Tools menu press and ho...

Page 21: ...09 2007 xxi Phaser 8860 8860MFP Service Manual 8860 Menu Map Introduction Initial Issue 8860 Menu Map NOTE Maps vary by model Figure 1 8860 Menu Map 1 2 Figure 2 8860 Menu Map 2 2...

Page 22: ...y Specifications Characteristic Specifications Minimum RAM 256 MB 8860 512 MB 8860MFP Maximum RAM 1 GB Supported RAM Supports up to 1 GB of DDR2 memory using 2 slots Table 3 Tray Capacity Media and We...

Page 23: ...ff cold start 12 minutes From power saver 4 minutes Table 8 Scanner DADF Functional Specifications Characteristic Specification Printing Process Print Engine Scan to Capabilities Scan to Disk mailbox...

Page 24: ...and visible light UV radiation which is emitted by the sun and fluorescent bulbs is particularly damaging to paper items The intensity and length of exposure to visible light on paper items should be...

Page 25: ...guidelines when loading originals into the document feeder Load originals face up so the top of the document enters first Place only loose sheets of paper in the document feeder Adjust the paper guide...

Page 26: ...09 2007 xxvi Phaser 8860 8860MFP Service Manual System Specifications Initial Issue Introduction...

Page 27: ...8860 8860MFP Service Manual Service Call Procedures Initial Issue 1 Service Call Procedures Service Call Procedures 1 3 Initial Actions 1 4 Routine Maintenance Activities 1 5 Cleaning Procedures 1 5...

Page 28: ...09 2007 1 2 Phaser 8860 8860MFP Service Manual Initial Issue Service Call Procedures...

Page 29: ...ot cause of the problem Use Service Diagnostics to check the system and optional components Use the Wiring Diagrams and Plug Jack Locator to locate test points Take voltage readings as instructed in t...

Page 30: ...media specifications Look for any damage to the copies oil marks image quality defects or other indications of an unreported problem NOTE If a fault code is displayed while performing a diagnostics p...

Page 31: ...ng Use a dry lint free cloth or a lint free cloth moistened with water for all cleaning unless directed otherwise in this manual Wipe with a dry lint free cloth if a moistened cloth is used 1 Feed Com...

Page 32: ...the supply of consumables Ensure that an adequate supply of consumables is available according to local operating procedures 3 Conduct any operator training that is needed Ensure the operator understa...

Page 33: ...9 13 1XX 4x Left Jetstack Thermal Faults 2 29 13 2XX 4x Right Jetstack Thermal Faults 2 30 13 XXX xx Printhead Reservoir Thermal Faults 2 30 13 XXX xx Ink Loader Thermal Faults 2 31 13 00x 6x Thermal...

Page 34: ...09 2007 2 2 Phaser 8860 8860MFP Service Manual Initial Issue Error Messages and Codes...

Page 35: ...de flashing on all three LEDs Control Panel LED PS LED and PE LED If initialization of the Control Panel fails POST errors will still report using the LED blink patterns The sum of the flashes equal t...

Page 36: ...Soft Control Panel version mismatch 08 01 Flutter only Soft Control Panel failed to initialize 09 01 Flutter only Soft Control Panel data error 10 01 Flutter then 10 blinks Hard Power control link fai...

Page 37: ...trol panel Off No Copy Defaults Setup Color Mode Color No 2 Sided Copying 1 1 No Output Quality Enhanced No Document Type Mixed No Paper Supply Tray 2 No Color Balance Cyan Color Balance 0 No Color Ba...

Page 38: ...Custom Units Inches mm No Cleaning Page Source Highest No Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command Menu Parameter Default Required System Controls Startup Page On No...

Page 39: ...a hardware problem The most common device faults troubleshooting procedures are docu mented in this section Program faults are indicated by a 6 in the tenths place of the fault code xx yyy 6x Unfortu...

Page 40: ...ces Tray Feeder PL 3 0 Left Side Harness 1 2 Figure 4 Pick Assy and Retard Roller Kit PL 3 0 Left Side Harness PL 5 0 Left Side Wire Routing 1 2 P J204 Table 2 525 Sheet Troubleshooting Procedure Step...

Page 41: ...ng and Plug Jack References NVRAM PL 5 0 Table 2 525 Sheet Feeder Troubleshooting Procedure Step Questions or Actions Yes No 1 Reseat all Electronics Module connec tions Does the problem persist Go to...

Page 42: ...r 2 006 65 ROM read error 2 007 66 idiags entry point access error Table 1 2 006 xx Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References I O Board PL 5 0 13 NVRAM PL 5 0 9...

Page 43: ...eseat all Electronics Module connec tions Does the problem persist Go to Step 2 Complete 2 Check ground integrity Are the system grounds connected Reset NVRAM If the error persists replace the NVRAM d...

Page 44: ...to Step 3 Go to Step 5 3 Check the Wiper drive and lock systems for ink obstructions or damage Is the Wiper drive function correctly Go to Step 4 Clear any ink or obstructions or replace any dam aged...

Page 45: ...re the system grounds connected Reset NVRAM If the error persists replace the NVRAM device REP 5 0 9 Reconnect the sys tem grounds Y Axis Sub System Faults 5 001 41 The Drum rotated once without a Dru...

Page 46: ...Sub System Faults Troubleshooting Procedure Step Questions or Actions Yes No Y Axis Sub System Program Faults 5 001 63 Y Axis sub system general fault 5 005 67 Sub system not in homeless or idle state...

Page 47: ...rol Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the X Axis Motor wiring Is the wiring faulty Replace the wiring Go to Step 2 2 Test the X Axis Motor Run the Servi...

Page 48: ...properly aligned ADJ 4 7 1 Is the Process Drive misaligned Perform ADJ 4 7 1 Go to Step 2 2 Test the Tilt Axis Drive Run the Service Diagnostics Tilt Axis Drive test Did the test pass Go to Step 3 Go...

Page 49: ...Table 2 Process Drive Faults 7 007 49 Troubleshooting Procedure Step Questions or Actions Yes No 1 Check that the Process Drive is properly aligned ADJ 4 7 1 Is the Process Drive misaligned Perform AD...

Page 50: ...the Wiper Drive Table 2 Head Tilt Solenoid Faults 7 008 41 Troubleshooting Procedure Step Questions or Actions Yes No Process Faults 7 009 42 Printhead is tilted back but not properly restrained Tabl...

Page 51: ...ace the Exit Module REP 3 0 7 Repair the Wiper Drive Table 2 Printhead Restraint Fault 7 009 42 Troubleshooting Procedure Step Questions or Actions Yes No Process Faults 7 010 43 Printhead is stuck or...

Page 52: ...ce the clutch REP 4 0 4 8 Test the Wiper Drive Run the Service Diagnostics Wiper Drive test Does the Wiper Drive operate correctly Replace the Exit Module REP 3 0 7 Repair the Wiper Drive 9 Test the m...

Page 53: ...to view the meshing of the roller gears to the Media Drive Did this correct the problem Complete Go to Step 4 2 For an 8 007 41 error Check for a missing KL clip securing the Head Maintenance Clutch...

Page 54: ...ve Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Reseat all Electronics Module connec tions Does the problem persist Go to Step 2 Complete 2 Check ground integrity Are th...

Page 55: ...Step 2 Remove any block age and or replace the ink stick Run clear ISC Fault test to clear the error This must be per formed following an ink loader replace ment 2 Test the appropriate Ink Melt Heater...

Page 56: ...smatch 11 043 66 Control Panel waiting error Table 1 11 0xx 4x Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References I O Board PL 2 0 Right Side Harness I O Control Figure 1...

Page 57: ...the troubleshooting procedure Troubleshooting Procedure Program Faults 11 100 60 The system reports an overheat condition Table 1 11 100 60 Troubleshooting Reference Table Applicable Parts Wiring and...

Page 58: ...detected a program fault during operation Table 1 12 000 60 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References NVRAM PL 5 0 Table 2 12 000 60 Program Faults Troubleshoot...

Page 59: ...estions or Actions Yes No 1 Check ground integrity for the printer Does the error persist Go to Step 2 Complete 2 Reset NVRAM Does the error persist Replace in the NVRAM device REP 5 0 9 If the error...

Page 60: ...he Service Diagnostics Drum Heater test Does the heater operate correctly Replace the Drum Assembly REP 2 0 3 Replace the Drum Temperature Sen sor REP 6 0 4 Table 2 13 008 47 and 13 010 49 Troubleshoo...

Page 61: ...mal Fault Troubleshooting Procedure Step Questions or Actions Yes No 1 Verify that the ambient temperature of the room is within the system s environmental specifications Is the room within operating...

Page 62: ...ns or Actions Yes No 1 Verify that the ambient temperature of the room is within the system s specifications Is the room within operating parameters Go to Step 2 Advise the customer of operational req...

Page 63: ...is open 13 517 43 The Yellow heater thermistor circuit is shorted 13 519 45 The Yellow heater thermistor returned faulty reading 13 456 45 The Black heater is too hot 13 458 47 The Black heater took t...

Page 64: ...segment ID that did not exist 13 007 68 Thermal power manager expected an initialization message but received other 13 008 60 Thermal power manager task received an unexpected message Table 1 6 0xx 6x...

Page 65: ...ad calibration program faults Table 1 6 0xx 6x Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References NVRAM PL 5 0 Table 2 X Axis Program Faults Troubleshooting Procedure Ste...

Page 66: ...troubleshooting procedure Troubleshooting Procedure Table 1 Jam Code Key Process Event Basis for Jam System State Media Supply A Deskew Flag B Preheater Flag C Strip Flag D Exit Flag E Tray 1 Width F...

Page 67: ...dure below Troubleshooting Procedure Check the fault history and troubleshoot the error listed immediately prior to these codes Oth erwise reboot the system to clear these error conditions NVRAM Fault...

Page 68: ...persists follow the procedure below Primary Causes The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure Troubleshooting Procedure Profile Library Faults 27 0xx...

Page 69: ...arts Wiring and Plug Jack References Media Drive Assy PL 4 0 Left Side Harness 2 2 Figure 7 Table 2 X Axis Program Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Take Aw...

Page 70: ...1 Width Sensor Faults Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Tray 1 Harness connection to the I O Board P J610 Is the connection secure and the harness undamaged Go to...

Page 71: ...re 8 Ink Sticks Table 2 Printhead NVRAM Fault Troubleshooting Procedure Step Questions or Actions Yes No 1 Check the Ink Loader chutes for improp erly installed Ink Sticks Has the Ink been loaded inco...

Page 72: ...mpting to position the Drum Maintenance Kit Table 1 36 000 40 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Drum Maintenance Kit PL 1 0 Drum Maintenance Pivot Plate...

Page 73: ...001 67 Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Drum Maintenance Kit PL 1 0 Drum Maintenance Pivot Plate PL 2 0 I O Board 2 2 Figure 12 Table 2 Drum Maintenanc...

Page 74: ...power than expected 37 011 44 The Cyan 1 Ink Melt Heater is drawing less power than expected 37 012 48 The Magenta 2 Ink Melt Heater is drawing less power than expected 37 013 48 The Black 3 Ink Melt...

Page 75: ...Unplug all connections to the Electronics Module Turn the system On Do the PE and PS indicators near the Power Switch flash momentarily Go to Step 3 Replace the Elec tronics Module REP 5 0 5 3 Shutdo...

Page 76: ...1 37 0XX 4x Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Head Maintenance Clutch PL 4 0 I O Board 2 2 Figure 12 Deskew Clutch PL 4 0 Left Side Harness 1 2 Figure 6...

Page 77: ...arness 2 2 Figure 7 Electronics Module PL 4 0 Left Side Harness 2 2 Figure 7 Table 2 PEST Purge Pump Fault Troubleshooting Procedure Step Questions or Actions Yes No 1 Test the Purge Pump Run the Serv...

Page 78: ...e Parts Wiring and Plug Jack References X Axis Motor PL 4 0 Right Side Harness I O Control Figure 10 Electronics Module PL 5 0 Right Side Wire Routing 2 2 Figure 3 Table 2 PEST X Axis Motor Faults Tro...

Page 79: ...Applicable Parts Wiring and Plug Jack References Media Drive PL 4 0 Left Side Harness 2 2 Figure 7 Electronics Module PL 5 0 Left Side Wire Routing 2 2 Figure 5 Table 2 PEST Media Drive Faults Trouble...

Page 80: ...over limit 37 054 45 The Power Supply 50 V source under limit 37 055 46 The Power Supply 50 V source over limit 37 056 47 The Power Supply 50 V source under limit 37 057 48 The Power Supply 15 V sourc...

Page 81: ...table lists parts and wiring referenced in the troubleshooting procedure Troubleshooting Procedure Scanner Subsystem Test Faults 39 002 40 The Scanner DRAM test failed 39 003 41 The Scanner Optical T...

Page 82: ...hooting Procedure Step Questions or Actions Yes No 1 Cycle system power and retest Does this correct the problem Complete Go to Step 2 2 Check the Scanner Power Supply status LED see Figure 2 Is the S...

Page 83: ...ing procedure Troubleshooting Procedure Document Feeder Disconnected or Missing Faults 39 010 8 The DADF was not detected Document Feeder Disconnected or DADH Missing appears on the Control Panel disp...

Page 84: ...e lists parts and wiring referenced in the troubleshooting procedure Troubleshooting Procedure Document Feeder Disconnected or Missing Faults 39 013 42 Media Jam in the DADF was detected Jam at Docume...

Page 85: ...W Imaging X Exit Z Shutdown 1 Tray 1 2 Tray 2 3 Tray 3 4 Tray 4 5 Chase Page 6 Duplex Table 2 8860MFP Jam Code Key Process Event Basis for Jam System State Media Supply A Deskew Flag B Preheater Flag...

Page 86: ...k system grounds Table 3 Jam Code Troubleshooting Code Description Procedure B2F B2S Preheater exit sensor in unexpected state during fault Preheater exit sensor in unexpected state during stage 1 Che...

Page 87: ...ked from Tray 3 The exit flag actuated unexpectedly when paper was picked from Tray 4 The exit flag actuated unexpectedly when paper was picked from Tray 1 The exit flag actuated unexpectedly when dup...

Page 88: ...utdown Media Drive motor stalled during a normal printer shutdown Media Drive motor stalled during mechanical recovery Media Drive motor stalled during printer warm up Media Drive motor stalled during...

Page 89: ...ck system grounds 3 Run the Check Drum Y Axis Encoder test 4 Remove the Preheater REP 2 0 17 and check the Preheater flag for ink or paper interference 5 Replace the Preheater REP 2 0 17 Table 3 Jam C...

Page 90: ...ectly 3 Run the Monitor Sensors test using Service Diagnostics 4 Check the Paper Size Switch Replace if necessary REP 6 0 7 5 Replace the Pivot Arm Table 3 Jam Code Troubleshooting Code Description Pr...

Page 91: ...maging Tray 4 Paper Size Switch activated during paper exit 1 Check system grounds 2 Check that the media guides are adjusted correctly 3 Run the Monitor Sensors test to test the Tray 4 Paper Size Swi...

Page 92: ...09 2007 2 60 Phaser 8860 8860MFP Service Manual Jam Codes Initial Issue Error Messages and Codes...

Page 93: ...5 Smudges or Smears 3 11 IQ16 Printed Image is Too Light or Too Dark 3 11 IQ17 No Image is Printed 3 12 IQ18 Color is Uneven or Color is Wrong 3 12 IQ19 Streaks or Lines Down the Print 3 13 IQ20 Scrat...

Page 94: ...09 2007 3 2 Phaser 8860 8860MFP Service Manual Initial Issue Image Quality...

Page 95: ...quality problem is not resolved using the image quality troubleshooting procedures see Analyzing Service Test Prints NOTE The Troubleshooting Print Quality page includes instructions for printing the...

Page 96: ...s rollers and separator pad Does the problem persist Go to Step 2 Complete 2 Check the CVT Window for ink build up Clean the CVT Window Does the problem persist Go to Step 3 Complete Advise the custom...

Page 97: ...Step 3 Complete 3 Perform the DADF to Scanner Calibration adjustment procedure ADJ 1 15 1 Does the problem persist Replace the DADF REP 1 0 15 Complete Table 1 IQ6 Fuzzy Text or Image Step Questions a...

Page 98: ...ombination of these set tings for a particular original might require several attempts In some cases these controls may not completely compensate for artifacts introduced in the scanning process Proce...

Page 99: ...DADF Input Tray 3 Check that image skew exceeds specifications 4 Reseat all DADF connections Procedure Table 1 IQ8 Dark Streaks on Copied Image Step Questions and Actions Yes No 1 Check the CVT Window...

Page 100: ...page and evaluate the Output Quality and Color Settings section 2 Use the Lighten Darken Output Quality adjustment to attempt to correct the problem 3 Check that the print mode is not set to Draft or...

Page 101: ...e has discolored jets therefore you would print the yellow solid fill Figure 2 Discolored Jets on the Light Stripes Page Table 1 IQ12 Fuzzy Text or Image Step Questions and Actions Yes No 1 Print the...

Page 102: ...s and Actions Yes No 1 Run the Eliminate Light Stripes routine from the Control Panel Multiple attempts are sometimes needed to clear obstructed jets Does the problem persist Go to Step 2 Complete 2 C...

Page 103: ...Drum Maintenance Kit and wipe the clear plastic blade with a lint free cloth Does the problem persist Replace the Drum Maintenance Kit If the problem per sists go to Step 5 Complete 5 Clean the rolle...

Page 104: ...results Initial Actions 1 Check that supported media is being used 2 Run the Eliminate Light Stripes routine from the Control Panel Procedure Table 1 IQ17 No Image is Printed Step Questions and Actio...

Page 105: ...the Drum Fan Does the fan operate correctly Go to Step 5 Replace the Drum Fan REP 4 0 6 5 Check that the Drum Temperature Sensor contacts the Drum Clean or replace the Drum Temperature Sen sor REP 6...

Page 106: ...for the affected color Does the problem persist Go to Step 7 Complete 7 Check the X Axis Drive If the X Axis Drive does not move the Print head smoothly vertical lines appear on the output Verify tha...

Page 107: ...Check for debris on the Preheater Run the Service Diagnostics Remove Print Smears routine Does the problem persist Go to Step 6 Complete 6 Force a sheet of thick 65 to 85 lb paper through the Preheate...

Page 108: ...media in the exit path 3 Run the Remove Print Smears routine from the Control Panel Procedure 4 Check the thermal regulation of the Drum Run the Service Diagnostics temperature tests Replace the Drum...

Page 109: ...stics temperature tests Replace the Drum Temperature Sensor REP 6 0 4 if necessary Does the problem persist Go to Step 5 Complete 5 Check Y Axis motion Run the Service Diagnostics Y Axis Encoder test...

Page 110: ...persist Replace the X Axis Motor REP 4 0 5 If the problem per sists replace the Electronics Mod ule REP 5 0 5 Complete 4 Try the procedure listed under the Solid Fill test prints Does the problem pers...

Page 111: ...p 5 Complete 5 Check these Drum maintenance system parts for damage or defects Drum Maintenance Pivot Plate Drum Maintenance Cam Shaft Is there any damage Replace any dam aged parts If the problem per...

Page 112: ...No 1 Check and clean the Drum Maintenance Kit Wiper Blade Does the problem persist Replace the Drum Maintenance Kit If the problem per sists go to Step 2 Complete 2 Check X Axis motion Verify that the...

Page 113: ...Service Diagnostics Drum Mainte nance tests Does the problem persist Replace any defective parts found Complete Table 1 IQ27 Oil Streaks on Print Step Questions and Actions Yes No Table 1 IQ28 Incompl...

Page 114: ...ed parts found Does the problem persist Go to Step 6 Complete 6 Check the Preheater temperature Run the Service Diagnostics Preheater tests Does the problem persist Replace the Trans fix Load Module R...

Page 115: ...tripes on Output Initial Actions 1 Check that supported media is being used 2 Print several solid fill test prints as a sample Procedure Table 1 IQ30 Repeating Print Defects Step Questions and Actions...

Page 116: ...as a result of a mismatch between the application and the driver Initial Actions 1 Check that supported media is being used 2 Print an Information page from the Control Panel 3 Check the application...

Page 117: ...id tipping tilting or using excessive force to close a tray can cause ink to infiltrate the upper portions of the Printhead blocking the flow of ink and air Symptoms of mishandling include Ink in the...

Page 118: ...cycles on the printhead to remove contaminants from the poorly performing jet Run a jet fix cycle by downloading the snippet from the customer support site If jet substitution mode is required see Je...

Page 119: ...e print do not show when projected Like wise some defects do not show until projected Causes Confirm that you are using the transparency that is supported for this system Clean or replace the paper re...

Page 120: ...gineering only YMCKRGB Solid Fills This test prints a single sided solid fill print in all seven colors to show uniformity of fill If colors are uneven or wrong see IQ18 Look for Even uniform fill thr...

Page 121: ...d to purge discoloration of a particular jet or color Figure 9 Single Primary Solid Fill Test Prints Look for 1 Even uniform fills throughout the print 2 There should be no wrinkling or deformity of t...

Page 122: ...e margin right side of paper left side of system of the paper The tolerance for margin is the margin 2 See the Media Margin Specifications NOTE The measurement for skew and margin for Side 1 and Side...

Page 123: ...ng situations where 3 or more consecutively numbered jets 1 are weak or missing Jet substitution requires the presence of an numerically adjacent functional jet to replace the affected jet As an examp...

Page 124: ...tions on the Eliminate Light Stripes menu are Light Stripes Test prints the Light Stripes page Use this to detect weak missing or dis colored jets Basic initiates a cleaning cycle followed by a Cleani...

Page 125: ...lex Roller 4 44 REP 3 0 5 Upper Duplex Guide and Solenoid 4 45 REP 3 0 6 Outer Duplex Guide 4 46 REP 3 0 7 Exit Module 8860MFP 4 46 REP 3 0 14 System Stabilizer 4 48 REP 3 0 18 Pick and Retard Rollers...

Page 126: ...09 2007 4 2 Phaser 8860 8860MFP Service Manual Initial Issue Repairs and Adjustments...

Page 127: ...r Figure 1 Procedural System Orientation Preparation CAUTION Following reassembly but before restoring power be sure the components are all in their home positions otherwise damage to the printer will...

Page 128: ...be used to correct the problem If you remove a silver blue tinted thread repair screw during disassembly replace the screw the same location or additional damage to the printer will occur Fasteners us...

Page 129: ...per Straps 2 Open the plug cover and disconnect P J650 from the right side of the Front Door 3 Release the wiring from cable retainers 4 Remove the Front Door Tray 1 MPT by releasing the left hinge pi...

Page 130: ...DADF REP 1 0 11 4 Remove the metal T 20 screw at the back of the system that secures the cover to the frame Figure 1 Removing the Left Side Cover 5 Release the tab near the top of the cover using a fl...

Page 131: ...e Service Tools Menu Power down the printer with the DADF closed 1 Remove the DADF REP 1 0 15 2 Disconnect the Scanner from the printer 3 Place the Scanhead in the locked position for removal Figure 1...

Page 132: ...ner Assembly 8860MFP Parts List on PL 1 0 Removal CAUTION Lock the Scanhead before removing the assembly A utility for locking the Scanhead is pro vided in the Service Tools Menu Power down the printe...

Page 133: ...1 0 13 DADF Front Cover 8860MFP Parts List on PL 1 0 Removal 1 Open the DADF Front Cover 2 Remove 3 plastic T 20 screws that secure the DADF Front Cover Figure 1 DADF Front Cover Fasteners 3 Close and...

Page 134: ...F from the Scanner Assembly NOTE If a replacement DADF is being installed recalibrate the Scanner using ADJ 1 15 1 Figure 1 DADF Removal REP 1 0 19 DADF Hinges 8860MFP Parts List on PL 1 0 Removal 1 R...

Page 135: ...the Scanner Assembly with attached DADF REP 1 0 11 2 Open the Front Door 3 Remove the Output Tray REP 1 0 6 4 Remove the metal T 20 screw at the back of the system that secures the cover Figure 1 Remo...

Page 136: ...3 Using either your fingers or a small flathead screwdriver loosen the Control Panel Cover on the left side and then slide it forward while lifting up to remove it from the printer Figure 1 Removing t...

Page 137: ...ight Side Cover REP 1 1 10 3 Remove the Exit Cover REP 1 1 7 4 Press the left and right sides of the Ink Loader inward then lift to access the 2 connectors 5 Disconnect the Ink Loader Power harness P...

Page 138: ...oor 3 Remove 1 metal T 20 screw 4 Release the tabs and remove the cover Figure 1 Removing the Left Side Cover REP 1 1 10 Right Side Cover 8860 Parts List on PL 1 1 Removal 1 Open the Exit Cover and Fr...

Page 139: ...4 Raise the Media Path Elevator to the up position Figure 1 Raising the Media Path Elevator 5 Press the left and right sides of the assembly inward then lift to access the 2 connectors Figure 2 Removi...

Page 140: ...tension when unlocking the Print head Restraints WARNING Allow adequate time for the system to cool before servicing The Roll Block that retains the Printhead Shaft remains hot longer than other near...

Page 141: ...1 Releasing the Printhead Wiper Lock 8 Lower the Printhead Wiper Assembly completely by rotating the Wiper drive gears as shown in Figure 2 Figure 2 Lowering the Printhead Wiper Assembly 9 Move the P...

Page 142: ...en rotate downward to allow it to rest in detents provided on the frame See Figure 4 Figure 4 X Axis Bias Spring Hook 11 Disconnect the Air Hose from the Purge Pump 12 Remove the left and right Printh...

Page 143: ...screwdriver inserted in the slot on the X Axis Motor to allow removal of the Printhead Restraints Figure 6 Removing the Printhead Restraints 13 Remove the Roll Block on the left end of the Printhead...

Page 144: ...ing the finger recesses as shown in Figure 11 and place the ends of the shaft in the cradle notches provided near the top of the frame as shown in Figure 9 Figure 9 Printhead Cradle Notch Location NOT...

Page 145: ...d 4025 are often the result of Printhead interference by the Print head Heater Harness Make certain the harness is properly restrained and does not obstruct Printhead movement 9 Install the 2 metal T...

Page 146: ...Place the Printhead Wiper Blade in its home position using ADJ 2 5 1 8 Remove the Exit Module REP 3 0 7 9 Remove the Drum Temperature Sensor REP 6 0 4 10 Remove the Transfix Load Module REP 2 0 15 11...

Page 147: ...overhang the sur face and rest the assembly on its feet 19 Lift the Drum Assembly straight out of the chassis using the metal grips provided Replacement CAUTION The Drum Temperature Sensor harness is...

Page 148: ...in the mounting ears on the Drum Assembly The Transfix Load Arms should point in the opposite direction as the Drum Thermistor Position the Cam Followers on the Transfix Load Arms under the Trans fix...

Page 149: ...ve Assembly harnesses 18 Connect the Drum Heater harness P J200 to the Relay Board 19 Connect the Drum Encoder harness P J120 to the Right Side Harness 20 Connect the Drum Temperature Sensor to the I...

Page 150: ...ADJ 2 2 1 36 Perform the Head Tilt Gear Homing procedure ADJ 4 13 1 37 Perform the Process Drive Homing Procedure ADJ 4 7 1 38 Turn system power On and print a Configuration page to test operation REP...

Page 151: ...s lowers the left end of the wiper producing slack in the Wiper Belt Remove the Wiper Belt from the Wiper Clip to release the Wiper Blade Replacement 1 When reinstalling the belt into the wiper clip p...

Page 152: ...Loader REP 1 1 8 Afterwards return to this procedure and begin at Step 6 When parked the Printhead is held in place by pins that are captured by left and right Print head Restraints If the pins are r...

Page 153: ...ure 2 Lowering the Printhead Wiper Blade 9 Hold the Printhead away from the Drum and push down on the left and right Printhead Restraint Arms to release the Printhead Tilt Spring tension Figure 3 Rele...

Page 154: ...astic T 20 screw that secures each Printhead Restraint and then shift the restraint inwards toward the Printhead while lifting toward the rear of the printer Figure 5 Removing the Printhead Restraint...

Page 155: ...ve your lever handle towards the center of the system as indicated in Figure 1 1 Remove the Ink Loader REP 2 0 1 or REP 1 1 8 for the 8860 2 Remove the Media Drive Assembly REP 4 0 14 3 Remove the Exi...

Page 156: ...d of the camshaft towards the rear of the system Next move the camshaft to the right then lift the camshaft through the slot while removing it to the right Figure 1 Removing the Drum Maintenance Camsh...

Page 157: ...ng the Control Panel REP 1 1 6 Afterwards return to this procedure and begin at Step 4 1 Remove the Scanner Assembly and attached DADF REP 1 0 11 2 Remove the Right Side Cover REP 1 0 21 3 Remove the...

Page 158: ...er Parts List on PL 2 0 Removal NOTE These steps describe Transfix Roller removal for the 8860MFP On 8860 models access the Transfix Roller by removing the Control Panel REP 1 1 6 Afterwards return to...

Page 159: ...with the Transfix Roller Shaft Restraint and pull the shaft out of the Stripper Carriage Assembly 11 Lift the Stripper Carriage Assembly and Transfix Roller up and out of the chassis 12 Remove the Tra...

Page 160: ...when releasing the Transfix Module spring hooks Move your lever handle towards the center of the system as indicated in Figure 1 1 Remove the Scanner Assembly and attached DADF REP 1 0 11 8860MFP onl...

Page 161: ...ase the Transfix Roller assembly from the chassis Figure 2 Removing the Transfix Load Arm Clevis Pins 12 Disconnect the Preheater Lift Solenoid P J202 from the harness 13 Remove the screw that secures...

Page 162: ...T 20 screws 2 at each end that secure the Transfix Load Module to the chassis Figure 5 Transfix Load Module Fasteners 16 Rotate the top of the Transfix Load Module forward and spread the chassis slig...

Page 163: ...odels access the Drum Maintenance Pivot Plate by removing the Control Panel Cover REP 1 1 5 Afterwards return to this procedure and begin at Step 3 CAUTION Use care not to damage the Drum while servic...

Page 164: ...ease P N 070E00890 Also check that the right end of the Pivot Plate Shaft is in contact with the Ground Plate following installation of the Drum Fan Perform the Head Tilt Gear ADJ 4 13 1 and Process D...

Page 165: ...place followed by the right Make sure the sensors are properly positioned when completing the installation REP 2 0 21 X Axis Bias Spring Parts List on PL 2 0 Removal CAUTION The X Axis Bias Spring is...

Page 166: ...he Right Side Cover REP 1 0 21 or REP 1 1 10 for the 8860 5 Remove the Upper Duplex Guide REP 3 0 5 6 Remove the Outer Duplex Guide REP 3 0 6 7 Disconnect the Preheater Solenoid P J202 8 Remove the sc...

Page 167: ...MFP On 8860 models access the Take Away Roller by removing the Control Panel REP 1 1 6 Afterwards return to this procedure and begin at Step 4 1 Remove the Front Door REP 1 0 1 2 Remove the Scanner As...

Page 168: ...e Take Away Roller REP 3 0 4 Duplex Roller Parts List on PL 3 0 Removal 1 Open the Front Door 2 Remove the Outer Duplex Guide REP 3 0 6 3 Remove the Lower Inner Duplex Guide REP 3 0 2 4 Remove the KL...

Page 169: ...Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Right Side Cover REP 1 0 21 or REP 1 1 10 for the 8860 4 Remove the Outer Duplex Guide REP 3 0 6 5 Disconnect the...

Page 170: ...1 Interlock Switches on the 8860MFP and remove the guide For 8860 models these connections are made on the Control Panel Figure 12 5 Remove the 4 plastic T 20 screws that secure the Outer Duplex Guide...

Page 171: ...the Exit Module and ground wire to the Back Frame 8 Disconnect these connections See Figure 3 Output Tray Full Sensor CN801 and CN802 Front Exit Module Harness P J303 Speaker P J410 Elevator Position...

Page 172: ...8 Pick and Retard Rollers Parts List on PL 3 0 Removal The Pick Roller catch is located on the ceiling of the tray cavity about 1 4 of the way across the unit from the right side and about 5 in 12 5 c...

Page 173: ...Removal CAUTION The Drum Temperature and Exit Module Sensor harnesses are routed through an opening in the Exit Module frame Use care during removal to avoid damaging these harnesses 1 Remove the Exi...

Page 174: ...he Scanner Power Supply Fan Replacement NOTE Route the fan harness behind the mylar insulator as shown in Figure 1 REP 4 0 4 Head Maintenance Clutch Parts List on PL 4 0 Removal NOTE These steps descr...

Page 175: ...1 0 21 or REP 1 1 10 for the 8860 2 Disconnect the X Axis Motor P J150 from the Right Side Harness 3 Remove 4 plastic T 20 screws that secure the motor to the frame Figure 1 Removing the X Axis Motor...

Page 176: ...r alignment Use a paper clip or similar object to pin the gears before removing the drive Replacement drives have pins installed Do not remove these pins until the drive has been installed Installatio...

Page 177: ...s align the holes in the Process Drive flange with the mounting bosses on the frame seat the gears and press the Process Drive tightly against the frame Next seat all three screws before torquing the...

Page 178: ...rsible damage to the chassis REP 4 0 9 Exit Elevator Motor 8860MFP Parts List on PL 4 0 Removal 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove...

Page 179: ...e Push Nut so the fingers point away from the shaft Place a 3 8 in nut driver over the nut and press firmly to seat the nut on the shaft REP 4 0 11 Y Axis Motor Assembly Parts List on PL 4 0 Removal N...

Page 180: ...ss Figure 2 Y Axis Assembly Electrical Connections 10 Release the harness from the retainers in the chassis NOTE Observe the routing of the Y Axis Motor harness The harness exits the motor cav ity thr...

Page 181: ...1 9 for the 8860 4 Disconnect the solenoid P J241 from the harness 5 Remove 1 plastic T 20 screw that secures the solenoid to the Media Drive Assembly Figure 1 Removing the Tray 1 Pick Solenoid Replac...

Page 182: ...ards return to this procedure and begin at Step 3 NOTE Do Not completely remove the Tray 1 Pick Solenoid screw A replacement solenoid is included with the new Media Drive Assembly Loosen the screw jus...

Page 183: ...CAUTION When replacing the Media Drive screws torque to no more than 12 in lbs Overtightening these fasteners can result in irreversible damage to the chassis To replace the Media Drive Assembly remo...

Page 184: ...ly and attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left Side Cover REP 1 0 7 or REP 1 1 9 for the 8860 4 Disconnect the fan P J207 from the Left Side Harness 5 Remove 2 pl...

Page 185: ...ll the cover right to release the left hook and position the cover out of the way Figure 3 Removing the Waste Tray Cover 9 Reach into the Waste Tray cavity and pull the gear and shaft from the chassis...

Page 186: ...aft 6 Perform the Head Tilt Gear ADJ 4 13 1 and Process Drive Alignment ADJ 4 7 1 adjustments before restoring system power REP 4 0 18 Fax Speaker 8860MFP Parts List on PL 4 0 Removal 1 Remove the Sca...

Page 187: ...the Head Tilt Solenoid from the harness 7 Remove 1 plastic T 20 screw that secures the solenoid actuator to the frame and remove it from the frame 8 Release the hook to release the solenoid from the f...

Page 188: ...that secure the board to the Back Frame Figure 1 Removing the Exit Module Control Board REP 5 0 2 Scanner Power Supply 8860MFP Parts List on PL 5 0 Removal WARNING Disconnect the AC Power Cord before...

Page 189: ...s before restoring system power REP 5 0 5 Electronics Module Parts List on PL 5 0 PL 5 1 Removal NOTE These steps describe Electronics Module removal for the 8860MFP On 8860 models access the Electron...

Page 190: ...7 Hard Drive Parts List on PL 5 0 Removal 1 Loosen the thumbscrews on the back cover of the Electronics Module 2 Disconnect the Hard Drive from the Electronics Module Figure 1 Removing the Hard Drive...

Page 191: ...n of the RAM device before removing it from the board 2 Disconnect the RAM module from the Electronics Module Figure 1 Removing RAM 3 Insert the replacement RAM and close the Back Cover REP 5 0 9 NVRA...

Page 192: ...screws torque to no more than 12 in lbs Overtightening these fasteners can result in irreversible damage to the chassis Position the corner of the board behind the Ground Tab before installing the sc...

Page 193: ...MFP Parts List on PL 5 0 Removal 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left Side Cover REP 1 0 7 4 Remove the Right Side Cover REP...

Page 194: ...he harnesses from the FDI board 5 Remove the 3 2 metal T 20 1 plastic T 20 screws that secure the board to the chassis Figure 1 Removing the FDI Board REP 6 0 1 Scanner Detect Sensor 8860MFP Parts Lis...

Page 195: ...for both the Front Door and Exit Door Interlocks Use this procedure to replace either interlock switch NOTE Replacement of the Front Door Interlock Switch does not require removal of the Outer Duplex...

Page 196: ...1 Removing the Drum Temperature Sensor REP 6 0 6 Waste Tray Detect Sensor Parts List on PL 6 0 Removal CAUTION Place a couple sheets of paper between the Wiper Assembly and the Drum to protect the Dr...

Page 197: ...7 1 adjust ments before restoring system power REP 6 0 7 Paper Size Switch Parts List on PL 6 0 Removal NOTE These steps describe Paper Size Switch removal for the 8860MFP On 8860 models access the s...

Page 198: ...Remove Tray 2 3 Remove the Pick Roller Assembly REP 3 0 18 4 Remove the Lower Duplex Guide REP 3 0 2 5 Remove the Inner Simplex Guide REP 3 0 1 6 Release the 4 hooks that secure the No Paper Sensor t...

Page 199: ...t Disconnect the Preheater Assembly P J0720 and P J860 to make additional room to replace the sensor Release the lock on P J0720 to remove it from the Preheater Assembly REP 6 0 11 Output Tray Full Se...

Page 200: ...rocedure when replacing the Scanner Assembly or DADF Start this procedure with the scanner having just made a duplex copy this ensures the lamps are up to temperature If the lamps are cold the calibra...

Page 201: ...Steps 5 7 9 Remove the Scanner Calibration page from the platen 10 Place the Scanner Calibration page in the DADF face up so the top edge enters first Adjust the paper guides so they fit against the p...

Page 202: ...the Pro cess Drive or system errors can result during system initialization Adjustment Use this procedure to move the Printhead to its parked position 1 Remove the Scanner Assembly with attached DADF...

Page 203: ...drive gear lower the blade and then reseat the gear 1 Remove the Scanner Assembly with attached DADF REP 1 0 11 2 Remove the Output Tray REP 1 0 6 3 Remove the Left Side Cover REP 1 0 7 or REP 1 1 9...

Page 204: ...d Head Tilt Gear Printhead Wiper Blade and Process Drive in their home positions before restoring system power Improper alignment could result in damage or errors Adjustment Examine the Process Drive...

Page 205: ...he Head Tilt Gear as shown in Figure 1 NOTE When the Head Tilt Gear is disengaged the two arrows on the left side of the printer align as shown in Figure 1 Figure 1 Head Tilt Gear Indicator Printhead...

Page 206: ...ating the Drum Maintenance Camshaft NOTE Rotate the Drum Maintenance Camshaft Gear until the hole in the gear reaches the 6 00 position 3 Disengagement of the Head Tilt Gear is indicated by the alignm...

Page 207: ...4 8570 Covers PL 1 1 8860 Covers 5 5 Imaging PL 2 0 Imaging 5 6 8570MFP Paper Path PL 3 0 8860MFP Paper Path 5 7 8570 Paper Path PL 3 1 8860 Paper Path 5 8 Drive PL 4 0 8860MFP Drive 5 9 Drive PL 4 1...

Page 208: ...09 2007 5 2 Phaser 8860 8860MFP Service Manual Initial Issue Parts List...

Page 209: ...O PL X X Item X folowing the part description indicates the part is included with the item identified in the referenced Parts List The notation with X Y following a part name indicates an assembly in...

Page 210: ...12 Upper Housing P O PL 1 0 Item 11 Includes Glass 13 DADF Front Cover P O PL 1 0 Item 15 14 DADF Upper Cover P O PL 1 0 Item 15 15 059K58460 DADF Assembly with 13 19 16 050K67610 DADF Input Tray 17 0...

Page 211: ...802E93850 Control Panel Cover 6 802K93650 Control Panel with Bezel 7 848K12760 Exit Cover with Badge 8 9 802K93660 Left Side Cover 10 802K93570 Right Side Cover with Doors 11 802E93870 Drum Maintenanc...

Page 212: ...K14800 Drum Maintenance Camshaft 11 008K02260 Transfix Camshaft 12 041K06500 Stripper Carriage Assembly 13 022E33180 Transfix Roller 14 809E69920 Y Axis Tension Spring 15 137E24130 Transfix Load Modul...

Page 213: ...3K27680 Exit Module Assembly with 10 11 20 8 809E78710 Spring Carriage 9 809E78700 Spring Carriage Roller 10 Pulley Exit Module P O PL 3 0 Item 7 11 Belt Exit Module P O PL 3 0 Item 7 12 059E05610 Exi...

Page 214: ...r Duplex Guide 3 038K17800 Lower Exit Guide Assembly 4 032K04640 Outer Duplex Guide with Switches 5 032K04630 Upper Duplex Guide with Solenoid 6 059E05610 Exit Roller 7 022E32420 Take Away Roller 8 02...

Page 215: ...27K53580 X Axis Motor 6 127E16010 Drum Fan 7 005K12780 Process Drive 8 127K56300 Exit Motor 9 059K58470 Elevator Motor Assembly 10 Lift Motor Gear Not Spared 11 127K56520 Y Axis Motor Assembly 12 121E...

Page 216: ...Assembly 3 121E20120 Tray 1 Pick Solenoid 4 121K44480 Head Tilt Solenoid 5 807E23090 Media Drive with 2 Clutches 6 604K31810 Tray Lift Motor 7 8 133K25010 Electronics Module Fan 9 807E16060 Head Tilt...

Page 217: ...90 128 MB SDRAM 9 237E23660 8 pin NVRAM 10 069E00570 Configuration Card 11 117E29790 Cable ZIF Wave Amp Drive 12 117E29820 Harness Right Side 13 960K22331 I O Board 14 117E29810 Cable Right Combined 1...

Page 218: ...ion Card NVRAM 6 117E29840 Cable Printhead Interface 7 121K45340 Hard Drive 8 237E23640 256 MB SDRAM 237E23650 512 MB SDRAM 237E23890 128 MB SDRAM 9 237E23660 8 pin NVRAM 10 069E00570 Configuration Ca...

Page 219: ...FP only 2 110E20390 Front Door Interlock Switch 3 137E24280 Engine Exit Flag 4 130K75210 Drum Temperature Sensor 5 130K75220 Exit Module Sensor Assembly 6 130E12620 Waste Tray Sensor 7 130K75230 Paper...

Page 220: ...6650 Control Panel Overlay Kit German 8860MFP only 650K26660 Control Panel Overlay Kit Spanish 8860MFP only 650K26670 Control Panel Overlay Kit Dutch 8860MFP only 650K26680 Control Panel Overlay Kit S...

Page 221: ...36 DADF Malfunction 6 39 Scanner Malfunction 6 40 Control Panel Malfunction 6 40 Exit Module Malfunction 6 41 Media Path and Transport Problems 6 41 Operating System and Application Problems 6 42 Net...

Page 222: ...09 2007 6 2 Phaser 8860 8860MFP Service Manual Initial Issue Diagnostics...

Page 223: ...Low level Power On Self Test POST diagnostics are performed The Control Panel dis plays status messages as each sub test is performed This test takes about 8 seconds All LEDs are off during the test I...

Page 224: ...ser 8860 8860MFP Service Manual System Power On Process Initial Issue Diagnostics Mechanical Engine Initialization Diagram Figure 1 Mechanical Engine Initialization 1 2 Figure 2 Mechanical Engine Init...

Page 225: ...s reported by a test and or the print engine Jam History Displays available information regarding the last 20 jams reported by a test and or the print engine Diagnostics History Displays Fault History...

Page 226: ...ral idea of the current test activity When the test completes the display changes to display the results In some menus the subsystems are identified as follows FP Control Panel Module subsystem EM Exi...

Page 227: ...imes 77 Clear PE NVRAM 121 Test FAX Modem Sub system 34 Paper Trail Edge Times 78 Set PE NVRAM To Defaults 122 Reset FAX Subsystem 35 Paper Sensor Bounce Times 79 Print DMU Blot 123 Report FP FW Versi...

Page 228: ...09 2007 6 8 Phaser 8860 8860MFP Service Manual Service Diagnostics Initial Issue Diagnostics Figure 1 8860MFP Service Diagnostics Menu 1 3 Figure 2 8860MFP Service Diagnostics Menu 2 3...

Page 229: ...may then be observed See the exercise menu table for a description of the individual test functions and results Check Menu A submenu containing a set of extensive manufacturing tests that return meas...

Page 230: ...em This test forces a hardware reset of the Exit Module Scanner DADF and FAX modules Table 3 Service Diagnostics Menu Definitions Menu Item Description Doc Handler Menu Report FW Version Reports the c...

Page 231: ...g with the upper right most LED and moves from top to bottom and left to right until all LEDs have been activated The pattern repeats As each LED is activated the LED name is displayed After terminati...

Page 232: ...Motor Purge Pump Motor Drum Fan Motor Electronics Fan Motor Media Path Motor Shafts Transfix Cam Shaft Drum Maintenance Cam Shaft Deskew Shaft Wiper Shaft Tray 1 Pick Shaft Tray 2 Pick Shaft Tray 3 Pi...

Page 233: ...conditions consistently If a test result differs significantly from the typical values defined in the following tables check the entire subsystem containing the problem component Each test included wi...

Page 234: ...ssibly due to heating during the test A change in heating behavior could indicate a problem with cooling or the thermal conductivity through the mounting Deviations from typical average values could i...

Page 235: ...nexpected resistance Shafts Menu Runs the selected shaft in both directions to determine shaft characteristics steady state drive requirements bearing status etc The objective of these tests is to per...

Page 236: ...ler causing a lump 5 CCW Off fe settling time sec N A Reports the time it takes the Media Drive Motor servo system to settle down after the sudden release of the deskew shaft load A larger value can i...

Page 237: ...rive Assembly servo system to react to the sudden addition of the wiper shaft load Larger values may indicate a slipping or slow to engage clutch 7 CW On peak fe N A Reports the peak effort required t...

Page 238: ...uld indicate extra friction between the cams and the lift plate followers wear contamination etc as well as high lift plate spring ten sion or higher shaft bearing drag Also if the pick shaft gear did...

Page 239: ...ween the activation of the Tray Motor and the detection of the raised lift plate Out of range values may indicate a problem with the lifting mecha nism which could effect the following friction measur...

Page 240: ...rts the peak temperature following the end of the heating interval 7 Peak Temperature Time ms N A Reports the time following the applica tion of power to the specified heater until the peak temperatur...

Page 241: ...perature at a fixed time following the peak temperature time Table 20 Drum Heater Nominal Values R Characteristic Typical Value Result 0 AC Line Voltage volts N A Reports the baseline AC voltage prior...

Page 242: ...verage of the power over the exit interval for all trays for Simplex oper ations only Duplex Operations Only 7 Duplex Turnaround Average Power N A Reports average of the power over the duplex turnarou...

Page 243: ...ed No Tray 2 value 3 not used undefined No Tray 2 value Tray 1 Source Tray 2 not used undefined No Tray 1 value 3 not used undefined No Tray 1 value 4 Deskew Trailing Edge Interval Time N A Reports de...

Page 244: ...could indicate something block ing the normal Printhead range of motion either inside of outside the right side frame or some significant binding loose cables foreign object Printhead not in the Read...

Page 245: ...Assembly Printhead latching mechanism Head Maintenance Clutch and related parts This test assumes that the tilt drive and the Wiper Assembly mecha nisms are functioning correctly Run the Tilt Drive te...

Page 246: ...stalls against the upper stop If the tray is empty the normal situation the No Paper Sensor is not activated but the Paper Height Sensor is If the tray contains 1 sheet of media additional media woul...

Page 247: ...roller is installed and is hanging down correctly 5 Lift Time sec N A Reports the interval from the motor start time until the Paper Height Sensor is activated This value indicates that the sensor is...

Page 248: ...equency of the most pow erful FFT frequency not including the drum or motor 6 FFT Power Ratio 2 none N A Reports the ratio of the FFT power amplitude of the second most powerful FFT frequency not incl...

Page 249: ...error during the roller down portion of the transfix operation Table 37 Y Axis Drive Belt Tension Nominal Values R Characteristic Typical Value Result 0 Min Resonant Frequency hz N A Reports the min r...

Page 250: ...revolution 7 Releasing Amplitude mpts N A Reports the magnitude of the reaction of the Drum to the withdrawal of the blade See R3 Table 39 Drum Maintenance Contact Nominal Values R Characteristic Typ...

Page 251: ...average value of the recording interval 4 Motor drive power ripple watts N A Reports variation of the motor drive power over the recording interval 5 Motor drive power average watts N A Reports the mo...

Page 252: ...of ink or not properly biased Head Tilt Spring missing or defective Also the trip lever could require extra effort to lift flat spring stronger than usual rough or warped engage surface with gear bin...

Page 253: ...position Next the X axis is moved to the right until the insulation makes contact with the right side frame and the drive cone unloads from the Printhead The X axis is then moved left for a fixed tim...

Page 254: ...rms diagnostic test results and subsequent repairs Component Checks Located under the Print Engine Exercise menu of Service Diagnostics is an extensive suite of component level tests that exercise ind...

Page 255: ...ce is indeterminate As is the case with simultaneous events In these cases a U is appended to the event to indicate an unknown sequence While event sequence can be important in determin ing cause the...

Page 256: ...order If either the Scanner turns on or the Exit Module initializes the Scanner Power Supply is oper ational If the Scanner turns on but the Exit Module doesn t initialize properly then the Power Sup...

Page 257: ...e to circuits within the Electronics Module may occur if the power supply capaci tors are not allowed to fully c Connect the Power Control cable to the I O Board connector J800 This connects the I O B...

Page 258: ...ontacts with isopropyl alcohol reinstall and then retest 5 Exchange the Configuration Card for a known working card to test operation System Power Supply The power supply is divided into two sections...

Page 259: ...re power to the Exit Module The Exit Module elevator should cycle up and down after the Scanner Assembly is raised and lowered The Exit Module Control Board receives power from the Scanner Power Suppl...

Page 260: ...shooting 4 Reseat the Scanner Assembly connection to the Electronics Module 5 With Power Cord connected touch the Electronics Module to discharge any static ESD damage may occur if static electricity...

Page 261: ...correct media tray The paper guides indicate to the system the size of media being used Ensure the media guides are set correctly Inspect the paper for bent torn or folded corners Check to ensure no s...

Page 262: ...ystem frame Operating System and Application Problems Print an internal test print from the system s control panel to ensure the problem is not system related There is additional help available at www...

Page 263: ...ing from another computer 5 If the error returns turn On the PostScript error handler through the Control Panel Post Script Error Info in the Support menu or CentreWare IS and print the document again...

Page 264: ...twork functions The logs contain TCP IP NetWare and AppleTalk initialization events The logs can also be accessed remotely via Cen treWare The logs list events chronologically The log is limited in le...

Page 265: ...a dial tone when attempting to send a Fax Fax operations are not completely blocked by this error Outgoing faxes can queue Fax subsystem parameters are adjustable and jobs received before the dial ton...

Page 266: ...ion Report In addition to the Results codes the Job Details section includes Mode and Job Type codes Definitions of all these codes appears on each report Table 1 Common Fax Communication Commands Com...

Page 267: ...gured properly for the local phone line Check the target Fax number If the number is in memory is it saved correctly Call the target Fax number from a desk phone and confirm a Fax tone response Check...

Page 268: ...em or an unusual or low quality ring signal A high Answer Delay setting Junk Fax Prevention or Fax Receive settings might impede inbound calls Troubleshooting Procedure Table 1 Remote Fax Answers then...

Page 269: ...edure for troubleshooting Printhead problems Complete this checklist as part of the Printhead replacement process Phaser 8860 8860MFP Printhead Troubleshooting Checklist Figure 1 Printhead Checklist P...

Page 270: ...09 2007 6 50 Phaser 8860 8860MFP Service Manual Printhead Troubleshooting Checklist Initial Issue Diagnostics Figure 2 Printhead Checklist Page 2 Figure 3 Printhead Checklist Page 3...

Page 271: ...ump solenoid opens 5 The Printhead tilts forward against the Wiper Blade and the purge and wipe cycle begins 6 The Control Panel indicates the system is performing the cleaning process 7 The Printhead...

Page 272: ...09 2007 6 52 Phaser 8860 8860MFP Service Manual Printhead Troubleshooting Checklist Printhead Initial Issue Diagnostics...

Page 273: ...09 2007 7 1 Phaser 8860 8860MFP Service Manual Wiring Data Initial Issue 7 Wiring Data How to use the Plug Jack Location List 7 3 Plug Jack Locations 7 4 Wire Routing 7 10 Wiring Diagrams 7 14...

Page 274: ...09 2007 7 2 Phaser 8860 8860MFP Service Manual Initial Issue Wiring Data...

Page 275: ...igure 12 F 107 Connects the Control Panel to the Front Door Interlock 110 Figure 9 B 107 Connects the Waste Tray Detect Sensor to the I O Board 118 Figure 2 C 107 Connects the Drum Fan to the Right Si...

Page 276: ...s the Drum Maintenance Pivot Plate to the I O Board 860 Figure 11 G 103 Connects the Preheater Board to the I O Board 870 Figure 9 G 106 Connects the Drum Temp Sensor to the I O Board 910 Figure 9 C 1...

Page 277: ...09 2007 7 5 Phaser 8860 8860MFP Service Manual Plug Jack Locations Wiring Data Initial Issue Figure 2 8860MFP Right Side P J Locations Figure 3 8860MFP Front Side P J Locations...

Page 278: ...09 2007 7 6 Phaser 8860 8860MFP Service Manual Plug Jack Locations Initial Issue Wiring Data Figure 4 Right Side Electronics Module P J Locations Figure 5 Left Side Electronics Module P J Locations...

Page 279: ...09 2007 7 7 Phaser 8860 8860MFP Service Manual Plug Jack Locations Wiring Data Initial Issue Figure 6 Top Electronics Module P J Locations Figure 7 8860MFP Exit Module Control Board P J Locations...

Page 280: ...09 2007 7 8 Phaser 8860 8860MFP Service Manual Plug Jack Locations Initial Issue Wiring Data Figure 8 8860MFP Scanner Power Supply P J Locations Figure 9 I O Board P J Locations...

Page 281: ...09 2007 7 9 Phaser 8860 8860MFP Service Manual Plug Jack Locations Wiring Data Initial Issue Figure 10 Drum Heater Relay Board P J Locations Figure 11 Underside of the Preheater Board P J Locations...

Page 282: ...09 2007 7 10 Phaser 8860 8860MFP Service Manual Plug Jack Locations Wire Routing Initial Issue Wiring Data Figure 12 Control Panel P J Locations Wire Routing Figure 1 8860MFP Back Frame Wire Routing...

Page 283: ...09 2007 7 11 Phaser 8860 8860MFP Service Manual Wire Routing Wiring Data Initial Issue Figure 2 Right Side Wire Routing 1 2 Figure 3 Right Side Wire Routing 2 2...

Page 284: ...09 2007 7 12 Phaser 8860 8860MFP Service Manual Wire Routing Initial Issue Wiring Data Figure 4 Left Side Wire Routing 1 2 Figure 5 Left Side Wire Routing 2 2...

Page 285: ...09 2007 7 13 Phaser 8860 8860MFP Service Manual Wire Routing Wiring Data Initial Issue Figure 6 Front Wire Routing Figure 7 Top Wire Routing 1 2...

Page 286: ...09 2007 7 14 Phaser 8860 8860MFP Service Manual Wiring Diagrams Initial Issue Wiring Data Wiring Diagrams Figure 1 8860MFP Scanner DADF Block Diagram Figure 2 8860MFP System Block Diagram 1 2...

Page 287: ...09 2007 7 15 Phaser 8860 8860MFP Service Manual Wiring Diagrams Wiring Data Initial Issue Figure 3 8860MFP System Block Diagram 2 2 Figure 4 8860 System Block Diagram 1 2...

Page 288: ...09 2007 7 16 Phaser 8860 8860MFP Service Manual Wiring Diagrams Initial Issue Wiring Data Figure 5 8860 System Block Diagram 2 2 Figure 6 Left Side Harness 1 2...

Page 289: ...09 2007 7 17 Phaser 8860 8860MFP Service Manual Wiring Diagrams Wiring Data Initial Issue Figure 7 Left Side Harness 2 2 Figure 8 Electronics Module...

Page 290: ...09 2007 7 18 Phaser 8860 8860MFP Service Manual Wiring Diagrams Initial Issue Wiring Data Figure 9 Electronics Module Power Figure 10 Right Side Harness I O Control...

Page 291: ...09 2007 7 19 Phaser 8860 8860MFP Service Manual Wiring Diagrams Wiring Data Initial Issue Figure 11 I O Board 1 2 Figure 12 I O Board 2 2...

Page 292: ...09 2007 7 20 Phaser 8860 8860MFP Service Manual Wiring Diagrams Initial Issue Wiring Data Figure 13 8860MFP Exit Module Control Board...

Page 293: ...09 2007 8 1 Phaser 8860 8860MFP Service Manual Theory of Operation Initial Issue 8 Theory of Operation System Overview 8 3 Image Input Terminal 8 3 System Electronics 8 6 Image Output Terminal 8 8...

Page 294: ...09 2007 8 2 Phaser 8860 8860MFP Service Manual Initial Issue Theory of Operation...

Page 295: ...Input Terminal IIT Document Feeder Scanner and Image Output Terminal IOT Print Engine IOT descriptions also apply to the 8860 Figure 1 Phaser 8860MFP Model This section describes these major assembli...

Page 296: ...the cover is open DADF operation is inhibited given sufficient time an error message appears on the Control Panel display instructing the user to close the access cover Pick Roller and Separator Pad...

Page 297: ...Figure 2 DADF Calibration Strip Automatic Scanner Calibration 1 Lamps turn on 2 The scanhead drives toward the automatic calibration target to ensure that the head lock is released 3 Scanhead moves ba...

Page 298: ...ower from the power supply contained in the Electronics Module Electronics Module The Electronics Module includes the main board image processing board power control board and the power supply The Ele...

Page 299: ...C section In the AC section power is routed to 10 tri acs Under the main board logic control the triacs supply AC power to the 10 heaters in the system Two fuses provide current protection to the tria...

Page 300: ...o both models NOTE The Electronics Module is also a subsystem of the IOT but was discussed previously For more information on the Electronics Module see Electronics Module Figure 1 IOT Subassemblies I...

Page 301: ...the paper This ensures that the leading edge is straight to prevent skewing The deskew rollers will not reverse during duplex printing Ink Loader Melts the ink as required by the Printhead The melted...

Page 302: ...rollers pull the paper to a predetermined location In this posi tion the trailing edge of the paper is adjacent to the exit rollers The exit rollers then pull the paper back into the duplex path From...

Page 303: ...actuator or the object itself to block the light path to detect an object or condition Photo reflective sensors have the light emitter and light receiver aligned on a single surface Output of the phot...

Page 304: ...system inde pendently or concurrently through the use of the swing gear in the gear train Operation of the transfix and drum maintenance system is controlled by the rotational direction of the motor W...

Page 305: ...ked Ink is added from the Ink Loader if necessary In the ready state the print process consists of the following steps Drum Preparation Printing Ink Loader Printhead Drum Assembly Transfix System Purg...

Page 306: ...ing jet When jet substitution is used the Printhead makes a second right to left movement to deposit the pixel columns of the substituted jets See Jet Substitution Mode Ink Loader The Ink Loader consi...

Page 307: ...droplets out the 1236 corresponding nozzles Looking at the Printhead face the nozzles are arranged in 12 rows in color order KYKYKYCMCMCM where K black Y yellow C cyan and M magenta During the printi...

Page 308: ...tween the jet stack and the drum The head tilt cam tilts the head into the basic four positions listed above The cam has five spe cial features and associated functions 1 The cam is combined with a mi...

Page 309: ...d the tilt gear disengages from the Process Drive The Head Tilt Solenoid is actuated and deactuated when the Head Tilt Gear rotates to the respective engaged and dis engaged positions The latching mec...

Page 310: ...nsfer The Y Axis assembly uses an active tension system to allow the pulley to float while the spring adjusts the tension NOTE The Drum rotates CW for Transfix CCW for Maintenance and Printing Figure...

Page 311: ...ne rotation the Process Drive rotates the cam lowering the oil roller and wiper blade away from the Drum The Drum has a floating deadband area The deadband is a narrow section of the Drum s sur face c...

Page 312: ...ilts into the Wiper Blade and the wipe cycle begins The pump runs again with the solenoid for approx imately 30 seconds creating a neutral balance between pressure and ink The Wiper Blade lowers and w...

Page 313: ...nsor ensuring the image is perfectly aligned for transfix to the paper The Process Drive lifts and lowers the Transfix Roller At the point which the Transfix Roller is loaded but before the Drum begin...

Page 314: ...skew rollers are not driven during transfixing The Media Drive rotates the Exit Rollers in the correct direction to pull the paper out with the deskew clutch deenergized As the Process Drive lifts the...

Page 315: ...ex 20 ips 17 ips 13 ips 7 ips Peak transfix speed Duplex 5 ips 5 ips 5 ips 5 ips Peak Transfix Speed Legal 20 ips 17 ips 13 ips 7 ips Peak transfix speed Tray 1 13 ips 7 ips 7 ips 7 ips First Sheet Tr...

Page 316: ...Password 33 Security Print Hosts 256 AppSocket On 1 AppSocket Enabled 1 LPR On 1 LPR Enabled 1 FTP On 1 FTP Enabled 1 IPP On 1 IPP Enabled 1 MIME On 1 MIME Enabled 1 EtherTalk On 1 EtherTalk Enabled...

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