XEROX PHASER 8860, PHASER 8860MFP User Manual

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Phaser 8860/8860MFP Service Documentation

705P01205 September 2007

Phaser 8860/8860MFP Service Manual

Service Documentation

Phaser 8860/8860MFP Service Manual

705P01205

Initial Issue

09/2007

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NOTICE: All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product trained service personnel only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future changes to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provided service. If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

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Introduction

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About This Manual .......................................................................................................... iii

Organization....................................................................................................................iii

Power Safety................................................................................................................... iv

Service 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 of the 8860MFP ..................................................................................................... xii

8860MFP Control Panel Layout ...................................................................................... xiv

Parts of the 8860............................................................................................................. xvi

8860 Control Panel Layout.............................................................................................. xviii

8860 Menu Map .............................................................................................................. xix

System Specifications ..................................................................................................... xx

Introduction

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Introduction

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About This Manual

The Phaser 8860/8860MFP Service Manual is the primary document used for diagnosing, repairing, maintaining, and troubleshooting these systems. The Service Manual is the controlling publication for a service call. Information on using this document is found in the Introduction section. To ensure understanding of this product, complete the Xerox Service Training Program for this particular system.

For manual updates, Service Bulletins, knowledge base, and technical support, visit www.xerox.com/office/support.

Service Manual Revision

Updates are issued as the system changes or as corrections are identified.

Organization

The titles of the sections and a description of the information contained in each section are contained in the following paragraphs:

Introduction and General Information

This section contains documentation organization, symbology and nomenclature, translated warnings, safety symbols, regulatory specifications, and general information about the printer.

Section 1 Service Call Procedures

This section contains procedures to be taken during a service call and in what sequence they are to be completed. This is the entry level for all service calls.

Section 2 Status Indicator RAPs

This section contains descriptions of the diagnostic 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 troubleshooting image quality problems, as well as image quality specifications and image defect samples.

Section 4 Repairs/Adjustments

This section contains all the removal, replacement, and adjustments procedures.

Repairs

Repairs include procedures for removal and replacement of spare parts listed in the Parts List. Use the repair procedures for the correct order of removal and replacement, for warnings, cautions, and notes.

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Phaser 8860/8860MFP Service Manual

Adjustments

Adjustments include procedures for adjusting the parts that must be within specification for the correct operation of the system. Use the adjustment procedures for the correct sequence of operation for specifications, warnings, cautions and notes.

Section 5: Parts Lists

This section contains the illustrated Parts List.

Section 6: Diagnostic Information

This section contains details of the embedded Service Diagnostics test suite, as well as troubleshooting procedures for system problems not related to a specific fault code.

Section 7: Wiring Data

This section contains drawings, lists of plug/jack locations, and diagrams of the power distribution wire networks in the machine. Individual wire networks are shown in the Circuit Diagrams contained in Section 2. This section also contains the Block Schematic Diagrams.

Section 8: Theory of Operation

This section contains detailed functional information on the print engine components.

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About This Manual, Organization

Introduction

Power Safety

Power Source

For 115 VAC printers, do not apply more than 135 volts RMS between the supply conductors or between either supply conductor and ground. For 230 VAC printers, do not apply more than 254 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. This manual assumes that the reader is a qualified service technician.

Plug the three-wire power cord (with grounding prong) into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock. A protective ground connection by way of the grounding conductor in the power cord is essential for safe

operation.

Disconnecting Power

WARNING

Turning the power off using the power switch does not completely de-energize the system. You must also disconnect the power cord from the system’s AC inlet. Disconnect the power cord by pulling the plug, not the cord.

Disconnect the power cord in the following cases:

• if the power cord or plug is frayed or otherwise damaged,

• if any liquid or foreign material is spilled into the product,

• if the printer is exposed to any excess moisture,

• if the printer is dropped or damaged,

• if you suspect that the product needs servicing or repair,

• whenever you clean the product.

Service Safety Summary

General Safety

The system and recommended supplies have been designed and tested to meet strict safety requirements. Attention to the following information will ensure the continued safe operation of the system.

Electrical Safety

• 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 that does not have a ground connection terminal.

• Do not use an extension cord or power strip.

• Do not place the system in an area where people might step on the power cord.

• Do not place objects on the power cord

• Do not block the ventilation openings. These openings are provided to prevent overheating of the system.

• Do not drop paper clips or staples into the system.

WARNING

Avoid the potential of electrical shock by ensuring that the system is properly grounded. Electrical products may be hazardous if misused.

The power cord is attached to the system as a plug-in device on the side of the system. If it is necessary to disconnect all electrical power from the system, disconnect the power cord from the electrical outlet.

WARNING

Do not remove the covers or guards that are fastened with screws unless you are installing optional equipment and are specifically instructed to do so. Power should be OFF when performing these installations. Disconnect the power cord when removing covers and guards for installing optional equipment. Except for user-installed options, there are no parts that you can maintain or service behind these covers

WARNING

The following are hazards to your safety:

• Damaged or frayed Power Cord

• Liquid spilled into the system

• Exposure to water or excessive moisture

If any of these conditions occur, do the following:

1. Turn off the Power Switch

2. Disconnect the Power Cord from the electrical outlet.

3. Call an authorized service representative.

Maintenance Safety

• Do not attempt any maintenance procedure that is not specifically described in the documentation supplied with your system.

• Do not use aerosol cleaners. The use of supplies that are not approved may cause poor performance and could create a hazardous condition.

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Power Safety, Service Safety Summary

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• Do not burn any consumables or routine maintenance items. For information on Xerox supplies recycling programs, go to www.xerox.com/gwa.

Operational Safety

The system and supplies were designed and tested to meet strict safety requirements. These include safety agency examination, approval, and compliance with established environmental standards.

Pay attention to these safety guidelines to ensure the continued, safe operation of the system.

• Use the supplies specifically designed for your system. The use of unsuitable materials may cause poor performance and a possible safety hazard.

• Follow all warnings and instructions marked on, or supplied with, the system, options and supplies.

CAUTION

Use of other than Genuine Xerox Solid Ink may affect print and copy quality and system reliability. It is the only ink designed and manufactured under strict quality controls by Xerox for specific use with this system. The Xerox Warranty, Service Agreements, and Total Satisfaction Guarantee do not cover damage, malfunction, or degradation of performance caused by use of non-Xerox supplies or consumables, or the use of Xerox supplies not specified for this system.

NOTE: The Total Satisfaction Guarantee is available in the United States and Canada. Coverage may vary outside these areas; please contact your local representative for details.

General Guidelines

For qualified service personnel only: Refer also to the preceding Power Safety Precautions.

Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person 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 exposed connections and components while power is on. Disconnect power before removing the power supply shield or replacing components.

Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied, be aware of the potential for electrical shock.

WARNING

Do not touch any electrical component unless you are instructed to do so by a service procedure.

Figure 1 Electrical Components Warning

Servicing Mechanical Components

WARNING

Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.

Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces and other metallic objects could come into contact with dangerous voltages and currents.

Warning Labels

Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all

warning labels remain in place.

Safety Interlocks

Make sure all covers are in place and all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.

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Figure 2 Mechanical Components Warning

Servicing Printhead Components

WARNING

This system uses heat to fuse the image to media. The Printhead is VERY HOT. Turn the printer power off and wait at least 30 minutes for the Printhead to cool before you attempt to service the Printhead or adjacent components.

Introduction

vii

Service Safety Summary

Moving the System

WARNING

Parts of the system are hot. To avoid personal injury or damage to the system, allow the ink to solidify. Run the shutdown procedure to park the Printhead and begin cooling the system. Wait at least 30 minutes for the system to cool before moving or packing the system.

• Allow the system to cool to avoid ink spills which can damage the system.

• Use the shutdown procedure from the Control Panel before moving the system.

• Never move the system if a Power Down Error-Head not Parked message is displayed. Damage to the system can occur if the Printhead is not locked before shipment.

• Use the power switch to turn off the system, and unplug all cables and cords. Do not turn off the system by pulling the power cord or using a power-strip with an on/off switch.

• For the 8860MFP, lock the scanhead shipping restraint before removing the scanner portion for shippment. Moving the scanner with the scanhead unlocked can damage the scanner.

• The system is heavy and must be lifted by two people.

Figure 2 System Lifting Technique

• Always move the system separately from optional Trays 3 and 4.

When shipping the system, repack the system using the original packing material and boxes or a Xerox repackaging kit. Instructions for repacking the system are included in the kit. If you do not have all the original packaging, or are unable to repackage the system, contact your local Xerox service representative

Figure 1 Locking the Scanhead

• Always remove the document feeder and Scanner before shipping the system.

Introduction

Moving the System

CAUTION

Failure to repackage the system properly for shipment can result in damage to the system. Damage to the system caused by improper packaging is not covered by the Xerox warranty, service agreement, or Total Satisfaction Guarantee.

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Symbology and Nomenclature

The following reference symbols are used throughout the documentation.

Warnings, Cautions, and Notes

Warnings, Cautions, and Notes will be found throughout the Service Documentation. The words WARNING or CAUTION may be listed on an illustration when the specific component associated with the potential hazard is pointed out; however, the message of the WARNI NG or

CAUTION is always located in the text. Their definitions are as follows:

WARNING

A Warning is used whenever an operating or maintenance procedure, a practice, condition, or statement, if not strictly observed, could result in personal injury.

CAUTION

A Caution is used whenever an operating or maintenance procedure, a practice, condition, or statement, if not strictly observed, could result in damage to the equipment.

NOTE: A Note is used whenever it is necessary to highlight an operating or maintenance procedure, practice, condition, or statement.

Table 2 Additional Warnings

REP 5.0.2 Scanner Power Supply

REP 5.0.19 Drum Heater Relay Board

WARNING

HIGH VOLTAGE!

DANGER: HAUTE TENSION!

Exercise care when making the voltage check in the following steps.

DANGER: Soyez extrêmement vigilant lorsque vous effectuez les tests de tension au cours des étapes qui suivent.

WARNING

Personal injury may result from grasping hot areas of Printhead. If a hot Printhead must be removed, grasp the Printhead by black plastic frame component.

DANGER: Des blessures peuvent résulter si les zones chaudes du module de four sont touchées. Si un module de four chaud doit être enlevé, le saisir par l'élément en plastique noir du bâti.

Common Warnings and Safety Icons

The following common warnings are used throughout the documentation and the safety icons are displayed on the machine. Additional specific warnings are included for the listed sections.

Common Warnings

WARNING

To avoid personal injury or shock, do not perform repair or adjustment activities with the power switch on or electrical power applied to the machine.

DANGER: Afin d'éviter des blessures ou des chocs électriques, ne pas effectuer des activités de maintenance ou de réglage avec l'équipement sur Marche ou avec le cordon d'alimentation branché.

The following sections have additional specific warning information.

Table 1 Introduction and Section 4

Introduction - Symbology and Nomenclature

Section 4 - Repairs and Adjustments

WARNING

A Warning is used whenever an operating or maintenance procedure, a practice, conditioning, or statement, if not strictly observed, could result in personal injury.

DANGER: Une note DANGER est utilisée à chaque fois qu’une procédure de maintenance ou qu’une manipulation présente un risque de blessure si elle n’a pas été strictement observée.

The following sections have additional specific warning information.

Table 2 Additional Warnings

REP 2.0.2 Printhead Assembly

REP 2.0.8 Left and Right Printhead Restraints

Machine Safety Icons

The following precautionary symbols may appear on the system.

This symbol indicates DANGER high voltage.

Figure 1 High Voltage Symbol

Protective ground (earth) symbol.

Figure 2 Protective Ground (earth) Symbol

These symbols indicate hot surface on or in the printer. Use caution to avoid personal injury.

Figure 3 Hot Surface Symbol

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Introduction

Symbology and Nomenclature

The surface is hot while the printer is running. After turning off the power, wait 30 minutes.

Figure 4 Wait 30 Minutes Symbol

Avoid pinching fingers in the printer. Use caution to avoid personal injury.

Figure 5 Pinch Injury Symbol

Voltage Measurement and Specifications

Measurements of DC voltage must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure. All measurements of AC voltage should be made with respect to the adjacent return or ACN wire.

Table 3 Voltage Measurement and Specifications

Voltage Specification

INPUT POWER 220 V 198 VAC TO 254 VAC

INPUT POWER 100 V 90 VAC TO 135 VAC

INPUT POWER 120 V 90 VAC TO 135 VAC

+5 VDC +4.75 VDC TO +5.25 VDC

+24 VDC +23.37 VDC TO +27.06 VDC

Logic Voltage Levels

Measurements of logic levels must be made with reference to the specified DC Common, unless some other point is referenced in a diagnostic procedure.

Use caution (or draws attention to a particular component). Refer to the manual(s) for information.

Figure 6 Use Caution Symbol

Electrostatic Discharge (ESD) Field Service Kit

The purpose of the ESD Protection Program is to preserve the inherent reliability and quality of electronic components that are handled by the Field Service Personnel. This program is being implemented now as a direct result of advances in microcircuitry technology, as well as a new acknowledgment of the magnitude of the ESD problem in the electronics industry today.

This program will reduce Field Service costs that are charged to PWB failures. Ninety percent of all PWB failures that are ESD related do not occur immediately. Using the ESD Field Service Kit will eliminate these delayed failures and intermittent problems caused by ESD. This will improve product reliability and reduce callbacks.

The ESD Field Service Kit should be used whenever Printed Wiring Boards or ESD sensitive components are being handled. This includes activities like replacing or reseating circuit boards or connectors. The kit should also be used 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 Procedures section of the Service Documentation.

Table 4 Logic Levels

Voltage H/L Specification

+5 VDC H= +3.00 TO +5.25 VDC

L= 0.0 TO 0.8 VDC

+24 VDC H= +23.37 TO +27.06 VDC L= 0.0 TO 0.8 VDC

DC Voltage Measurements in RAPs

The RAPs have been designed so that when it is required to use the DMM to measure a DC voltage, the first test point listed is the location for the red (+) meter lead and the second test point is the location for the black meter lead. For example, the following statement may be found in a RAP:

There is +5 VDC from TP7 to TP68.

In this example, the red meter lead would be placed on TP7 and the black meter lead on TP68.

If a second test point is not given, it is assumed that the black meter lead may be attached to the copier frame.

Introduction

Symbology and Nomenclature

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Electrostatic Discharge Precautions

Some semiconductor components, and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

Be sure the power is off to the chassis or circuit board, and observe all other safety precautions.

• Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.

• After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

• Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices.

• Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it.

• Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

• Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity 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 Circuit

Boards (PCB’s).

Regulatory Specifications

Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.

United States (FCC Regulations)

The Phaser 8860/8860MFP has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial installation. This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with these instructions, it may cause harmful interference to radio communications. Operation of Class A equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. There is no guarantee that interference will not occur in a particular installation.

If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiver.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/television technician for help.

Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.

Canada (Regulations)

This Class A digital apparatus (8860/8860MFP) complies with Canadian ICES-003.

Cet appareil numérique (8860/8860MFP) de la classe A est conforme du Canada.

à la norme NMB-003

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Introduction

Electrostatic Discharge Precautions, Regulatory

European Union

This is a class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

Radio Equipment & Telecommunications Terminal Equipment Directive

The Phaser 8860MFP has been self-certified by Xerox for pan-European single terminal connection to the analogue public switched telephone network (PSTN) in accordance with Directive 1999/5/EC. The product has been designed to work with the national PSTNs and compatible PBXs of the following countries:

Table 1 Supported Countries

Austria Germany Luxembourg Sweden

Belgium Greece Netherlands Switzerland

Denmark Iceland Norway United Kingdom

France Ireland Portugal Finland

Italy Spain

In the event of a problem you should contact your authorized local dealer in the first instance. This product has been tested to and is compliant with TBR21, a specification for terminal equipment for use on analogue-switched telephone networks in the European Economic Area. This product provides an user-adjustable setting of the country code. Refer to the customer documentation for this procedure. Country codes should be set prior to connecting this product to the network.

NOTE: Although the 8860MFP can use either loop disconnect (pulse) or DTMF (tone) signaling, it is recommended that it is set to use DTMF signaling. DTMF signaling provides reliable and faster call setup. Modification of this product, connection to external control software or to external control apparatus not authorized by Xerox, will invalidate its certification.

This product, if used properly in accordance with the user’s instructions, is neither dangerous for the consumer nor for the environment.

Phaser 8860/8860MFP Overview

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 PostScript 3 and PCL5c page description languages. The system is a high performance, Letter or A4, 30 page per minute (ppm) product, supporting resolutions up to 525 x 1200 dots-per-inch (dpi). The both products feature USB and 10/100 base T Ethernet ports. The 8860MFP includes an RJ-11 Fax port with an optional Foreign Device Interface (FDI) for specialized installations. The 8860/8860MFP provides a 100-sheet Tray 1 from which specialty media, card stock, and envelopes are fed. Tray 1 also supports manual feeding. Tray 2 provides 525 sheets of capacity. The Output Tray holds 250 sheets facedown. The 8860MFP features a Duplex Automatic Document Feeder (DADF) providing enhanced document handling functionality.

Phaser 8860/8860MFP options add memory, media capacity and functionality. RAM memory upgrades are available to raise installed memory to the 1 GB maximum. A 525-Sheet Feeder is also available. Two 525-Sheet Feeders may be installed to raise the maximum media input storage capacity to 1675 sheets. The System Cart is available for mobility and increased media storage.

After a predefined period of time since its last activity, the Phaser 8860/8860MFP enters a power saving standby mode. All communications interfaces remain active and have the ability to wake the system up.

CAUTION

Phaser 8860/8860MFP products use a new formulation of Ink having unique properties. The Ink Loader on these products is keyed to accept this Ink shape only. The use of Ink not specifically designed for this product can result in system failures.

A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

Introduction

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Figure 1 Phaser 8860MFP Multifunction Product with Optional Trays

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System Configurations

Standard Features

The Phaser 8860/8860MFP offers these standard features:

• Maximum print speed (pages per minute) based on letter-size plain paper:

NOTE: Print speeds for media fed from Tray 1 may be up to 50% slower.

Table 1 Phaser 8860/8860MFP Print Speeds

Phaser 8860 Color Printer Phaser 8860MFP Multifunction Product

PostScript Print Quality Modes: – Fast Color: 30 ppm

– Standard: 24 ppm

– Enhanced: 16 ppm

– High Resolution/Photo: 10 ppm

PCL Print Quality Modes: – 300 x 600 dpi: 16 ppm

– 600 x 600 dpi: 8 ppm

• First-page-out: 6 seconds for color prints, 15 seconds for color copies

• Copy, Print, Scan, Fax capabilities (options vary according to configuration and memory)

• Connections: USB, Ethernet 10/100 Base-Tx, Foreign Device Interface (available)

• RJ-11 Fax Modem (8860MFP only)

Available Configurations

Ta b l e 2 lists the standard configurations.

Table 2 Phaser 8860/8860MFP Configurations

Features 8860 8860MFP

Memory 256 MB 512 MB

Hard Drive No* Yes

Automatic 2-sided Printing (DADF) No Yes

525-Sheet Feeder No* No*

System Cart No* No*

Copy No Yes

Scan to PC No Yes

Scan to E-mail No Yes

Scan to Hard Drive No Yes

Fax No Yes

* This option can be purchased separately for this configuration.

PostScript Print Quality Modes: – Fast Color: 30 ppm

– Standard: 24 ppm

– Enhanced: 16 ppm

– High Resolution/Photo: 10 ppm

PCL Print Quality Modes: – 300 x 600 dpi: 16 ppm

– 600 x 600 dpi: 8 ppm

• Memory

•System Cart

Additional Trays

Trays 1 and 2 are standard on all configurations. The following additional tray combinations are supported:

• One 525-Sheet Feeder (Tray 3)

• Two 525-Sheet Feeders (Trays 3 and 4)

Memory

All configurations have two memory slots supporting 256 MB, 512 MB, and 1 GB SODIMM modules (up to maximum of 1 GB DDR2).

System Cart

The System Cart supports a fully-optioned system and provides space for media storage.

Metered Printing

Metered printing (PagePack), involves the combination of control software and specialized Ink Sticks to meter system activity for billing purposes. The Configuration page lists Metered Ink as Enabled when metering is enabled.

Metered Operation

When a metered printer is initialized at first power-up, the customer sets the printer to Metered operation using a unique, factory-supplied, 4-digit PIN. Once set to Metered operation, the control software performs the following:

1. The Mode and PIN-entered values in Engine Control Board NVRAM are set.

2. The Control Panel momentarily displays “Metered Ink is now enabled”, then returns to “Ready” (if no other errors).

3. The First Time Tips pages and the Configuration page are printed.

If an incorrect PIN is entered, “Incorrect numeric password” displays with a prompt “Retry” or “Do not retry.” Retry returns to the enter prompt, “Do not retry” returns to the Replace Ink Stick error message. The error persists until the correct PIN is entered.

NOTE: The Hidden Service menu provides an Enable Metered Ink option to restore the Metered mode parameters to NVRAM should they become lost or corrupt.

Metered Ink

To support metered printing, metered Ink Sticks are available in all four colors. The shape of the metered Ink Stick differs from the non-metered versions.

Product Options

Phaser 8860/8860MFP options include:

• Additional Trays

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System Configurations

Parts of the 8860MFP

Front View

Figure 1 8570MFP Front View

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 Kit and Waste Tray access

12. Front Door Latch

Open View

Figure 2 Open View

1. Output Tray

2. Short Paper Stop

3. Exit Cover

4. Ink Loader Cover

5. Scan Head Lock

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Side View with Interface Connections

Figure 3 Side View with Interface Connections

1. Drum Maintenance Kit

2. Waste Tray

3. AC Power Cord Connection

4. Power Switch

5. Scanner Cable Connection

6. USB Connection

7. Ethernet Connection

8. Configuration Card

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 Electronics Module. The Electronics Module’s rear panel allows access to the RAM, and NVRAM chips. The optional Hard Drive mounts on the rear panel.

Figure 4 Back View

1. RAM Connectors

2. NVRAM Device

3. Hard Drive

4. Printer Stabilizer (8860MFP only)

NOTE: When replacing the electronics module, transfer these components to the new module.

•RAM

• Configuration Card

• NVRAM Device

• Hard Drive or Flash Disk

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Routine Maintenance Items

8860MFP Control Panel Layout

The Control Panel functions are segregated into three areas.

Figure 1 8860MFP Control Panel

Table 1 Control Panel Functional Areas

Left Side Center Right Side

Copy, Scan, and Fax functions and indicator LEDs

Control Panel Left

The left side of the Control Panel contains the copy, scan, fax controls and LEDs. A lighted LED indicates the current selection. Figure 2 shows each function’s location.

Display, Mode, Navigation buttons, and status LED’s

Numeric keypad, Stop, Start, Clear, and Clear All buttons

Figure 5 Routine Maintenance Items and Consumables

Table 1 Routine Maintenance Life Expectancy

Routine Maintenance Items

Extended-Capacity Maintenance Kit 30,000 cycles (0-20% coverage)

Standard-Capacity Maintenance Kit 10,000 cycles

Waste Tray Empty every 7 Purges

DADF Pick Rollers and Separator Pad 50,000 scans

20,000 cycles (20-100%) coverage.

Consumables

CAUTION

Introduction

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Parts of the 8860MFP, 8860MFP Control Panel Layout

Figure 2 Left Side Control Panel

1. Color Mode selects 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 output quality mode for copies: fast color, standard, enhanced, or high-resolution/photo.

4. 2-Sided selects either one or 2-sided for the original and one- or 2-sided for the output.

5. Lighten/Darken selects a setting for copy, scan, or fax jobs.

6. Reduce/Enlarge selects scale percentage for output: 25, 50, 100, 150, 200, 400.

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7. The Down Arrow reduces the reduce/enlarge percentage in one percent increments.

8. The Up Arrow increases the reduce/enlarge percentage in one percent increments.

9. Reduce/Enlarge Percentage display indicates the current educe/enlarge setting.

Control Panel Center

The center of the Control Panel contains the display, mode and navigation buttons, as well as the status LED. Figure 3 shows each function’s location.

Figure 3 Center Control Panel

1. Copy displays the Copy menu.

2. Scan displays the Scan menu.

3. Print displays the Print menu.

4. Fax displays the Fax menu.

5. System displays the System Setup menu.

6. Help(?) provides additional information about the menu or message displayed.

7. OK accepts the highlighted menu selection.

8. Down Arrow scrolls downward through menu selections.

9. Up Arrow scrolls upward through menu selections.

10. Back returns the previous menu to the display.

11. Control Panel display.

12. Status LED uses color to indicate these states of the current function:

• Green indicates the system is ready to print, copy, scan, 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 Right

The right side of the Control Panel contains the numeric keypad, Start, Stop, and Clear buttons, as well as Fax control functions. Figure 4 shows each function’s location.

Figure 4 Right Side Control Panel

1. Numeric keypad for entering numbers for sending a fax, selecting a number of copies, or entering a numeric password.

2. Start initiates the selected function (copy, scan. or fax).

3. Stop pauses a print, copy, scan, or fax job. To cancel the job, follow the instructions indicated on the display.

4. Clear All resets all job settings and returns to the top of the default function.

5. Pause enters a pause in a fax number.

6. Delayed Send stores a time for fax transmission.

7. Send List to view or add fax numbers to a list.

8. Speed Dial accesses directories of groups or individual fax numbers.

Control Panel Shortcuts

Table 2 Short Cuts

Mode Press this selection at Power On

Skip execution of POST diagnostics OK

Print Service Diagnostics Map INFO

Reset PostScript NVRAM BACK+ON

Password Bypass UP+DOWN

NOTE: To enter Service Diagnostics, press the BACK and ? buttons before the Xerox logo stops scrolling and until Beginning Service Mode appears.

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8860MFP Control Panel Layout

Parts of the 8860

Front View

Figure 1 8570MFP Front View

Side View with Interface Connections

Figure 2 Side 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 Module

The system’s main electronics and power supply are enclosed in a metal case called the Electronics Module. The rear panel allows access to the electronics module, RAM, and NVRAM chips. The system’s Hard Drive, if installed, is mounted on the rear panel.

1. Tray 4 (optional)

2. Tray 3 (optional)

3. Tray 2

4. Tray 1 (MPT)

5. Control Panel

6. Exit Cover Release

7. Front Door Release

8. Exit Cover

9. Ink Loader

10. Output Tray Extension

11. Interface Cover

12. Side Door

Introduction

Parts of the 8860

NOTE: When replacing the electronics module, transfer these components to the new module.

•RAM

• Configuration Card

• NVRAM Device

• Hard Drive or Flash Disk

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Figure 3 Back View

1. Hard Drive (optional)

2. Memory

3. Configuration Card

4. NVRAM Device

Routine Maintenance Items

Drum Maintenance Kit life expectancy depends on the kit capacity. For example, the standardcapacity kits produce 10,000 prints regardless of the colors used. Extended-capacity Drum Maintenance Kits for 8860 models produce 30,000 pages up to 20% coverage and 20,000 pages when coverage exceeds 20%. The Phase 8860/8860MFP uses a unique Drum Maintenance Kit. See Section 5 for the correct replacement part.

Figure 4 Routine Maintenance Items and Consumables

Table 1 Routine Maintenance Life Expectancy

Routine Maintenance Items

Extended-Capacity Maintenance Kit 30,000 cycles (0-20% coverage)

20,000 cycles (20-100%) coverage.

Standard-Capacity Maintenance Kit 10,000 cycles

Waste Tray Empty every 7 Purges

DADF Pick Rollers and Separator Pad 50,000 scans

Consumables

CAUTION

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8860 Control Panel Layout

Figure 1 8860 Control Panel

1. Status LED.

• Green is Ready to Print

• Yellow is Warning condition, printer continues to print

• Red is Startup sequence or error condition

• Blinking is printer is busy or warming up

2. Display

3. Cancel button cancels the current print job

4. Back button returns to the previous menu item

5. Up Arrow button scrolls upward through the menus

6. Down Arrow button scrolls downward through the menus

7. OK button accepts the selected setting

8. Help (?) button provides additional information, such as status, error messages, and maintenance information

Control Panel Shortcuts

Table 1 Short Cuts

Mode or Menu Press These Buttons

FTTR (Fast Time To Ready)

Printer goes to the ready state without waiting for temperatures to reach operating values. On power-up, when the Xerox splash screen displays, press and release the Up Arrow button, then press the Down Arrow button. If the printer detects ink on the drum, the display indicates a warming-up status.

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 hold the Up Arrow, and

then press the Down Arrow.

Service Diagnostics When the Display turns black, press and hold Back and Help until

“Beginning Service Mode” appears.

Control Panel language Press and hold the Cancel button, then press the Help button.

Bypass protected menus Press and hold the Cancel button, then press the Back button..

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8860 Menu Map

NOTE: Maps vary by model.

Figure 1 8860 Menu Map (1/2)

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Figure 2 8860 Menu Map (2/2)

Introduction

8860 Menu Map

System Specifications

Functional Specifications

Table 1 Functional Specifications

Characteristic Specifications

Printing Process Four-color (CMYK) solid ink Printhead architecture.

Image System Transfix transfer from oil coated Drum

Color Medium Cyan, Magenta, Yellow, and Black Ink Sticks

Resolution Fast Color: 225 x 400 dpi

Standard: 300 x 450 dpi Enhanced: 525 x 450 dpi Photo: 525 x 2400 dpi

First Page-Out (from Ready)

Warm-up Time Color and Monochrome: 12 minutes from Power On

Color: 8 seconds Monochrome: 8 seconds

Physical Dimensions and Clearances

Table 4 8860MFP Print Engine

Dimensions Value

Height 620 mm (24.4 in.)

Width 530 mm (20.9 in.)

Depth 660 mm (26.2 in.)

Weight 42 kg (93 lb.)

Table 5 8860 Print Engine

Dimensions Value

Height 368 mm (14.5 in.)

Width 422 mm (16.6 in.)

Depth 514 mm (20.2 in.)

Weight 26.8 kg (59 lb.)

Memory Specifications

Table 2 Memory 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

Media Tray Capacity

Table 3 Tray Capacity

Media and Weight Tray 1 Trays 2 and 3 DADF

Standard Paper 100 Sheets 525 Sheets 50 Sheets

Transparency 100 Sheets 50 Sheets

Envelopes 50

Weight

The DADF accommodates sizes from 114 x 140 mm (4.5 x 5.5 in.) to 216 x 356 mm (8.5 x

14.0 in.). The weight range includes 60-120 g/m2 (16-32 lb. Bond) (22-45 lb. Cover).

75-220 g/m

75-255* g/m

Table 6 525-Sheet Feeder

Dimensions Value

Height 132 mm (5.2 in.)

Width 422 mm (16.6 in.)

Depth 514 mm (20.24 in.

Weight 5.2 kg (11.5 lb.)

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Figure 1 Minimum Clearances

Print Engine Specifications

Table 7 Print Engine Functional Specifications

Characteristic Specification

Printing process Solid-ink

Controller 500 MHz processor

Color medium Yellow, cyan, magenta, and black ink sticks, each shape-

Color Management Automatic, Black & White,

FPOT, Color Copy < 15 seconds per page/1st copy

Memory 2 slots; minimum 256 MB, maximum 1 GB, PC133 DRAM

Fonts 137 PostScript 3

Warm-up time From Off (cold start): 12 minutes

coded. The system uses the subtractive color system to produce the colors red, green, and blue

Office: sRGB, Vivid Color, None, Press: Commercial, Euroscale, SWOP

subsequent copies at printer speed.

81 PCL5c

From power saver: 4 minutes

8860MFP Scanner/DADF Specifications

Table 8 Scanner/DADF Functional Specifications

Characteristic Specification

Printing Process Print Engine

Scan to Capabilities Scan to Disk (mailbox) function

Scan/Copy Process Flatbed platen and C-shape DADF paper path

Copies per Minute DADF: 20 ppm simplex, 10 ppm duplex

Memory 2 MB (1M x 16 SDRAM)

Image Buffer 32 MB SDRAM for Platen

Bit Depth Reading: 48 bits

Optical Resolution 600 x 300 to 600 x 2400 dpi (FS x SS)

Output Resolution from Scanner

Calibration Time less than 2 seconds (performed prior to copier and scan

Power Saver Mode Scanner and DADF are switched OFF. Also, lamps automati-

Scan to PC

Charge Coupled Device scanhead RGB color pack The scan controller provides 16 bit DMA interface for sending image data through the scanner board to the image processor board in the electronics module.

128 MB SDRAM for DADF

Output: 24 bits

Always equals optical resolution

operations)

cally turn off after 20 minutes.

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System Specifications

Table 8 Scanner/DADF Functional Specifications

Characteristic Specification

Noise Standby: < or equal to 45 dB

Scanning: < or equal to 50 dB

Electrical Specifications

Table 9 Electrical Specifications

Characteristic Specification

Primary Line Voltages 90-135 VAC

Primary Line Voltage Frequency Range

Power Consumption at Rated Voltage Input

Energy Star 70 W (43 W 8860)

Scanner Power Supply 30 W

180-254 VAC

47 - 63 Hz

300 W (230 W 8860) average during printing 1500 W (1250 W 8860) peak - 1000 typical 220 W (180W 8860) at idle

Image Specifications

Table 10 Print Engine Only Skew Specifications

Characteristic Specification

Printed Left Side Margin 5.0 mm +

Leading Edge Margin 5.0 mm +

NOTE: To derive the skew specification for a particular media size, measure the width of the leading edge in millimeters. Next, divide the measured length by 1000, then multiply by the appropriate Image Area Tolerance specification in milli-radians. For example, A 5 in. by 7 in. custom page would have a leading edge width, in millimeters, of 127mm (5 in.). Dividing the 127 by 1000 (127/1000), then multiplying the result by the 11 milli-radians specification results in a maximum skew of 1.4 mm (127/1000) x 11 = 1.4 mm.

Table 11 System Skew Specifications Scan, Copy, Print

Characteristic Specification

Printed Left Side Margin 5.0 mm +

Leading Edge Margin 5.0 mm +

Image Area Tolerance Zone

Image Skew, Envelopes 15.5 milli-radians max across the width of the leading edge.

Image Skew, Index Card 18.0 milli-radians max across the width of the leading edge.

Image Skew, All other sizes 11.0 milli-radians max across the width of the leading edge.

2.0 mm (0.197 in. + .080 in.)

1.3 mm (0.197 in. + .050 in.)

4.0 mm (0.197 in. + .157 in.)

3.3 mm (0.197 in. + .130 in.)

Table 12 Image Specifications

Characteristic Specification

Maximum Print Area 206 mm x 346 mm

Guaranteed Image Area 206 mm x 346 mm

Resolution/Gradation Fast Color: 300 x 300 dpi

Standard: 300 x 450 dpi Enhanced: 563 x 400 dpi Photo/Hi Res: 525 x 2400 dpi

Environmental Specifications

Table 13 Environmental Specifications

Characteristic Specification

Operating Storage

Temperature

Humidity 10% - 80% RH Non-Condensing

Altitude 0 to 2,438 meters (8,000 ft.) 0 to 6,092 meters (20,000 ft.)

Acoustic Noise (db) Operating Mode Standby Mode

NOTE: Check that the printer is on a stable, non-vibrating suface. Advise the customer to use care not to shake the printer excessively when loading media or closing the Front Door. During operation, the ink is in liquid form an can spill from the Printhead reservoir resulting in output defects.

- 32º C / 50º - 90º F operating

operating

-30°C to 60°C (-22 F to 140 F)

30% to 95% RH, non-condensing

Media and Tray Specifications

The media trays accommodate most sizes and types of paper, transparencies, or other specialty media. Print the Paper Tips page for a list of supported media.

Media that May Damage the System

The system can use a variety of media for print and copy jobs. However, some media can cause poor output quality, increased jams, or damage. Unacceptable media includes:

• Rough, plastic, or porous media

• Paper that has been stapled, folded, photocopied, or wrinkled

• Envelopes with windows, metal clasps, padding, or adhesives with release strips

• CD labels

• Media that is less than 60 g/m2 or more than 220 g/m2

Media Storage Guidelines

If media handling problems are a common occurrence, review the following storage guidelines with the customer.

• Store paper in dark, cool, relatively dry locations. Most paper items are susceptible to damage from ultraviolet (UV) 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 reduced as much as possible.

• Maintain constant temperatures and relative humidity

• Avoid light, heat, and dampness.

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• Avoid attics, kitchens, garages, and basements for storing paper. Inside walls are drier than outside walls where moisture can collect.

• Store paper flat. Paper should be stored on pallets, cartons, shelves, or in cabinets.

• Avoid having food or drinks in the area where paper is stored or handled.

• Do not open sealed packages of paper until needed. Leave paper in the original packaging. For most commercial grades, the wrapper’s inner lining protects the paper.

• Some specialty media is packaged inside sealed plastic bags. Leave the media inside the bag until needed; return unused media to the bag.

DADF Media Guidelines

The DADF accommodates sizes from 114 x 140 mm (4.5 x 5.5 in.) to 216 x 356 mm (8.5 x 14.0 in.), with weights within the following range: 60–120 g/m2 (16–32 lb. Bond) (22–45 lb. Cover).

Follow these 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 guides so they fit against the originals.

• Insert paper in the document feeder only when the ink on the paper is completely dry.

Use the glass rather than the document feeder to copy or scan the following types of originals:

• Paper with paper clips or staples attached

• Paper with wrinkles, curls, folds, tears, or notches

• Coated or carbonless paper, transparencies, or items other such as cloth or metal

• Envelopes

Supported Media

The following sections provide information about paper sizes and weights that can be used in

the system trays. For more detailed information about supported paper and other media, print

the Paper Tips page:

1. On the Control Panel, press the System button.

2. Select Information, and then press the OK button.

3. Select Information Pages, and then press the OK button.

4. Select Paper Tips, and then press the OK button to print.

See also: Recommended Media List at www.xerox.com/paper

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Service Call Procedures.................................................................................................. 1-3

Initial Actions................................................................................................................... 1-4

Routine Maintenance Activities ....................................................................................... 1-5

Cleaning Procedures....................................................................................................... 1-5

Final Actions.................................................................................................................... 1-6

1 Service Call Procedures

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Service Call Procedures

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Service Call Procedures

This section provides an overview of the steps a service technician should take to service the system and attached options. The system’s diagnostic routines report problems using error messages and fault codes displayed on the Control Panel, logged in the Service Usage Profile, or by flashing LEDs. These error indications serve as the entry point into the troubleshooting process. System problems not directly indicated by or associated with an error message or fault code are covered in Section 6, General Procedures. Print-quality problems are covered in Section 3, Image Quality.

The steps listed here are a guide for performing any service on this system. If you choose not to use these steps, it is recommended that you start at the appropriate troubleshooting procedure and proceed from there. When servicing the system, follow the safety measures detailed in Service Safety Summary.

1. Identify the problem.

• Verify the reported problem does exist.

• Check for any error codes and write them down.

• Print normal customer prints and service test prints.

• Make note of any print-quality problems in the test prints.

• Make note of any mechanical or electrical abnormalities present.

• Make note of any unusual noise or smell coming from the printer.

• Print a Service Usage Profile, if the printer is able to print.

• View the Engine Error and Jam Histories under the Service Tools menu.

• Verify the AC input from the wall outlet is within specifications.

2. Inspect and clean the system.

• Follow the cleaning instructions given in Section 6.

• Verify that the power cord is in serviceable condition.

• Restart the system to check if the error reoccurs.

3. Find the cause of the problem.

• Use the troubleshooting procedures to find the root 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 the troubleshooting procedure.

4. Correct the problem.

• Use the Parts List to locate a part number.

• Use the Repair procedures to replace the part.

5. Final checkout

• Test the printer to verify the problem is corrected and no new problems arose.

Accessing Engine Fault History

Listed below are three ways in which you can access fault history records.

1. Print (if possible) the Status page from the Troubleshooting menu --> Service Tools. The Engine Error History and Jam History are listed on the second page of the report.

2. View the system’s fault history on the Control Panel. Go to Troubleshooting->Service Tools --> Engine Error History.

NOTE: Definitions of the codes that appear in the Fault and Jam History appear in Section 2.

3. If the system is connected to a network and has a TCP/IP address, view the system’s web page using a web browser.

a. Open a web browser.

b. Enter the system’s IP address as the URL.

c. Select the Support --> Troubleshooting --> Diagnostics Logs and the fault history dis-

plays.

Technician’s Tool Kit

Tabl e 1 lists required, recommended, and optional tools used to service this and other similar

products.

Table 1 Service Tools

Description Detail

Required Tools

Torx Driver Bits T5, T8, T10, T15 (T20 P/N 003086600)

Phillips Drivers Phillips # 2 and # 1 5.0 x 75 mm, 3.0 x 75 mm, 6.0 x 100 mm

Flathead Drivers 5.0 x 75 mm, 3.0 x 75 mm

Torque Screw Driver Required for this system P/N 003082700

Driver Extension

Small Channel lock Pliers

Needle Nose Pliers

Wire Cutters

Flashlight

Assorted Nut Drivers

Lint-Free Cloths

Lubricant/Grease Reolube P/N 070E00890

Cleaners Multipurpose surface cleaner and Alcohol

ESD Strap

Highly Recommended Tools

Nut Driver 5.5mm (magnetic) P/N 600T2123

Serial Adaptor Cable 600T80374

Network Cross-over cable Tech

Scanner Calibration page P/N 109K01910

Toner Vac Toner and general cleaning

Multimeter Volts, Ohms, Current

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Service Call Procedures

Table 1 Service Tools

Description Detail

Optional Tools

Canned Air

3 -Prong Claw Part-Retriever

Pointer with Magnetized Head

Tweezers

Utility Knife

Dental Mirror

Screw Box

Soldering Iron

Heat Shrink tubing

Electrical Tape

Jeweler's Screwdriver Kit

Precision/Hobby tool set phillips, flathead, pliers, small torx drivers

Serial & Parallel Loop Back Plugs

Bootable CDs and Floppy Disks

IC Chip Puller

Initial Actions

Purpose

Use the following procedure to determine the reason for the service call and to identify and organize the actions which must be performed.

Procedure

1. Gather the information about the service call and the condition of the copier/printer.

a. Question the operator(s). Ask about the location of most recent paper jams. Ask

about the image quality and the copier/printer performance in general, including any unusual sounds or other indications.

b. After informing the customer that the machine will not be available for copying and

printing, disconnect the machine from the customer’s network.

c. If a new installation, be sure all packing material is removed.

d. Check that the power cords are in good condition, directly plugged in to the power

source, and free from defects. Repair or replace the power cords as required. Check that the circuit breaker, if present, is not tripped.

e. If the system appears is inoperative, go to Electrical Troubleshooting and repair the

problem. Then continue below.

f. Inspect any rejected copies. Inquire as to, or otherwise determine, the paper quality

and weight. Print the Paper Tips page for specific 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 procedure, go to that fault code RAP and repair the fault. Return to Diagnostics and continue with the procedure that you were performing.

g. Display and review the information in the Fault History, Jam History, Service Usage

Profile. Classify this information into categories:

Information that is related to the problem that caused the service call.

Information that is related to secondary problems.

Information that does not require action, such as a single occurrence of a problem.

2. Perform any required routine maintenance activities. Refer to the Routine Maintenance Activities section.

3. If any DADF feed jams are reported, or fault codes are logged, replace the Feed Roll Kit.

4. Try to duplicate the problem by running the same jobs that the customer ran once repairs are complete to verify repairs are effective.

5. Go to General Procedures to further investigate the problem.

Service Call Procedures

Service Call Procedures, Initial Actions

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Routine Maintenance Activities

Procedure

1. Clean the Pick Rollers on every call.

2. Use the Control Panel to check maintenance item counters.

3. Compare the counter values to those listed in Ta b l e 1 .

4. Advise the customer of any routine maintenance items that are approaching or over the service limit.

Table 1 Routine Maintenance Item Life Expectancy

Routine Maintenance Items

Extended-Capacity Maintenance Kit 30,000 cycles (0-20% coverage)

20,000 cycles (20-100%) coverage.

Standard-Capacity Maintenance Kit 10,000 cycles

Waste Tray Empty every 7 Purges

DADF Pick Rollers and Separator Pad 50,000 scans

Cleaning Procedures

Purpose

The purpose is to provide cleaning procedures to be performed at every call.

Procedure

CAUTION

Do not use any solvents unless directed to do so in this manual.

General Cleaning

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 Components (Rolls and Pads)

Follow the General Cleaning procedure above.

2. Jam Sensors

Clean the sensors with a dry cotton swab.

3. Scanner

a. Using the optical Cleaning Cloth, clean the Document Glass.

b. Clean the Document Cover.

4. DADF

Check the paper path for debris or damage. Clean the rolls with a clean cloth and Film Remover as required.

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Routine Maintenance Activities, Cleaning Proce-

Final Actions

Purpose

The intent of this procedure is to be used as a guide to follow at the end of every service call.

Procedure

1. Check that the exterior of the system and the adjacent area is clean. Use a dry cloth or a cloth moistened with water to clean the exterior of the system. Do not use solvents.

2. Check 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 understands the periodic maintenance procedures in the User Guide.

4. Reconnect the system to the customer network. Verify function by printing one or more test prints. Present these to the customer as examples of system performance.

5. Issue copy credits as needed.

6. Discuss the service call with the customer to ensure that the customer understands what has been done and is satisfied with the results of the service call.

Service Call Procedures

Final Actions

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Power On Self Tests ....................................................................................................... 2-3

NVRAM Reset................................................................................................................. 2-5

Error Message Troubleshooting ...................................................................................... 2-7

1,00X.4x 525-Sheet Feeder Faults ................................................................................. 2-8

1,000.6x 525-Sheet Feeder Program Faults................................................................... 2-9

2,00X.xx I/O Board Errors............................................................................................... 2-9

2,006.xx I/O Board Program Faults................................................................................. 2-10

2,0XX.6x Configuration Card Faults................................................................................ 2-10

3,0XX.6x IPC Program Faults ......................................................................................... 2-11

4,0xx.4x Process Control Errors ..................................................................................... 2-11

4,024.42 Wiper Alignment Fault...................................................................................... 2-12

4,025.46 Drum Transfix Fault.......................................................................................... 2-12

4,0xx.6x Process Control Program Faults....................................................................... 2-13

5,0xx.4x Y-Axis Sub-System Faults................................................................................ 2-13

5,0xx.6x Y-Axis Sub-System Program Faults ................................................................. 2-14

6,0xx.4x X-Axis Fault ...................................................................................................... 2-15

6,0xx.6x X-Axis Program Faults...................................................................................... 2-15

7,002.44 Process Drive Fault.......................................................................................... 2-16

7,006.4x Head Tilt Solenoid Fault ................................................................................... 2-16

7,007.49 Process Drive Fault.......................................................................................... 2-17

7,008.41 Printhead Tilt Fault ........................................................................................... 2-17

7,009.42 Printhead Restraint Fault ................................................................................. 2-18

7,01X.4x Process Faults ................................................................................................. 2-19

7,0xx.6x Program Faults ................................................................................................. 2-20

8,0XX.4x Wiper or Media Drive Faults ............................................................................ 2-21

8,0xx.6x Media Drive Program Faults............................................................................. 2-22

9,0XX.4x Ink Loader Faults ............................................................................................. 2-22

9,009.44 and 9,00X.6x Ink Loader Program Faults ........................................................ 2-23

11,0XX.xx Electronics Module Interface Faults............................................................... 2-24

11,100.60 Electronics Module Temperature Fault .......................................................... 2-25

11,300.6x EMC Motor Control Faults.............................................................................. 2-25

12,000.60 Program Faults............................................................................................... 2-26

13,000.48 Printhead Thermal Fault................................................................................. 2-26

13,003.42 and 13,007.46 Thermal Faults ....................................................................... 2-27

13,008.47 and 13,010.49 Drum Thermal Faults ............................................................. 2-27

13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults ......................................... 2-28

13,XXX.4x Preheater Thermal Faults ............................................................................. 2-29

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 Program Faults................................................................................. 2-32

19,0XX.4x Printhead Calibration Faults .......................................................................... 2-32

19,0XX.6x Waveform Program Faults............................................................................. 2-33

21,000.69 Diagnostic Firmware Version Mismatch......................................................... 2-33

22,0XX.6x Jam Fault....................................................................................................... 2-34

23,0XX.6x NVRAM Faults............................................................................................... 2-34

23,133.4x RAM Faults..................................................................................................... 2-35

2 Error Messages and Codes

26,0XX.6x Printing Faults................................................................................................ 2-35

27,0XX.6x Profile Library................................................................................................. 2-36

29,0XX.6x Jam Manager Faults ...................................................................................... 2-36

31,001.40 Mechanical Initialization Jam.......................................................................... 2-37

31,0XX.6x Program Faults .............................................................................................. 2-37

33,00X.4x Tray 1 Width Sensor Faults............................................................................ 2-38

34,00X.4x Printhead NVRAM Faults ............................................................................... 2-38

34,01X Ink Level Sense Faults........................................................................................ 2-39

36,000.40 Drum Maintenance Faults .............................................................................. 2-40

36,001.67 Drum Maintenance Drive Faults..................................................................... 2-41

36,002.44 Drum Maintenance Kit Fault........................................................................... 2-41

37,0XX.xx PEST Heater Faults....................................................................................... 2-42

37,01X.41 PEST Fan Faults............................................................................................ 2-42

37,016.43 PEST 50 Volt Supply Fault............................................................................. 2-43

37,0XX.4x PEST Clutch/Solenoid Faults ........................................................................ 2-44

37,024.48 PEST Tray 2 Lift Motor Fault.......................................................................... 2-44

37,026.44 PEST Purge Pump Fault ................................................................................ 2-45

37,02X.4x PEST Relay Board Faults .............................................................................. 2-45

37,03X.4x PEST X-Axis Motor Faults ............................................................................. 2-46

37,035.44 and 37,036.45 PEST Y-Axis Motor Faults...................................................... 2-46

37,037.46 and 37,038.47 PEST Media Drive Faults....................................................... 2-47

37,039.48 and 37,040.40 PEST Process Drive Faults.................................................... 2-47

37,0XX.4x PEST Power Supply Faults ........................................................................... 2-48

39,002.40 and 39,003.41 Scanner Subsystem Test Faults ............................................ 2-49

39,004.42 Scanhead Locked or Shipping Restraint Faults ............................................. 2-49

39,005.43 Scanner Missing Fault.................................................................................... 2-50

39,010.8 Document Feeder Disconnected or Missing .................................................... 2-51

39,011.40 and 39,012.40 DADF Subsystem Test Faults ................................................ 2-51

39,013.42 Document Feeder Jam................................................................................... 2-52

39,014.43 Document Feeder Calibration Fault ............................................................... 2-52

Jam Codes ...................................................................................................................... 2-53

Initial Issue

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Error Messages and Codes

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Initial Issue

Phaser 8860/8860MFP Service Manual

Power On Self Tests

This section covers the start-up, Power On Self Test (POST), Service Diagnostics, and power supply operations of the system to aid in troubleshooting problems not associated with a reported error. For problems associated with an error message or code, see Error Message

Troubleshooting. Troubleshooting tips are available at: www.xerox.com/support.

Check the main menu for current data and historical error data.

• Status Page

• Usage Profile

• Fault History

• Diagnostic History

Power-Up Error Messages and LED Codes

The system has three sets of tests that are run when first powered on:

• Built-In Self Tests (BIST)

• Power On Self Tests (POST)

• Print Engine Self Tests (PEST)

NOTE: BIST and POST errors are not stored in the fault history logs.

In addition to the numeric error codes appearing on the Control Panel display, the system uses the Control Panel, PS, and PE LEDs to communicate errors. Figure 1 shows location of the PS and PE LEDs on the Electronics Module.

BIST Error Reporting

BIST verifies basic Electronics Module CPU operation and reports failures using PS and PE LEDs. These LEDs are located on the Electronics Module directly above the Scanner Assembly connection. BIST tests occur immediately at power-up, before POST tests are run or the Control Panel is initialized.

The following table defines the blink patterns associated with a failure:

Table 1 BIST Blink Pattern Error Reporting

PE LED PS LED Description

Off or 1 blink, then Off

On solid (dim) On solid (dim) Initialization failure. The system is held in reset mode. This

Off PS and Control

1 Rapid Blinking The CPU and/or PCI bus is not communicating. Reboot the

2 Rapid Blinking ROM not responding. Reboot the system, if the error still

3 Rapid Blinking System hangs during initialization

Off or 1 blink, then Off

Panel blink at 1/ 2 sec. intervals

The power supply could not remain regulated when DC power was applied so it shut down. Follow the troubleshooting procedures for electrical shorts (see Electrical Trouble-

shooting) and check the power supply fuses.

can be caused by an Electronics Module fault or a +3.3 V power supply failure. See Electrical Troubleshooting.

Boot loader memory test failure. Ensure the systems RAM is properly seated and that the correct RAM type is installed.

system. If the error persists, replace the Electronics Module (REP 5.0.5).

occurs, replace the Electronics Module (REP 5.0.5).

1. Unplug all connections to the Electronics Module.

2. Plug in the Power Cable.

3. Power on the system.

4. If the problem persists, reseat the RAM Modules.

5. Replace the Electronic Module (REP 5.0.5).

Figure 1 PS and PE LED Locations

Initial Issue

Phaser 8860/8860MFP Service Manual

POST Error Reporting

POST checks the communication paths within the Electronics Module and to other various system components

POST testing initializes the Control Panel, and in most cases if an error occurs, a text message is displayed on the Control Panel along with an LED blink code 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 the error code. If the code has more than 5 flashes, there is a brief pause between each set of 5 flashes to make them easier to count. After all flashes occur within the code, there is a long pause and then the flash pattern repeats.

“Soft” POST errors, that do not prevent the system from powering up completely, are displayed on the Control Panel for 5 seconds, and then the system continues through the remainder of POST. There are no rear panel LED codes associated with soft errors. Most soft errors will cause the system to print a Startup Page with the error message on it.

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Error Messages and Codes

Power On Self Tests

NOTE: Before replacing the Electronics Module for any POST errors, do the following:

1. Unplug all wiring and/or cables to the Electronics Module.

2. Plug in the AC power cable and power on the Electronics Module.

3. If the error blink pattern is now different from the original error reported before Step 1, the problem may not be in the Electronics Module. See Electrical Troubleshooting.

Table 2 POST Blink Pattern Error Reporting

Error

PS, PE, and Control

Code

Panel LED s

01.01 Flutter then 01 blinks Hard Bad error code

02.01 Flutter then 02 blinks Hard Failed machine check

02.02 Flutter then 02 blinks Hard System panic

03.01 Flutter only Soft ID read failure

03.02 Flutter then 03 blinks Hard Mismatch

03.03 Flutter only Soft Version mismatch

03.04 Flutter then 03 blinks Hard Access failure

04.01 Flutter then 04 blinks Hard ID read failure

04.02 Flutter then 04 blinks Hard ID mismatch

04.03 Flutter then 04 blinks Hard TMVL mismatch, read/write failed

04.04 Flutter then 04 blinks Hard TMVL mismatch, read/write failed

05.01 Flutter then 05 blinks Hard I/O Board serial communication error.

05.02 Flutter only Soft I/O Board serial mismatch error.

6.08 No indication Soft Hard Drive failure

07.01 Flutter only Soft Control Panel communications error

07.02 Flutter only 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 failure

10.02 Flutter only Soft Power control link invalid, mismatch error

11.01 Flutter then 11 blinks Hard EEPROM read failure

11.02 Flutter then 11 blinks Hard EEPROM write failure

11.03 Flutter then 11 blinks Hard EEPROM re-read failure

11.04 Flutter then 11 blinks Hard EEPROM data failure

12.nn Flutter only Soft Configuration Card failure

13.01 Flutter then 13 blinks Hard PHY reset failure (Low)

13.02 Flutter then 13 blinks Hard PHY ID error

14.nn Flutter then 14 blinks Hard USB ASIC error

15.01 Flutter then 15 blinks Hard CPU interrupt error

15.02 Flutter then 15 blinks Hard CPU interrupt error

15.03 Flutter then 15 blinks Hard CPU interrupt error, IRQ

15.04 Flutter then 15 blinks Hard CPU interrupt error

15.05 Flutter then 15 blinks Hard CPU interrupt error

15.06 Flutter then 15 blinks Hard CPU interrupt error

Error Type Description

Table 2 POST Blink Pattern Error Reporting

Error

PS, PE, and Control

Code

Panel LED s

15.07 Flutter then 15 blinks Hard CPU interrupt error

15.08 Flutter then 15 blinks Hard CPU interrupt error

15.09 Flutter then 15 blinks Hard CPU interrupt error

15.10 Flutter then 15 blinks Hard CPU interrupt error

15.11 Flutter then 15 blinks Hard CPU interrupt error

16.01 Flutter only Soft Real Time Clock read failure

16.02 Flutter only Soft Real Time Clock write failure

16.03 Flutter only Soft Real Time Clock re-read failure

16.04 Flutter only Soft Real Time Clock failure

17.01 Flutter then 17 blinks Hard Insufficient RAM memory

18.01 Flutter then 18 blinks Hard IPCB ID read failure

18.02 Flutter then 18 blinks Hard IPCB ID mismatch

18.03 Flutter then 18 blinks Hard IPCB PCI configuration failure

18.04 Flutter only Soft IPCB version mismatch

19.01 Flutter then 19 blinks Hard Hard Drive failure

PEST Error Reporting

PEST tests occur after POST tests have been run and PostScript has been initialized. PEST checks the connections and operation of various system components.

Error codes for PEST tests are displayed on the Control Panel and are all in the 37,XXX.xx series. For troubleshooting PEST error codes, see Error Message Troubleshooting.

Error Type Des cription

Error Messages and Codes

Power On Self Tests

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Initial Issue

Phaser 8860/8860MFP Service Manual

NVRAM Reset

Many of the troubleshooting procedures in this section include an NVRAM reset as a procedural step. Following an NVRAM reset, the system is unable to communicate on the network and has lost several parameters specific to the customer’s configuration. If possible, print a Configuration page to capture networking parameters. and discuss the customer’s configuration to document these settings before resetting NVRAM.

Ta b l e 1 lists the parameters reset by NVRAM Reset. Required parameters (Yes) must be con-

figured to restore default system operation on the network.

Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command

Menu Parameter Default Required

TCP/IP Setup TCP/IP On Yes

DHCP/BOOTP On Yes

AutoIP On Yes

TCP/IP Address 0.0.0.0 Yes

TCP/IP Network Mask 0.0.0.0 Yes

TCP/IP Gateway 0.0.0.0 Yes

Port 9100 On Yes

LPR On Yes

IPP On Yes

SLP On Yes

SSDP On Yes

CentreWare IS On Yes

Network Setup Ethernet Speed Auto Yes

EtherTalk On Yes

USB Setup USB Port On Yes

Wait Timeout (USB) 30 Yes

Page Description Language (USB) AutoSelect Yes

Control Panel Setup Control Panel Language English No

Control Panel Brightness 5 No

Control Panel Contrast 5 No

Accessible Control 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 Balance -> Magenta Color Balance 0 No

Color Balance -> Yellow Color Balance 0 No

Color Balance -> Black Color Balance 0 No

Laser Original Off No

Prescan Glass On No

Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command

Menu Parameter Default Required

Copy Main Number of Copies 1 No

Paper Suppy Tray 2 No

Original Size Supply No

Prescan Glass On No

Preset Reduce/Enlarge None No

Collate Auto No

Edge Erase -> Left 0.0 No

Edge Erase -> Right 0.0 No

Edge Erase -> Top 0.0 No

Edge Erase -> Bottom 0.0 No

Margin Shift -> Long Edge 0.0 No

Margin Shift -> Short Edge 0.0 No

Auto Center Off No

Book Copy -> Both Pages ->Gutter Erase 0.0 No

Book Copy -> Left Page -> Gutter Erase 0.0 No

Book Copy -> Right Page -> Gutter Erase 0.0 No

Auto Suppression Off No

Covers -> Cover Tray Tray 1 No

Blank Separator Off No

Blank Separator Tray Tray 2 No

Create Booklet (8860MFP Only) Off No

Repeat Image (8860MFP Only) Off No

Repeat Image -> Rows 1 No

Repeat Image -> Columns 1 No

N-Up Off No

Poster Off No

Color Balance -> Cyan Color Balance 0 No

Color Balance -> Magenta Color Balance 0 No

Color Balance -> Yellow Color Balance 0 No

Color Balance -> Black Color Balance 0 No

Laser Original Off No

Fax Main Fax To None No

Resolution Standard No

Original Size Automatic No

Auto Suppression Off No

Transmission Report On No

Starting Rate Super G3 No

Initial Issue

Phaser 8860/8860MFP Service Manual

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2-5

Error Messages and Codes

NVRAM Reset

Table 1 Parameters Reset with the Service Diagnostics NVRAM Reset Command

Menu Parameter Default Required

Fax Send Setup Transmission Report Never No

Reduced Image (8860 only) Off Yes

Redial Count 3 No

Redial Time Interval 15 No

Auto Resend Policy Unsent Pg Yes

Auto Resend Count 3 Yes

Document Type Mixed No

Resolution Standard No

Transmission Header (8860 only) On No

Fax Receive Setup Paper Suplly Tray 2 Yes

Fax Receive On Yes

Answer Delay 0 Yes

Secure Receive (8860 only) Off Yes

Secure Receive Password (8860 only) None Yes

Junk Fax Prevention Off Yes

2-Sided Fax Printing 1-1 No

Fax Configuration Line Name None Yes

Dial Type Tone Yes

Line Monitor Volume 2 No

Auto Activity Report Off No

Starting Rate Super G3 Yes

Error Correction Mode On Yes

Fax Configuration Dial Pause 3 No

Dial Delay 0 No

Max Compression JBIG/MMR No

File Security Daily Removal Off Yes

Remove At 00:00 Yes

Age-based Removal Off Yes

Remove at Age 24 Yes

Paper Handing Setup Load Paper Timeout 3 min. No

Tray 1 Mode Dynamic No

Tray 1 Prompt 30 sec. No

Tray 2 ~ [N] Mode Dynamic No

Tray 2 ~ [N] Prompt None No

Letter/A4 Substitution On No

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

Auto Clear Timeout 60 sec. No

Power Saver Timeout 4 hours No

Date and Time None No

Intelligent Ready On No

Default Function Copy No

Color Copy Password Disabled No

Print Job Interrupt (8860 only) On No

Paper Tray Setup Tray 1 Paper - Media Size Guide Size No

Tray 1 Paper - Media Type Plain No

Tray 2 Paper - Media Type Plain No

Tray 3 Paper - Media Type (if installed) Plain No

Tray 4 Paper - Media Type (if installed) Plain No

Print Defaults Setup Paper Source Auto No

2-Sided Printing Disabled No

PS-PCL Setup Pitch 10.00 No

Point Size 12.00 No

Symbol Set PC8 No

Oreientation Portrait No

Form Length 6 No

Line Termination On No

Draft Mode Off No

Color Mode Color No

Scan Default Setup Color Mode Color No

Document Type Mixed No

Scan Resolution 100x100 No

Laser Original Off No

Scan Main Scan To Public No

Scan Resolution 100x100 No

Original Size Automatic No

Auto Suppression Off No

Laser Original Off No

Tabl e 2 summarizes system parameters not affected by an NVRAM Reset.

Table 2 System Parameters Not Affected by an NVRAM Reset

Parameter Comment

Metric Defaults

MAC Address Set by the Configuration Card

Serial Number

Model number

Error Messages and Codes

NVRAM Reset

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Initial Issue

Phaser 8860/8860MFP Service Manual

Table 2 System Parameters Not Affected by an NVRAM Reset

Parameter Comment

License Number

PostScript Version

PostScript Revision

Activation Date The activation date is stored in Usage Profile NVRAM.

Adobe Serial Number

System Date and Time

Fax Country Fax Configuration

Fax Line ID Fax Configuration

Overwrite Removals File Security

Speed Dial Individual Directory Fax Send

Speed Dial Group Directory Fax Send

Tray Media Types and Sizes Unconfirmed following NVRAM Reset.

Metered Supplies Metered operation

Print Counter System Print Count

Billing Meters

Substituted Jets Jet Substitution Mode

Warm-up Mode Set in CWIS

Warm-up Settings Set in CWIS

Stand-by Settings Set in CWIS

Error Message Troubleshooting

This section covers troubleshooting procedures utilizing Control Panel error messages and codes. Some procedures require running Service Diagnostic test functions to verify that a component is operating correctly. Procedures that direct a test to be run are referencing tests from within the Hidden Service menu. For information on Service Diagnostics, see Ser vice Diagnos-

tics.

For troubleshooting problems not associate with an error code or message, such as startup or power on, media, paper path, print-quality or image problems, and electrical failures, see Gen-

eral Troubleshooting.

Fault Code Error Reporting

Fault codes are saved to NVRAM and can be retrieved from the printer’s fault history.

In normal customer mode, the printer will reboot each time an error occurs. If three of the same errors occur within 72 hours, or 1000 pages, the fault will be displayed on the printer’s Control Panel.

Interpreting Fault Codes

• Failing system (XX,yyy.zz)

• Failing subsystem (xx,YYY.zz)

• Checksum (xx,yyy.zZ)

• Type of problem (xx,yyy.Zx)

• Print engine page count when the error occurred (xx,yyy.zz:123)

Device faults are indicated by a 4 in the tenths place of the fault code (xx,yyy.4x). This indicates a hardware problem. The most common device faults troubleshooting procedures are documented in this section.

Initial Issue

Phaser 8860/8860MFP Service Manual

Program faults are indicated by a 6 in the tenths place of the fault code (xx,yyy.6x). Unfortunately, there are too many program faults to enumerate them all and most program faults will not mean anything unless you are intimately familiar with the code base. Some of the more common program faults are documented in this section.

CPU exceptions are indicated by a 7 in the tenths place of the fault code (xx,yyy.7z). The error code indicates both the Power PC exception number and the region of firmware that was executing when the exception occurred: Engine, PostScript, Network, or Operating System.

NOTE: A CPU exception can either be caused by hardware or firmware error. Refer to the infoSMART Knowledge Base for descriptions of the most common faults.

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NVRAM Reset, Error Message Troubleshooting

Error Messages and Codes

1,00X.4x 525-Sheet Feeder Faults

The following troubleshooting procedure applies to these errors:

525-Sheet Feeder Errors

1,001.46 An over current condition was detected in the upper 525-Sheet Feeder.

The lift motor or clutch may be shorted.

1,002.47 An over current condition was detected in the lower 525-Sheet Feeder.

The lift motor or clutch may be shorted.

Initial Actions

• Check the tray to ensure it is free of obstructions or debris.

• Check the operation of the Tray Lift Plate.

• Check the condition of the Feed and Pick Rollers.

• Reseat the optional tray connection to the system.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 1,000.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

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 Questions or Actions Yes No

5 Check the wiring from the feeder to Elec-

tronics Module. Is the wiring defective?

6 Check ground integrity.

Are the system grounds connected?

Replace the harness. If the error persists, go to Step 6.

Reset NVRAM. If the error persists, replace the feeder.

Replace the feeder.

Reconnect the system grounds.

Troubleshooting Procedure

Table 2 525-Sheet Troubleshooting Procedure

Step Questions or Actions Yes No

1 Remove the 525-Sheet Feeder and check

the connections for damage. Are the connectors damaged?

2 Check the Pick Assembly for dirt, damage,

or wear. Are the rollers damaged or worn?

3 Test the Pick Clutch.

Run the Service Diagnostics Pick Clutch test for the affected tray. Does the Pick Clutch operate correctly?

4 Test the Lift Motor.

Run the Service Diagnostics Lift Motor test for the affected tray. Does the Lift Motor operate correctly?

Error Messages and Codes

Replace the damaged connections.

Replace the Pick Assembly (REP

3.0.18).

Go to Step 3. Replace the feeder.

1,00X.4x

Go to Step 2.

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Initial Issue

Phaser 8860/8860MFP Service Manual

1,000.6x 525-Sheet Feeder Program Faults

A firmware error has occurred. The following troubleshooting procedure applies to these errors:

2,00X.xx I/O Board Errors

The following troubleshooting procedure applies to these errors:

525-Sheet Feeder Program Errors

1,006.x The 525-Sheet Feeder has encountered a program fault.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 1,000.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 525-Sheet Feeder Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

I/O Circuit Board Errors

2,001.47 The Print Engine does not detect the I/O Board

Initial Actions

• Check the I/O Board for obvious signs of damage.

• Check that all connections to the board are secure by reseating each connection.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 2,00X.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

I/O Board, PL 5.0 Right Side Harness / I/O Control - Figure 8

Right Side Harness, PL 5.0 Right Side Wire Routing (1/2) - Figure 2

I/O Board Power Control Cable, PL 5.0

Right Side Wire Routing (1/2) - Figure 2

Troubleshooting Procedure

Table 2 I/O Board Error Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the I/O Board for damage.

Are the connectors damaged?

2 Reseat all I/O Board connections.

Does the problem persist?

3 Check I/O Power Control Cable continuity

between P/J840 on the I/O Board and P/

J10 on the Electronics Module.

Is the wiring defective?

Repair the damaged connections.

Go to Step 3. Complete.

Replace the cable. If the error persists, replace the I/O Board.

Go to Step 2.

Replace the I/O Board (REP 5.0.13).

Initial Issue

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Error Messages and Codes

1,000.6x, 2,00X.xx

2,006.xx I/O Board Program Faults

The following troubleshooting procedure applies to these errors:

2,0XX.6x Configuration Card Faults

The following troubleshooting procedure applies to these errors:

I/O Board Program Faults

2,001.69 The Electronics Module Failed to initialize.

2,002.61 Firmware program fault

2,003.62 Firmware program fault

2,004.63 Failure to start the Print Engine in Suspend Mode.

2,005.64 ROM read error

2,006.65 ROM read error

2,007.66 idiags entry point access error

Initial Actions

• Reset NVRAM and retest.

• Check that all connections to the Electronics Module and I/O Board are secure by reseating each connection.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

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

Troubleshooting Procedure

Table 2 I/O Board Error Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all I/O Board connections.

Does the problem persist?

2 Reseat all Electronics Module connec-

tions. Does the problem persist?

3 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Go to Step 3. Complete.

Replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

I/O Board Program Faults

2,008.67 The Configuration Card is Missing

2,009.68 The Configuration Card is Bad

2,010.69 The Configuration Card is Blank

2,011.61 The Configuration Card is for the wrong product

2,012.62 The Configuration Card is an invalid model

Initial Actions

• Turn Off the system.

• Check that the Configuration Card is correct for the system.

• Turn the system On.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 2,006.xx Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0

Configuration Card, PL 5.0

Troubleshooting Procedure

Table 2 Configuration Card Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Replace the Configuration Card, restart

the system, and retest. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

3 Replace the Electronics Module.

Does the problem persist?

Go to Step 2. Complete.

Go to Step 3. Reconnect the sys-

tem grounds.

Complete.

Error Messages and Codes

2,006.xx, 2,0XX.6x

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Initial Issue

Phaser 8860/8860MFP Service Manual

3,0XX.6x IPC Program Faults

A firmware communications error has occurred. The following troubleshooting procedure applies to these errors:

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 3,000.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

4,0xx.4x Process Control Errors

The following troubleshooting procedure applies to these errors:

Process Control Errors

4,017.47 The ambient temperature is too low ( < 10°C).

4,018.48 The Printhead temperature is too low.

4,020.41 Fast Time To Ready (FTTR) mode with head/cap flag set in NVRAM.

4,021.42 Fast Time To Ready (FTTR) mode with a dirty Drum.

Initial Actions

• Check the ambient air temperature.

• Check that the system is located in a suitable environment.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 2 I/O Board Error Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Table 1 4,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0 Right Side Wire Routing (2/2) - Figure 3

Printhead, PL 2.0 Electronics Module - Figure 6

Drum Assembly, PL 2.0 Electronics Module Power - Figure 7

Drum Heater Relay Board, PL 5.0 Right Side Wire Routing (1/2) - Figure 2

Drum Temperature Sensor, PL 6.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedure

Table 2 Process Control Error Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the heaters.

Run the Service Diagnostics Monitor Heaters tests with all heaters On. Do the heaters function properly?

2 Check the harness to the failed heater.

Is the harness damaged?

Replace the Electronics Module (REP

5.0.5).

Replace the harness.

Go to Step 3.

Replace the failed component.

Initial Issue

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2-11

Error Messages and Codes

3,0XX.6x, 4,0xx.4x

4,024.42 Wiper Alignment Fault

The following troubleshooting procedure applies to this error:

4,025.46 Drum Transfix Fault

The following troubleshooting procedure applies to this error:

Wiper Blade Misalignment Errors

4,024.42 Printhead Wiper Blade misaligned

Initial Actions

• Check Wiper Alignment.

• Check damage, debris, or Ink build-up near the Printhead.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 4,024.42 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Head Maintenance Clutch, PL 4.0 I/O Board (2/2) - Figure 12

Media Drive Assembly, PL 4.0 Left Side Harness (2/2) - Figure 7

Wiper Blade, PL 2.0

Troubleshooting Procedure

Table 2 4,024.42 Wiper Alignment Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Wiper alignment.

Run the Service Diagnostics Check Wiper Alignment test. Did the test Fail?

2 Test the Wiper drive.

Run the Service Diagnostics Wiper Drive test. Did the test fail?

3 Check the Wiper drive and lock systems

for ink, obstructions, or damage. Is the Wiper drive function correctly?

4 Check the Head Maintenance Clutch.

Is there any oil, contamination, or obvious damage?

5 Test the Head Maintenance Clutch.

Run the Service Diagnostics Head Maintenance Clutch test. Does the clutch function correctly?

Perform (ADJ 2.5.1) and retest. If the test fails again, go to Step 2.

Go to Step 3. Go to Step 5.

Go to Step 4. Clear any ink or

Clean the interior of the system or replace the clutch if necessary.

Replace in order: Exit Module Media Drive Assy Wiper Blade

Go to Step 2.

obstructions or replace any damaged components.

Go to Step 5.

Replace the Head Maintenance Clutch (REP 4.0.4).

Drum Transfix Fault

4,025.46 Drum Transfix does not reach home position.

Initial Actions

• Check for dirt, debris, or obstructions around the Printhead.

• Check that the Waste Tray is correctly installed.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 4,025.46 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 5.0 Right Side Harness / I/O Control - Figure 10

X-Axis Motor, PL 2.0 Right Side Harness / I/O Control - Figure 10

Head Tilt Solenoid, PL 5.0 Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 4,025.46 Drum Transfix Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check for ink build up in the Head Tilt

drive, Waste Tray, or wires interfering with Printhead motion. Is the Printhead clear of obstructions?

2 Check the Process Drive for damage.

Ensure the gears are correctly aligned (see ADJ 4.7.1). Is the process gearbox damaged?

3 Check the X-Axis Motor connection (P/

J150).

Run the Service Diagnostics X-Axis Motor test. Did the test fail?

4 Test the Printhead Tilt Drive.

Run the Service Diagnostics Tilt Drive test. Did the test fail?

Go to Step 11. Clear any obstruc-

Replace the Process Drive (REP

4.0.7).

Replace the X-Axis Motor (REP 4.0.5).

Replace the Process Drive (REP

4.0.7).

tions to Printhead movement. If the error persists, go to Step 2.

Go to Step 3.

Go to Step 4.

Error Messages and Codes

4,024.42, 4,025.46

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2-12

Initial Issue

Phaser 8860/8860MFP Service Manual

4,0xx.6x Process Control Program Faults

A firmware communications error has occurred. The following troubleshooting procedure applies to these errors:

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 4,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Process Control Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

5,0xx.4x Y-Axis Sub-System Faults

The following troubleshooting procedure applies to these errors:

Y-Axis Sub-System Faults

5,001.41 The Drum rotated once without a Drum Home Position Sensor activation.

5,002.42 The Y-Axis Encoder is faulty, or the Drum has stalled.

5,003.43 Problem in the Y-Axis sub-system.

5,004.44 Problem with the Y-Axis motion sub-system.

Initial Actions

• Check for obstructions or debris.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 5,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Y- A x i s B e lt , PL 2.0

Y--Axis Motor, PL 4.0 Electronics Module Power - Figure 9

Drum Assembly (Encoder) Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedure

Table 2 Y-Axis Sub-System Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Y-Axis Encoder.

Run the Service Diagnostics Y-Axis Encoder test from the Monitor menu. Did the test pass?

2 Check the Y-Axis Motor connection (P/

J18).

Is the wiring faulty?

3 Check the Y-Axis Encoder wiring.

Is the wiring faulty?

4 Test the Y-Axis Drive.

Run the Service Diagnostics Y-Axis Drive test. Did the test pass?

5 Test Y-Axis Belt tension.

Run the Service Diagnostics Y-Axis Belt Tension test. Did the test pass?

Go to Step 2. Go to Step 3.

Replace the wiring. Go to Step 4.

Replace the wiring. Replace the Drum

Assy (REP 2.0.3).

Go to Step 5. Replace the Y-Axis

Motor (REP 4.0.11).

Go to Step 6. Replace the Y-Axis

Belt (REP 2.0.4).

Initial Issue

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Error Messages and Codes

4,0xx.6x, 5,0xx.4x

Table 2 Y-Axis Sub-System Faults Troubleshooting Procedure

Step Questions or Actions Yes No

6 Test the Y-Axis Motor.

Run the Service Diagnostics Y-Axis Motor test. Did the test pass?

Replace the Drum Assembly (REP

2.0.3).

Replace the Y-Axis Motor (REP 4.0.11).

5,0xx.6x Y-Axis Sub-System Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

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, software fault.

5,006.68 Software fault.

5,007.60 Software fault.

5,008.61 PostScript failed to fill the buffer.

5,009.62 Imaging errors. Possible jets On/Off outside the deadband area.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 5,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Y-Axis Sub-System Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Error Messages and Codes

5,0xx.4x, 5,0xx.6x

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Initial Issue

Phaser 8860/8860MFP Service Manual

6,0xx.4x X-Axis Fault

An X-Axis drive error has occurred. The following troubleshooting procedure applies to this error:

X-Axis Motor Error

6,000.41 X-Axis Motor current error.

Initial Actions

• Check for Ink build-up or other obstructions around the Printhead.

• Check the Printhead power (P/J4) connection and related wiring.

• Verify the Printhead travels smoothly from left to right.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 6,0xx.4x Troubleshooting Reference Table

Applicable 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

6,0xx.6x X-Axis Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

X-Axis Program Faults

6,001.64 The X-Axis task received an unexpected message.

6,002.65 Attempt to home X-Axis drive from wrong state.

6,008.62 Attempt to use X-Axis drive without initialization.

6,011.65 Attempt to service X-Axis drive in wrong state.

6,013.67 Unknown X-Axis program fault.

6,017.62 Attempt to drive X-Axis using wrong server.

6,018.63 Attempt to move with the X-Axis not initialized.

6,019.64 Attempt to move with the X-Axis not at home position.

6,023.68 Could not allocate memory for X-Axis parameters.

6,025.66 Attempt to home the X-Axis drive without initialization.

6,032.68 Unrecognized X-Axis motion.

6,033.60 Could not allocate memory for X-Axis move parameters.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Troubleshooting Procedure

Table 2 Process Control Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the X-Axis Motor wiring.

Is the wiring faulty?

2 Test the X-Axis Motor.

Run the Service Diagnostics X-Axis Motor test. Did the test pass?

Initial Issue

Phaser 8860/8860MFP Service Manual

Replace the wiring. Go to Step 2.

Replace the X-Axis Motor (REP 4.0.5).

Replace the Electronics Module (REP

5.0.5).

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 6,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

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Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Error Messages and Codes

6,0xx.4x, 6,0xx.6x

7,002.44 Process Drive Fault

A Process Drive error has occurred. The following troubleshooting procedure applies to this error:

7,006.4x Head Tilt Solenoid Fault

A Printhead tilt error has occurred. The following troubleshooting procedure applies to this error:

Process Faults

7,002.44 The Process Drive stalled during operation.

Initial Actions

• Check that the Process Drive gear train is properly homed.

• Check for obstructions in or around the Process Drive gearbox.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,002.44 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedure

Table 2 Process Drive Fault 7,002.44 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?

2 Test the Tilt Axis Drive.

Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?

3 Check the Process Drive for damage,

debris, or obstructions. Is there any damage?

4 Test the Process Drive Motor.

Run the Service Diagnostics Process Motor Test. Did the test fail?

5 Test the Transfix Cams

Run the Service Diagnostics Transfix Drive Slow test. Do the Transfix Cam operate correctly?

Perform ADJ 4.7.1. Go to Step 2.

Go to Step 3. Go to Step 4.

Replace the Process Drive (REP

4.0.7).

Replace the Process Drive (REP

4.0.7).

Replace the Process Drive (REP

4.0.7).

Go to Step 4.

Go to Step 5.

Verify the transfix cams are not damaged. If the error persists, replace the Transfix Cam Shaft (REP 2.0.10).

Process Faults

7,006.xx The Head Tilt Solenoid is not activating the Head Tilt Cam, or the Print-

head is not tilting properly.

Initial Actions

• Check for obstructions or ink spills around the Printhead.

• Verify the Printhead travels smoothly from left to right.

• Check the Printhead Restraint Arms.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Head Tilt Gear, PL 4.0

Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2) - Figure 7

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedures

The Head Tilt Solenoid is not activating the Head Tilt Gear, or the Printhead is not tilting properly

Table 2 Head Tilt Solenoid Faults 7,006.xx 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?

2 Reboot the system.

Is the tilt-head activating the Head Tilt Gear.

3 Check for Ink spills on or near the Head

Tilt Gear.

4 Review instructions for 7,008.xx and

7,010.xx fault codes.

Perform ADJ 4.7.1. Go to Step 2.

Go to Step 4. Go to Step 3.

Remove ink spills or reinstall the head-tilt and start over with Step 1.

Follow recommended actions for error codes and reboot the printer.

Go to Step 4.

Error Messages and Codes

7,002.44, 7,006.4x

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Initial Issue

Phaser 8860/8860MFP Service Manual

7,007.49 Process Drive Fault

A Process Drive or Printhead error has occurred. The following troubleshooting procedures applies to this error:

7,008.41 Printhead Tilt Fault

A Process Drive or Printhead error has occurred. The following troubleshooting procedure applies to this error:

Process Drive Fault

7,007.49 The Process Drive stalled while tilting the Printhead.

Initial Actions

• Check that the Process Drive gear train is properly homed.

• Check for obstructions or ink spills around the Printhead.

• Verify the Printhead travels smoothly from left to right.

• Check the Printhead Restraint Arms.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,007.49 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedure

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?

2 Remove the Printhead and inspect the

Head Tilt Gear, Spring, and Process Drive gears for ink spills. Clean if necessary. Does the error persist?

3 Realign the Process Drive (ADJ 4.7.1).

Does the error persist?

Perform ADJ 4.7.1. Go to Step 2.

Go to Step 3. Complete.

Replace the Process Drive (REP

4.0.7).

Complete.

Process Faults

7,008.41 Printhead tilt is not engaged, or the Printhead is stuck in the tilt position.

Initial Actions

• Check that the Process Drive gear train is properly homed.

• Check for obstructions or ink spills around the Printhead.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,008.41 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2) - Figure 7

Head Tilt Gear, PL 4.0

Troubleshooting Procedure

The Head Tilt Solenoid is not activating the Head Tilt Cam, or the head is not tilting properly

Table 2 Head Tilt Solenoid Faults 7,008.41 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reboot the system.

Does the error persist?

2 Check for Ink spills on or near the Head

Tilt Gear. Clean and reboot the system. Does the error persist?

3 Check that the Printhead moves properly

to the left and right. Does the Printhead move correctly?

4 Realign the Process Drive (ADJ 4.7.1).

Does the error persist?

5 Check the Process Drive for damage,

debris, or obstructions. Is there any damage?

6 Test the Tilt Axis Drive.

Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?

Go to Step 2. Complete.

Go to Step 3. Complete.

Go to Step 4. Remove any

obstructions or replace any defective parts.

Go to Step 5. Complete.

Replace the Process Drive (REP

4.0.7).

Go to Step 7. Replace the Pro-

Go to Step 6.

cess Drive (REP

4.0.7).

Initial Issue

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Error Messages and Codes

7,007.49, 7,008.41

Table 2 Head Tilt Solenoid Faults 7,008.41 Troubleshooting Procedure

Step Questions or Actions Yes No

7 Test the Head Maintenance Clutch.

Run the Service Diagnostics Head Maintenance Wiper Clutch test. Does the clutch operate correctly?

8 Check the Printhead Wiper alignment.

Is the Printhead Wiper properly aligned?

9 Test the Wiper Drive.

Run the Service Diagnostics Wiper Drive test. Does the Wiper Drive operate correctly?

Go to Step 8. Replace the clutch

Go to Step 9. Perform ADJ 2.5.1.

Replace the Exit Module (REP 3.0.7).

(REP 4.0.4).

Repair or replace the Wiper Drive.

7,009.42 Printhead Restraint Fault

A Process Drive or Printhead error has occurred. The following troubleshooting procedure applies to this error:

Process Faults

7,009.42 Printhead is tilted back, but not properly restrained.

Initial Actions

• Check for obstructions or ink spills around the Printhead.

• Check the Printhead Restraint Arms.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,009.42 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Restraint Arms, PL 2.0

Head Maintenance Clutch, PL 4.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedure

The Printhead is tilted back, but not properly restrained in the Printhead Restraints.

Table 2 Printhead Restraint Fault 7,009.42 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the restraints for damage or debris.

Are the restraints damaged?

2 Check the Printhead Wiper alignment.

Is the Printhead Wiper properly aligned?

3 Check Printhead wire routing and the Tilt

Gear. Does the Printhead move freely?

4 Check that the Process Drive is aligned

(ADJ 4.7.1). Is the Process Drive misaligned?

5 Replace the Process Drive (REP 4.0.7).

Does the error persist?

6 Test the Head Maintenance Clutch

Run the Service Diagnostics Head Maintenance Wiper Clutch test. Does the clutch operate correctly?

Replace damaged parts (REP 2.0.8).

Go to Step 4. Perform ADJ 2.5.1.

Remove ink spills or reinstall the Printhead.

Perform ADJ 4.7.1. Go to Step 5.

Go to Step 6. Complete.

Go to Step 7. Replace the clutch

Go to Step 2.

Go to Step 4.

(REP 4.0.4).

Error Messages and Codes

7,008.41, 7,009.42

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Initial Issue

Phaser 8860/8860MFP Service Manual

Table 2 Printhead Restraint Fault 7,009.42 Troubleshooting Procedure

Step Questions or Actions Yes No

7 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.

7,01X.4x Process Faults

A Process Drive or Printhead error has occurred. The following troubleshooting procedures apply to these errors:

Process Faults

7,010.43 Printhead is stuck or is not tilting properly. See IQ35.

7,011.44 Soft fault. System continues to operate.

7,012.45 Transfix Home Sensor does not indicate home position.

7,014.47 The Printhead is not locked in the restraint spring.

7,015.48 The Head Tile Restraint Spring is out of place.

Initial Actions

• Check that the Process Drive gear train is properly homed.

• Check for obstructions or ink spills around the Printhead. Spilled ink could indicate the system was tipped while hot. Check for blockage in the Purge Tube.

• Verify the Printhead travels smoothly from left to right.

• Check the Printhead Restraint Arms.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,010.4x through 7,015.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2) - Figure 7

Head Tilt Gear, PL 4.0

Restraint Arms, PL 2.0

Head Maintenance Clutch, PL 4.0 I/O Board (2/2) - Figure 12

Initial Issue

Phaser 8860/8860MFP Service Manual

Troubleshooting Procedure

The Printhead is stuck, or incorrectly positioned.

Table 2 Printhead Restraint Fault 7,010.xx through 7,015.xx Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reboot the system.

Does the error persist?

2 Check the Printhead Lock Arms.

Do the arms rotate correctly?

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Go to Step 2. Complete.

Go to Step 3. Repair or replace the

Printhead Restraints (REP 2.0.8).

Error Messages and Codes

7,009.42, 7,01X.4x

Table 2 Printhead Restraint Fault 7,010.xx through 7,015.xx Troubleshooting Procedure

Step Questions or Actions Yes No

3 Check for ink spills around the Printhead

and Printhead Tilt Gears. The Printhead should move when pushed left or right. Is the area around the Printhead clean and unobstructed?

4 Check the X-Axis Motor.

Does the X-Axis Motor drive the Printhead to the center position?

5 Check that the Process Drive is properly

aligned (ADJ 4.7.1). Check that the Process Shaft and Drive Module Shaft are at their home positions. Is the Process Drive misaligned?

6 Check for ink spilled on the Head Tilt Gear

or its drive train. Are the gears clean?

7 Test the Head Maintenance Clutch

Run the Service Diagnostics Head Maintenance Wiper Clutch test. Does the clutch operate correctly?

8 Test the Wiper Drive.

Run the Service Diagnostics Wiper Drive test. Does the Wiper Drive operate correctly?

9 Test the maintenance drive.

Run the Service Diagnostics Load Maintenance Clutch test. Does the drive operate correctly?

10 Check that the Head Tilt Gear engages.

Manually engage the Head Tilt Gear. Does the gear engage the drive?

11 Test the Tilt Axis Drive.

Run the Service Diagnostics Tilt Axis Drive test. Did the test pass?

12 Test the Process Drive.

Run the Service Diagnostics Process Motor test. Does the Process Drive operate correctly?

Go to Step 4. Remove ink spills or

Go to Step 5. Check the X-Axis

Realign the Process Drive (ADJ 4.7.1).

Go to Step 7. Clean the gears.

Go to Step 8. Replace the clutch

Replace the Exit Module (REP 3.0.7).

Go to Step 9. Check the mainte-

Go to Step 11. Set the Head Tilt

Go to Step 12. Replace the Pro-

Complete. Replace the Pro-

obstructions.

Drive (6,0xx.4x).

Go to Step 6.

(REP 4.0.4).

Repair the Wiper Drive.

nance drive system and replace any defective parts.

Gear.

cess Drive (REP

4.0.7).

cess Drive (REP

4.0.7).

7,0xx.6x Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Process Program Faults

7,0xx.6x The system detected a program fault during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 7,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Process Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Error Messages and Codes

7,01X.4x, 7,0xx.6x

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Initial Issue

Phaser 8860/8860MFP Service Manual

8,0XX.4x Wiper or Media Drive Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Wiper or Media Drive Faults

8,005.48 The media path motor stalled while moving the wiper to the home position.

8,006.49 The wiper cannot verify the home position.

8,007.41 The wiper stalled finding home.

8,008.42 The wiper stalled while trying to move away from home position.

8,009.43 The media path motor stalled while moving without the clutch engaged.

8,015.49 The media path motor stalled while moving the cap/wipe to the park position.

8,025.41 The media path motor stalled while moving the cap/wipe from the park position.

8,035.42 The media path motor stalled while moving the cap/wipe UP.

8,045.43 The media path motor stalled while moving the cap/wipe DOWN.

8,055.44 The media path motor stalled while engaging head tilt.

Initial Actions

• Check for paper in the paper path.

• Check the condition of the Pick and Retard Rollers.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 8,0XX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Media Drive Assembly, PL 4.0 Left Side Harness (2/2) - Figure 7

Head Maintenance Clutch, PL 4.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedure

Table 2 Media Drive Troubleshooting Procedure

Step Questions or Actions Yes No

1 For an 8,005.48 error:

1. Check the area surrounding the Take Away Roller.

2. Remove the Tray 1 Pick Solenoid (REP 4.0.12) to view the meshing of the roller gears to the Media Drive.

Did this correct the problem?

Complete. Go to Step 4.

Table 2 Media Drive Troubleshooting Procedure

Step Questions or Actions Yes No

2 For an 8,007.41 error:

Check for a missing KL-clip securing the Head Maintenance Clutch. Replace if missing. Check for oil on the right end of the Exit Roller shaft. Oil leaks from the brass bushing can cause the clutch to slip. Did this correct the problem?

3 For an 8,009.43 error:

1. Check for paper in the paper path.

2. Ensure the Media Drive Assembly is fully seated and correctly installed.

3. Remove the Tray 1 Pick Solenoid to check that the Take Away Roller shaft is properly seated to its drive gear in the Media Drive Assembly.

4. Ensure the feed rollers are properly engaged in the drive gears.

Did this correct the problem?

4 Check the Wiper drive.

Run the Service Diagnostics Wiper Drive test. Does the Wiper operate correctly?

5 Align the Printhead Wiper (ADJ 2.5.1).

Does the Wiper align?

6 Inspect the wiper system for improper

operation, obstructions, or damage (broken gear or belt). Look for ink in the wiper belt channels. Did this correct the problem?

7 Check the Wiper Clutch.

Run the Service Diagnostics Head Maintenance Clutch test. Does the clutch operate correctly?

8 Check the right side Wiper Lock.

Does the lock operate correctly?

9 Check for obstructions or spilled ink on the

Wiper Blade, Head Tilt Gear drive, and under the Printhead. Is the Wiper, Media Drive, and Printhead clear or ink or obstructions?

Complete. Go to Step 4.

Complete. Replace the Media

Go to Step 5. Go to Step 6.

Go to Step 7. Go to Step 6.

Complete. Go to Step 7.

Go to Step 8. Replace the clutch

Go to Step 9. Replace the Exit

Replace the Exit Module (REP 3.0.7).

Drive Assembly (REP 4.0.14).

(REP 4.0.4).

Module (REP 3.0.7).

Clean the system and retest.

Initial Issue

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Error Messages and Codes

8,0XX.4x

8,0xx.6x Media Drive Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Media Drive Program Faults

8,0xx.6x The system detected a program fault during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 8,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Media Drive Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

9,0XX.4x Ink Loader Faults

An Ink Loader error has occurred. The following troubleshooting procedure applies to these errors:

Ink Loader Faults

9,000.44 The Ink Loader failed during operation.

9,005.49 The Cyan Ink Melt Heater is on, but no ink is detected.

9,006.41 The Magenta Ink Melt Heater is on, but no ink is detected.

9,007.42 The Yellow Ink Melt Heater is on, but no ink is detected.

9,008.43 The Black Ink Melt Heater is on, but no ink is detected.

9,015.41 Ink Loader Door opened to clear Cyan Ink Stick Jam.

9,016.41 Ink Loader Door opened to clear Magenta Ink Stick Jam.

9,017.41 Ink Loader Door opened to clear Yellow Ink Stick Jam.

9,018.41 Ink Loader Door opened to clear Black Ink Stick Jam.

9,025.41 Ink Loader Door opened twice to clear Cyan Ink Stick Jam.

9,026.41 Ink Loader Door opened twice to clear Magenta Ink Stick Jam.

9,027.41 Ink Loader Door opened twice to clear Yellow Ink Stick Jam.

9,028.41 Ink Loader Door opened twice to clear Black Ink Stick Jam.

9,035.41 Ink count flag stuck after melting 2.5 Cyan Ink Sticks.

9,036.41 Ink count flag stuck after melting 2.5 Magenta Ink Sticks.

9,037.41 Ink count flag stuck after melting 2.5 Yellow Ink Sticks.

9,038.41 Ink count flag stuck after melting 2.5 Black Ink Sticks.

Initial Actions

• Check that the Ink Sticks are genuine Xerox.

• Check for obstructions in the Ink Wells.

• Check the Ink Loader data (P/J0150) and power (P/J5) connections.

• Verify the Ink Sticks advance in the Ink Loader.

• If the problem persists, follow the procedure below.

Error Messages and Codes

8,0xx.6x, 9,0XX.4x

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 9,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Ink Loader Assy, PL 2.0 I/O Board (2/2) - Figure 12

NOTE: Following Ink Loader Assembly replacement, or for Ink count flag stuck errors, clear the Ink Stick Count (ISC) fault using the Clear ISC Fault menu item located in the Service Diagnostics Function menu.

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Phaser 8860/8860MFP Service Manual

Initial Issue

Troubleshooting Procedure

Table 2 Process Drive Faults 9,0XX.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check that the ink stick is able to advance

in the ink loader chute. Check for broken or wrong type ink sticks. Are the Ink Sticks loading properly?

2 Test the appropriate Ink Melt Heater.

Run the Service Diagnostics Ink Melt [1,2,3,4] test.

• 1 = Yellow

•2 = Cyan

• 3 = Magenta

•4 = Black

Did the test pass?

Go to Step 2. Remove any block-

Replace the Printhead (REP 2.0.2).

age and/or replace the ink stick. Run clear ISC Fault test to clear the error. This must be performed following an ink loader replacement.

Replace the Ink Loader (REP 2.0.1).

9,009.44 and 9,00X.6x Ink Loader Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Ink Loader Program Faults

9,009.44 Communications error in NVRAM.

9,0xx.6x The system detected a program fault during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 9,009.44 and 9,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Ink Loader Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device. (REP 5.0.9).

Reconnect the system grounds.

Initial Issue

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Error Messages and Codes

9,0XX.4x, 9,009.44 and 9,00X.6x

11,0XX.xx Electronics Module Interface Faults

A communications error has occurred. The following troubleshooting procedure applies to these errors:

Ink Loader Faults

11,001.47 The Upper 525-sheet feeder broken serial link detected.

11,002.48 The Lower 525-sheet feeder broken serial link detected.

11,003.49 Control Panel broken serial link detected

11,004.41 Control Panel or I/O Board broken serial link detected.

11,005.42 Power control broken serial link detected.

11,006.43 Printhead broken serial link detected.

11,007.44 PCI error detected.

11,008.45 The DMA hardware is not responding.

11,009.46 Communication timeout failure detected.

11,010.47 Hardware version mismatch.

11,011.48 Software version mismatch.

11,012.49 The power control PLD does not match the expected version.

11,013.41 I/O PLD version mismatch.

11,014.42 Control Panel version mismatch.

11,015.43 Printhead PLD version mismatch.

11,016.44 Lower 525-sheet feeder PLD version mismatch.

11,017.45 Upper 525-sheet feeder PLD version mismatch.

11,018.46 Titan version mismatch.

11,043.66 Control Panel waiting error

Initial Actions

• Check that all system grounds are secured.

• Check or reseat all connections to the Electronics Module.

• Check the condition of all harnesses.

• If the problem persists, follow the procedure below.

Troubleshooting Procedure

Table 2 Process Drive Faults 11,0xx.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check ground integrity for the printer.

Does the error persist?

2 Reseat all system interconnections and

check that the cables are properly dressed. Does the error persist?

3 Reset NVRAM.

Does the error persist?

For errors 11, 001.47 and 11,017.45 Replace the Tray Lift Motor. Does the error persist?

For errors 11,002.48 and 11, 016.44 Check the Option Tray connection. Does the error persist?

For errors 11,003.49 and 11,0014.42 Replace the I/O

For errors 11,004.41 and 11,013.41 Replace the I/O Board (REP 5.0.13). Does the error persist?

For errors 11,006.43 and 11,015.43 Replace the Print-

For error 11,009.46 Replace the I/O Board (REP 5.0.13). Does the error persist?

For all other 11,000.4x errors: Replace the Elec-

Go to Step 2. Complete.

Go to Step 3. Complete.

Locate the error code below.

Replace the Electronics Module (REP

5.0.5).

Replace the optional tray.

Board (REP 5.0.13)

Replace the Control Panel (REP 1.0.9).

head (REP 2.0.2).

Replace the Electronics Module (REP

5.0.5).

tronics Module (REP

5.0.5).

Complete.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

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 10

Right Side Harness, PL 5.0 Right Side Harness / I/O Control - Figure 10

I/O Board Power Control Cable, PL 5.0 Right Side Harness / I/O Control - Figure 10

Left Side Harness, PL 5.0 Left Side Harness (1/2) - Figure 6

Electronics Module, PL 5.0 Electronics Module - Figure 8

Optional Feeder, PL 3.0 Left Side Harness (1/2) - Figure 6

Error Messages and Codes

11,0XX.xx

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Initial Issue

Phaser 8860/8860MFP Service Manual

11,100.60 Electronics Module Temperature Fault

The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting procedure applies to this error:

Program Faults

11,100.60 The system reports an overheat condition.

Initial Actions

• Check the ambient room temperature.

• Check for obstructions in the Air Vents. If obstructions are cleared, allow time for the system to cool.

• If the problem persists, follow the procedure below.

11,300.6x EMC Motor Control Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Program Faults

11,300.6x Motor told to move too late..

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 11,100.60 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0 Electronics Module Power - Figure 9

Electronics Module Fan, PL 4.0 Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 Temperature Fault 11,100.60 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check that the air ducts are free of

obstructions and the fans are operating correctly. Are the fans operating correctly?

Replace the Electronics Module (REP

5.0.5).

Replace the defective fan.

Table 1 11,300.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0 Electronics Module Power - Figure 9

Troubleshooting Procedure

Table 2 12,000.60 Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Replace the Electronics Module (REP

5.0.5).

Reconnect the system grounds.

Initial Issue

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Error Messages and Codes

11,100.60, 11,300.6x

12,000.60 Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Program Faults

12,000.60 The system detected a program fault during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

13,000.48 Printhead Thermal Fault

A thermal error is detected in the Printhead. The following troubleshooting procedure applies to this error:

Process Thermal Faults

13,000.48 A thermal fault was detected in the Printhead.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Table 1 12,000.60 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 12,000.60 Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 13,000.48 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check ground integrity for the printer.

Does the error persist?

2 Reset NVRAM.

Does the error persist?

3 Reseat all system connections to the

Printhead and check that the harnesses are properly dressed. Does the error persist?

Go to Step 2. Complete.

Replace the NVRAM device (REP 5.0.9).

Replace the Printhead (REP 2.0.2).

Complete.

Error Messages and Codes

12,000.60, 13,000.48

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Initial Issue

Phaser 8860/8860MFP Service Manual

13,003.42 and 13,007.46 Thermal Faults

A thermal error has occurred. The following troubleshooting procedures apply to these errors:

Thermal Faults

13,003.42 Thermal fault

13,007.46 Thermal fault

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,003.42 and 13,007.46 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Electronics Module, PL 5.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 13,003.42 and 13,007.46 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check ground integrity for the printer.

Does the error persist?

2 Reset NVRAM.

Does the error persist?

Go to Step 2. Complete.

Replace in the NVRAM device (REP 5.0.9). If the error persists, replace the Electronics Module (REP

5.0.5).

Complete.

13,008.47 and 13,010.49 Drum Thermal Faults

A Drum Assembly thermal error has occurred. The following troubleshooting procedures apply to these errors:

Drum Thermal Faults

13,008.47 The Drum Heater is too hot

13,010.49 The Drum Heater took too long to reach the setpoint temperature.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,008.47 and 13,010.49 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Drum Fan, PL 4.0 Right Side Harness / I/O Control - Figure 10

Drum Assembly Electronics Module Power - Figure 9

Drum Temperature Sensor, PL 6.0 I/O Board (2/2) - Figure 12

Electronics Module Fan Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 13,008.47 and 13,010.49 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Verify that the ambient temperature is

within environmental specifications. Is the room within operating parameters?

2 Check ground integrity for the printer.

Does the error persist?

3 Is the error code associated with an over-

heat condition?.

4 Check airflow at the vents.

Is there adequate clearance, and are the vents clean?

5 Test the Drum Fan

Run the Service Diagnostics Drum Fan Motor test. Does the fan operate correctly?

6 Test the Electronics Module Fan.

Does the Fan operate correctly?

Go to Step 2. Advise the customer

of operational requirements.

Go to Step 2. Complete.

Go to Step 4. Go to Step 6.

Go to Step 5. Clean the vents.

Go to Step 6. Replace the Drum

Fan (REP 4.0.6).

Go to Step 7. Replace the Elec-

tronics Module Fan (REP 4.0.15).

Initial Issue

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Error Messages and Codes

13,003.42 and 13,007.46, 13,008.47

Table 2 13,008.47 and 13,010.49 Troubleshooting Procedure

Step Questions or Actions Yes No

7 Test the Drum Temperature Sensor.

Run the Service Diagnostics Drum Temperature Sensor test. Does the sensor operate correctly?

8 Test the Drum Heater.

Run the Service Diagnostics Drum Heater test. Does the heater operate correctly?

Go to Step 8. Replace the Drum

Replace the Drum Assembly (REP

2.0.3).

Temperature Sensor. (REP 6.0.4).

Replace the Drum Temperature Sensor. (REP 6.0.4).

13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults

A Drum Temperature Sensor error has occurred. The following troubleshooting procedures apply to these errors:

Drum Temperature Sensor Faults

13,067.43 The Drum Thermistor circuit is open.

13,069.45 The Drum Thermistor circuit is shorted.

13,071.47 The Drum Thermistor returned faulty reading.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Drum Temperature Sensor, PL 6.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedures

Table 2 13,067.43, 13,069.45 and 13,071.47 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Drum Temperature Sensor.

Run the Service Diagnostics Drum Temperature Sensor test. Does the sensor operate correctly?

2 Check the Drum Heater Sensor harness.

Is the harness free from defects or damage?

Go to Step 2. Replace the Drum

Replace the Drum Temperature Sensor. (REP 6.0.4).

Temperature Sensor. (REP 6.0.4).

Repair the wiring.

Error Messages and Codes

13,008.47, 13,067.43, 13,069.45, 13,071.47

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Initial Issue

Phaser 8860/8860MFP Service Manual

13,XXX.4x Preheater Thermal Faults

A Preheater thermal error has occurred. The following troubleshooting procedures apply to these errors:

13,1XX.4x Left Jetstack Thermal Faults

A thermal error in the Printhead jetstack has occurred. The following troubleshooting procedures apply to these errors:

Preheater Thermal Faults

13,072.48 The Preheater is too hot.

13,074.41 The Preheater took too long to reach the setpoint temperature.

13,131.44 The Preheater Thermistor circuit is open.

13,133.46 The Preheater Thermistor circuit is shorted.

13,135.48 The Preheater Thermistor returned faulty reading.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,XXX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Preheater, PL 2.0 I/O Board (1/2) - Figure 11

I/O Board, PL 5.0 I/O Board (1/2) - Figure 11

Right Combined Cable, PL 5.0

Troubleshooting Procedures

Table 2 Preheater Thermal 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 parameters?

2 Test the Preheater.

Run the Service Diagnostics Preheater test. Does the Preheater operate correctly?

3 Check Preheater connections and wiring.

Are the connections secure and the wiring undamaged?

Go to Step 2. Advise the customer

Replace the I/O Board (REP 5.0.13).

Replace the Preheater (REP 2.0.17).

of operational requirements.

Go to Step 3.

Repair or replace the wiring.

Left Jetstack Thermal Faults

13,136.49 The left jetstack heater is too hot.

13,138.42 The left jetstack heater took too long to reach the setpoint temperature.

13,195.45 The left jetstack heater thermistor circuit is open.

13,197.47 The left jetstack heater thermistor circuit is shorted.

13,199.49 The left jetstack heater thermistor returned faulty reading.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,1XX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 Left Jetstack Thermal Fault Troubleshooting Procedure

Step Questions 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?

2 Check ground integrity for the printer.

Does the error persist?

3 Test the Left Jetstack.

Run the Service Diagnostics Left Jetstack Temperature test. Does the Preheater operate correctly?

4 Check Printhead connections and wiring.

Are the connections secure and the wiring undamaged?

Go to Step 2. Advise the customer

Go to Step 3. Complete.

Go to Step 4. Replace the Print-

Replace the Printhead (REP 2.0.2).

of operational requirements.

head (REP 2.0.2).

Repair the wiring.

Initial Issue

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Error Messages and Codes

13,XXX.4x, 13,1XX.4x

13,2XX.4x Right Jetstack Thermal Faults

A thermal error in the Printhead jetstack has occurred. The following troubleshooting procedures apply to these errors:

13,XXX.xx Printhead Reservoir Thermal Faults

A Printhead Reservoir thermal error has occurred. The following troubleshooting procedures apply to these errors:

Right Jetstack Thermal Faults

13,200.41 The right jetstack heater is too hot.

13,202.43 The right jetstack heater took too long to reach the setpoint temperature.

13,259.46 The right jetstack heater thermistor circuit is open.

13,261.48 The right jetstack heater thermistor circuit is shorted.

13,263.41 The right jetstack heater thermistor returned faulty reading.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,2XX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 Right Jetstack Troubleshooting Procedure

Step Questions 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?

2 Check ground integrity for the printer.

Does the error persist?

3 Test the Right Jetstack.

Run the Service Diagnostics Right Jetstack Temperature test. Does the Preheater operate correctly?

4 Check Printhead connections and wiring.

Are the connections secure and the wiring undamaged?

Go to Step 2. Advise the customer

Go to Step 3. Complete.

Go to Step 4. Replace the Print-

Replace the Printhead (REP 2.0.2).

of operational requirements.

head (REP 2.0.2).

Repair the wiring.

Printhead Reservoir Thermal Faults

13,264.42 The Printhead reservoir heater is too hot.

13,266.44 The Printhead reservoir heater took too long to reach setpoint temp.

13,323.47 The Printhead reservoir heater thermistor circuit is open.

13,325.49 The Printhead reservoir heater thermistor circuit is shorted.

13,327.42 The Printhead reservoir heater thermistor returned faulty reading.

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 13,XXX.xx Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 Printhead Reservoir Thermal Fault Troubleshooting Procedure

Step Questions 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?

2 Check ground integrity for the printer.

Does the error persist?

3 Test the Printhead Reservoir temperature.

Run the Service Diagnostics Reservoir Temperature test. Does the Printhead operate correctly?

4 Check Printhead connections and wiring.

Are the connections secure and the wiring undamaged?

Go to Step 2. Advise the customer

Go to Step 3. Complete.

Go to Step 4. Replace the Print-

Replace the Printhead (REP 2.0.2).

of operational requirements.

head (REP 2.0.2).

Repair the wiring.

Error Messages and Codes

13,2XX.4x, 13,XXX.xx Printhead Reservoir

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Initial Issue

Phaser 8860/8860MFP Service Manual

13,XXX.xx Ink Loader Thermal Faults

A thermal error has occurred. The following troubleshooting procedures apply to these errors:

Ink Loader Thermal Faults

13,328.43 The Cyan heater is too hot.

13,330.45 The Cyan heater took too long to reach the setpoint temperature.

13,387.48 The Cyan heater thermistor circuit is open.

13,389.41 The Cyan heater thermistor circuit is shorted.

13,391.43 The Cyan heater thermistor returned faulty reading.

13,392.44 The Magenta heater is too hot.

13,394.46 The Magenta heater took too long to reach the setpoint temperature.

13,451.49 The Magenta heater thermistor circuit is open.

13,453.42 The Magenta heater thermistor circuit is shorted.

13,455.44 The Magenta heater thermistor returned faulty reading.

13,456.45 The Yellow heater is too hot.

13,458.47 The Yellow heater took too long to reach setpoint temp.

13,515.41 The Yellow heater thermistor circuit 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 too long to reach setpoint temp.

13,515.41 The Black heater thermistor circuit is open.

13,517.43 The Black heater thermistor circuit is shorted.

13,519.45 The Black heater thermistor returned faulty reading.

Troubleshooting Procedures

Table 2 Ink Loader Ink Melt Heater 13,328.43 through 13,581.44 Procedure

Step Questions 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?

2 Check ground integrity for the printer.

Does the error persist?

3 Test the appropriate Ink Melt heater.

Run the Service Diagnostics Ink Melt test.

1. Yellow

2. Cyan

3. Magenta

4. Black

Does the Ink Melt Heater operate correctly?

4 Check Ink Loader connections and wiring.

Are the connections secure and the wiring undamaged?

Go to Step 2. Advise the customer

Go to Step 3. Complete.

Replace the Electronics Module (REP

5.0.5).

Replace the Ink Loader (REP 2.0.1).

of operational requirements.

Go to Step 4.

Repair or replace the wiring. If the error persists, replace the I/O Board (REP

5.0.13).

Initial Actions

• Check that all system grounds are secured.

• Check the ambient room temperature.

• Check the fan operation and vents.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedures.

Table 1 Ink Loader Thermal Fault Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Ink Loader, PL 2.0 Electronics Module - Figure 8

I/O Board, PL 5.0 I/O Board (2/2) - Figure 12

Electronics Module, PL 5.0 Electronics Module - Figure 8

Right Combined Cable, PL 5.0

Initial Issue

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Error Messages and Codes

13,XXX.xx

13,00x.6x Thermal Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

X-Axis Program Faults

13,001.62 Thermals failed to read system NVRAM.

13,002.63 Value not in valid range.

13,003.64 Thermal control task received an unexpected message.

13,004.65 Thermal control task was expecting initialization message, but received other.

13,005.66 Thermal code tried to command a segment ID that did not exist.

13,006.67 Thermal code tried to command a 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.

19,0XX.4x Printhead Calibration Faults

The root problem for this error is temperature sensitivity with the power supply’s opto-isolator chips. The following troubleshooting procedure applies to this error:

Printhead Calibration Faults

19,001.46 The HFD server failed due to NVRAM operation. THis fault should only occur

when the system is in manufacturing mode.

19,002.47 The system attempted a Printhead operation without position data in NVRAM.

19,003.48 Scale and offset voltage error too large. Something is wrong with the Electron-

ics Module or Wave Amplifier.

19,004.40 The Printhead and Electronics Module do not match.

19,005.41 Improper ground connection

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 6,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Initial Actions

• Check electrical connections to the Printhead.

• Check for obstructions or damage near the Printhead. If obstructions are cleared, retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 19,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0 Electronics Module - Figure 8

Printhead, PL 2.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 Process Drive Faults 7,0xx.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check and reseat all connections to the

Printhead. Does the problem persist?

Replace the Printhead (REP 2.0.2). If the error persists, replace the Electronics Module (REP

5.0.5).

Complete.

Error Messages and Codes

13,00x.6x, 19,0XX.4x

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Initial Issue

Phaser 8860/8860MFP Service Manual

19,0XX.6x Waveform Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

21,000.69 Diagnostic Firmware Version Mismatch

A software error has occurred. The following troubleshooting procedure applies to these errors:

X-Axis Program Faults

19,001.68 to 19,039.61

Waveform Printhead calibration program faults.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 6,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Check that the ground straps are place between the Media Drive Motor and YAxis Assembly. Also check the ground clip at the Tray 2 Pick Clutch. Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

X-Axis Program Faults

21,000.69 The diagnostics firmware doesn’t match the engine firmware.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 6,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Update the Diagnostic firmware.

Does the problem persist?

2 Replace the Electronics Module (REP

5.0.5).

Go to Step 2. Complete.

Complete.

Initial Issue

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Error Messages and Codes

19,0XX.6x, 21,000.69

22,0XX.6x Jam Fault

A jam has occurred. The system generates a four-digit, alphanumeric code associated to a particular area of the paper path, followed by the value of the system page counter when the jam occurred <jam code><page count>. Jam code syntax is defined in Ta bl e 1 . A listing of common Jam Codes appears at the end of this section.

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 Front Door G Exit Door H Tray 2 Media J Tray 3 Media K Tray 4 Media M Media Drive N Y-Axis Motor P Process Drive V Tray 2 Event W Tray 3 Event X Tray 3 Pick Flag Y Tray 4 Event Z Tray 4 Pick Flag

As an example, the Jam Code W2Q1 indicates a Tray 3 Paper Size Switch unexpectedly activated while a paper pick operation occurred from Tray 1. See Jam Codes for a listing of the most commonly seen codes.

2 Sensor Event 3 Timeout 4 Motor Stall 5 Motor Position 6 Length Short 7 Length Long

A Abnormal shutdown B Normal shutdown C Mechanical recovery D Warmup E Ready F Fault G Auto Drum Maintenance H Printhead Maintenance J Printhead purge K Oil Transfix Roller L Standby M Pick from Tray 2 N Pick from Tray 3 P Pick from Tray 4 Q Pick from Tray 1 R Pick from DUplex S Stage for transfix T Transfix V Pint Drum Maintenance W Imaging X Exit Z Shutdown

1 Tray 1 2 Tray 2 3 Tray 3 4 Tray 4 5 Chase Page 6 Duplex

23,0XX.6x NVRAM Faults

An NVRAM error has occurred. The following troubleshooting procedure applies to these errors:

NVRAM Faults

23,0xx.6x The system detected an NVRAM fault during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 23,0XX.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Initial Actions

• Clear the paper path of obstructions or debris.

• Check that the media meets specifications and is loaded correctly.

• Check that the Pick Rollers are clean and in good condition.

Troubleshooting Procedure

Locate the code in the Jam Codes listing and follow the procedure, if available

Error Messages and Codes

22,0XX.6x, 23,0XX.6x

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Initial Issue

Phaser 8860/8860MFP Service Manual

23,133.4x RAM Faults

An RAM DIMM error has occurred. The following troubleshooting procedure applies to these errors:

26,0XX.6x Printing Faults

A printing process error has occurred. The following troubleshooting procedure applies to these errors:

NVRAM Faults

23,133.4x The system detected an NVRAM fault during operation.

Initial Actions

• Reseat RAM devices and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 23,0XX.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

SDRAM, PL 5.0 or PL 5.1

Electronics Module, PL 5.0 or PL 5.1 (8860)

Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat the SDRAM devices in the Elec-

tronics Module. Does the problem persist?

2 Replace SDRAM.

Does the problem persist?

Go to Step 2. Complete.

Replace the Electronics Module (REP

5.0.5 or PL 5.1

(8860)).

Complete.

Printing Faults

26,0xx.6x A printing process fault occurred during operation.

26,962.64 A fall out code fault.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Troubleshooting Procedure

Check the fault history and troubleshoot the error listed immediately prior to these codes. Otherwise, reboot the system to clear these error conditions.

Initial Issue

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Error Messages and Codes

23,133.4x, 26,0XX.6x

27,0XX.6x Profile Library

A profile library error has occurred. The following troubleshooting procedure applies to these errors:

Profile Library Faults

27,0xx.6x A printing process fault occurred during operation.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Troubleshooting Procedure

Check system ground integrity.

29,0XX.6x Jam Manager Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Jam Manager Faults

29,0XX.6x Jam Manager program faults.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 29,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Jam Manager Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Error Messages and Codes

27,0XX.6x, 29,0XX.6x

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Initial Issue

Phaser 8860/8860MFP Service Manual

31,001.40 Mechanical Initialization Jam

A software error has occurred. The following troubleshooting procedure applies to this error:

31,0XX.6x Program Faults

A software error has occurred. The following troubleshooting procedure applies to these errors:

Mechanical Initialization Fault

31,001.40 Mechanical initialization jam fault.

Initial Actions

• Check routing of tray sensor harnesses.

• Check that the Take Away Rollers are free of obstructions.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 31,0xx.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Media Drive Assy, PL 4.0 Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 X-Axis Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the Take Away Rollers.

Do the rollers show signs of excessive wear or damage?

2 Test the Media Drive.

Run the Service Diagnostics Paper Path Drive test. Does the Media Drive operate correctly?

3 DId the Media Drive run extremely fast? Replace the Media

4 Check the rollers.

Remove the Media Drive Assembly and check each roller for binding or drag. Do the rollers rotate correctly?

Replace the affected roller.

Go to Step 4. Go to Step 3.

Drive Assembly (REP 4.0.14).

Replace the Media Drive Assembly (REP 4.0.14).

Go to Step 2.

Go to Step 4.

Repair or replace rollers.

Program Faults

31,0XX.6x Program faults.

Initial Actions

• Reset NVRAM and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 31,0xx.6x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

NVRAM, PL 5.0

Troubleshooting Procedure

Table 2 Program Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat all Electronics Module connec-

tions. Does the problem persist?

2 Check ground integrity.

Are the system grounds connected?

Go to Step 2. Complete.

Reset NVRAM. If the error persists, replace the NVRAM device (REP 5.0.9).

Reconnect the system grounds.

Initial Issue

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Error Messages and Codes

31,001.40, 31,0XX.6x

33,00X.4x Tray 1 Width Sensor Faults

The Paper Width Sensor, located in the Tray 1/Front Door Assembly is reporting out of range values. The following troubleshooting procedure applies to these errors:

34,00X.4x Printhead NVRAM Faults

The Printhead is unable to access system NVRAM. The following troubleshooting procedure applies to these errors:

Tray Manager Device Faults

33,001.42 Tray 1 width value too low.

33,002.43 Tray 1 width value too high.

Initial Actions

• Check electrical connection to Tray 1 (P/J650).

• Check for obstructions or damage to the Media Guides.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 33,00x.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Tray 1/Front Door Assembly, PL 1.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedure

Table 2 Tray 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?

2 Test the Width Sensors.

Run the Service Diagnostics Tray 1 Width Sensor test. Does the sensor operate correctly?

Go to Step 2. Repair or replace the

Replace the I/O Board (REP 5.0.13).

harness.

Replace the Tray 1/ Front Door Assembly (REP 1.0.1).

Printhead NVRAM Faults

34,001.43 An error occurred while attempting read/write access to the Printhead calibra-

34,002.44 An error occurred while attempting read/write access to the Printhead ink data

34,003.45 An error occurred while attempting read/write access to the Printhead data par-

34,004.46 An error occurred while accessing the Printhead NVRAM hardware for pur-

tion partition in NVRAM. The Printhead cable may be unplugged.

partition in NVRAM.

tition in NVRAM.

poses of initialization. The Printhead cable may be unplugged.

Initial Actions

• Check data connection to the Printhead.

• Check for obstructions or damage to the Media Guides.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 34,00x.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

Printhead Interface Cable, PL 5.0 Electronics Module - Figure 8

Troubleshooting Procedure

Table 2 Printhead NVRAM Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the Printhead data cable connec-

tions (P/J3 and P/J180). Are the connections secure and the cable undamaged?

2 Replace the Printhead (REP 2.0.2).

Does the error persist?

Go to Step 2. Repair or replace the

cable.

Replace the Electronics Module (REP

5.0.5).

Complete.

Error Messages and Codes

33,00X.4x, 34,00X.4x

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Initial Issue

Phaser 8860/8860MFP Service Manual

34,01X Ink Level Sense Faults

There are two known ways an Ink level sense over-range fault can occur. One fault condition results from an internal short in the sensor or Printhead. In these cases, replacement of the Printhead is required. A more common fault condition is caused by ink contamination. If different color or type of inks mix in the reservoir, the sensor’s function is impaired producing the over range fault. If multiple colors have mixed or the wrong type of ink has been used, remove the source of the ink contamination, and then purge the Printhead.

NOTE: The Ink level sensors can detect contamination before color mixing appears on prints.

Ink Contamination Faults

34,015.48 An over range level sense error occurred in the Cyan Printhead reservoir.

34,016.40 An over range level sense error occurred in the Magenta Printhead reser voir.

34,017.41 An over range level sense error occurred in the Yellow Printhead reservoir.

34,018.42 An over range level sense error occurred in the Black Printhead reservoir.

Allow adequate time for the system to cool before servicing the printer.

Initial Actions

• Check the Ink Loader for improperly installed Ink Sticks.

• Shutdown the printer and allow it to cool until the Ink solidifies (approximately 30 minutes).

• Investigate where the contamination came from and remove the contamination source.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Applicable Parts Wiring and Plug/Jack References

Printhead, PL 2.0 Electronics Module - Figure 8

Ink Sticks

Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the Ink Loader chutes for improp-

Check The Cyan reservoir for contamination.

Check The Magenta reservoir for contamination.

Check The Yellow reservoir for contamination.

Check The Black reservoir for contamination.

WARNING

Table 1 34,00x.4x Troubleshooting Reference Table

Table 2 Printhead NVRAM Fault Troubleshooting Procedure

Go to Step 2. Go to Step 7. erly installed Ink Sticks. Has the Ink been loaded incorrectly or the wrong ink used?

Table 2 Printhead NVRAM Fault Troubleshooting Procedure

Step Questions or Actions Yes No

2 CAUTION

Do not attempt to remove ink from the Printhead reservoir. Purge the reservoir using solid color test prints as described.

Clear the Ink Loader of Ink. For these types of errors, clear the Ink Loader of the incorrect Ink.

1. Remove the Ink Loader.

2. Load the correct Ink into the chutes.

3. Clean the area surrounding the Printhead reservoir for the affected color(s).

4. Install the Ink Loader.

Has all the improper Ink been removed from the Ink Loader and Printhead area?

3 Disable Ink Loader level sensing.

1. Open the Ink Loader Door.

2. Switch the power On and interrupt the initialization process immediately after the Xerox logo is replaced by the words “Warming Up” by holding down the Up Arrow button while pressing the OK button.

If successful, the words “Level sense disabled” momentarily appear on the display. If these words don’t appear, power Off the system and attempt the procedure again. Ink level sensing remains disabled for approximately 5 minutes. Is level sense disabled?

4 Close the Ink Loader Door and allow the

system to reach “Ready”. Is the system Ready?

5 Access the Service Tools menu to purge

the Printhead contamination using the Ink Flush Prints routine. Select the affected color to print 20 solid fill prints. Were 20 solid fills printed?

6 Check that the contamination has been

purged.

1. Shutdown the system.

2. Turn the system On.

Did the system reach “Ready” without error?

Go to Step 3. Continue cleaning

until no residual ink remains in the Ink Loader or area surrounding the Printhead.

Go to Step 4. Continue Step 3 until

level sensing is disabled.

Go to Step 5. Go to Step 7.

Go to Step 6. Continue printing

solid fills in the affected color(s).

Complete. Go to Step 2 and

attempt a second purge procedure. If unsuccessful, go to Step 7.

Initial Issue

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2-39

Error Messages and Codes

34,01X

Table 2 Printhead NVRAM Fault Troubleshooting Procedure

Step Questions or Actions Yes No

7 Replace the Printhead (REP 2.0.2).

Does the error persist?

Replace the Electronics Module (REP

5.0.5).

Complete.

36,000.40 Drum Maintenance Faults

An error occurred while attempting to position the Drum Maintenance Kit. The following troubleshooting procedure applies to these errors:

Printhead NVRAM Faults

36,000.40 An error occurred while attempting to position the Drum Maintenance Kit.

Initial Actions

• Check for ink spills or obstructions near the Drum Maintenance Kit.

• Check for obstructions or damage to the Pivot Plate and Cam Rollers.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

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 PL 2.0 I/O Board (2/2) - Figure 12

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedure

Table 2 Drum Maintenance Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check that system grounds are in place.

Are the grounds secure and undamaged?

2 Check the Drum Maintenance Pivot Plate

for cracks, and the Dram Maintenance Cam Rollers for damage or improper movement. Is there damage to the Pivot Plate or Cam Rollers?

3 Test Drum Maintenance operation.

Run the Service Diagnostics Drum Maintenance/Transfix Home test. Does the system operate correctly?

4 Test the Drum Maintenance drive.

Run the Service Diagnostics Drum Maintenance Drive test. Does the drive operate correctly?

Go to Step 2. Repair or replace the

Replace any damaged parts.

Go to Step 4. Replace the Pro-

Complete. Replace the Pro-

grounds.

Go to Step 3.

cess Drive (REP

4.0.7).

cess Drive (REP

4.0.7)

Error Messages and Codes

34,01X, 36,000.40

09/2007

2-40

Initial Issue

Phaser 8860/8860MFP Service Manual

36,001.67 Drum Maintenance Drive Faults

An error occurred while attempting to position the Drum Maintenance Kit. The following troubleshooting procedure applies to this error:

36,002.44 Drum Maintenance Kit Fault

An error occurred while attempting to position the Drum Maintenance Kit. The following troubleshooting procedure applies to this error:

Drum Maintenance Drive Faults

36,001.67 An error occurred while attempting to position the Drum Maintenance Kit.

Initial Actions

• Check for ink spills or obstructions near the Drum Maintenance Kit.

• Check for obstructions or damage to the Pivot Plate and Cam Rollers.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 36,001.67 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

Troubleshooting Procedure

Table 2 Drum Maintenance Drive Faults 36,001.67 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check that system grounds are in place.

Are the grounds secure and undamaged?

2 Test Drum Maintenance operation.

Run the Service Diagnostics Drum Maintenance/Transfix Home test. Does the system operate correctly?

3 Test the Drum Maintenance drive.

Run the Service Diagnostics Drum Maintenance Drive test. Does the drive operate correctly?

Go to Step 2. Repair or replace the

Go to Step 3. Replace the Pro-

Replace the Drum Maintenance Pivot Plate and Shaft (REP 2.0.16).

grounds.

cess Drive (REP

4.0.7).

Replace the Process Drive (REP

4.0.7)

Drum Maintenance Drive Faults

36,002.44 The system can not write to the Drum Maintenance Kit.

Initial Actions

• Check for ink spills or obstructions near the Drum Maintenance Kit.

• Check for obstructions or damage to the Pivot Plate and Cam Rollers.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 36,001.67 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

Troubleshooting Procedure

Table 2 Drum Maintenance Drive Faults 36,001.67 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check that the Drum Maintenance Kit is

correctly installed. Is the installation correct?

2 Replace the Drum Maintenance Kit

Does the error persist?

Go to Step 2. Correct and retest.

Replace the Drum Maintenance Pivot Plate and Shaft (REP 2.0.16).

Complete.

Initial Issue

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2-41

Error Messages and Codes

36,001.67, 36,002.44

37,0XX.xx PEST Heater Faults

An heating error has occurred. The following troubleshooting procedure applies to these errors:

37,01X.41 PEST Fan Faults

An fan error has occurred. The following troubleshooting procedure applies to these errors:

PEST Heater Faults

37,001.46 An error occurred during PEST execution.

37,002.47 The Left Jetstack is drawing less power than expected.

37,003.48 The Right Jetstack is drawing less power than expected.

37,004.40 Ink Reservoir 0 is drawing less power than expected.

37,005.41 Ink Reservoir 1 is drawing less power than expected.

37,006.42 The Drum Heater is drawing less power than expected.

37,008.44 The Preheater is drawing less power than expected.

37,009.45 All Ink Melt Heaters are drawing less power than expected.

37,010.46 The Yellow (0) Ink Melt Heater is drawing less 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 Heater is drawing less power than expected.

Initial Actions

• Check the Printhead, Preheater and Ink Loader power connections.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,0XX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Ink Loader Assy, PL 2.0 Electronics Module - Figure 8

Printhead, PL 2.0 Electronics Module - Figure 8

Preheater, PL 2.0 Electronics Module Power - Figure 9

PEST Heater Faults

37,014.41 The Electronics Module Fan is drawing less power than expected.

37,015.41 The Drum Fan is drawing less power than expected.

Initial Actions

• Check the Electronics Module and Drum Cooling Fans.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,01X.41 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module Fan, PL 4.0 Left Side Harness (2/2) - Figure 7

Drum Fan, PL 4.0 Right Side Harness / I/O Control - Figure 10

Troubleshooting Procedure

Table 2 PEST Fan Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the affected component.

Run the Service Diagnostics test for the affected fan. Does the affected fan operate correctly?

2 Check wiring to the affected component.

Is the wiring damaged?

Go to Step 2. Replace the fan.

Repair or replace the harness.

Replace the affected component.

Troubleshooting Procedure

Table 2 PEST Heater Faults 37,0XX.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the affected component.

Run the Service Diagnostics test for the affected component. Does the affected component reach operating temperature?

2 Check wiring to the affected component.

Is the wiring damaged?

Error Messages and Codes

Go to Step 2. Replace the affected

Repair or replace the harness.

37,0XX.xx, 37,01X.41

component.

Replace the affected component.

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Initial Issue

Phaser 8860/8860MFP Service Manual

37,016.43 PEST 50 Volt Supply Fault

An error has occurred related to the Electronics Module 50 V Power Supply. The clutches operate at 50 V. The Head Maintenance, Deskew, and Pick clutches are drawing too much power indicating a short in the supply or one of the components connected to it.

PEST 50 V Supply Fault

37,016.43 All three clutches failed.

Initial Actions

• Check the Electronics Module indicators.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,016.43 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 4.0 Left Side Harness (1/2) - Figure 6

I/O Board, PL 5.0 I/O Board (2/2) - Figure 12

Troubleshooting Procedure

CAUTION

Damage to circuits within the Electronics Module may occur if the power supply capacitors are not allowed to fully discharge.

Table 2 PEST 50 V Supply Fault 37,016.43 Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check for a short in the Electronics Mod-

ule. Measure the 50 V power supply output. The test point is located on the power control board below the main board RAM DIMMs. Is there 50 V across the TP and ground?

2 Shutdown the system and wait 30 sec-

onds for the capacitors to discharge. 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 2. Go to Step 2.

Go to Step 3. Replace the Elec-

tronics Module (REP

5.0.5).

Table 2 PEST 50 V Supply Fault 37,016.43 Troubleshooting Procedure

Step Questions or Actions Yes No

3 Shutdown the system and wait 30 sec-

onds for the capacitors to discharge. Connect I/O Board connector (P/J840). Turn the system On. Do the PE and PS indicators (near the Power Switch) flash momentarily?

4 Check the 50 V Supply LED.

If the 50V LED (Figure 2) illuminates, the short is on one of the external devices unplugged earlier. In this case, systematically turn off the printer, plug a wiring harness back in, and turn the printer on until the 50V LED fails to illuminate. Was the defective part isolated?

5 Shutdown the system and wait 30 sec-

onds for the capacitors to discharge. Disconnect all connections to the I/O Board. Test the resistance of the I/O Board across pin 1 of J270 and ground. Pin 1 is on the left end of the jack. Is the resistance still less than 1K ohm?

6 Reconnect connections on the I/O Board

until you find one that creates a short at J270-1. Does a short appear at J270-1?

7 Reconnect the Wave Amplifier.

Turn the system On. Does the error persist?

8 Reconnect the Printhead.

Turn the system On. Does the error persist?

Go to Step 4. Go to Step 5.

Replace the defective part.

Replace the I/O Board (REP 5.0.13).

Replace the affected component.

Go to Step 8. Leave power on to

Replace the Electronics Module (REP

5.0.5).

Go to Step 5.

Go to Step 6.

Go to Step 7.

ensure the problem is fixed.

Leave power on to ensure the problem is fixed.

Initial Issue

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Error Messages and Codes

37,016.43

37,0XX.4x PEST Clutch/Solenoid Faults

An heating error has occurred. The following troubleshooting procedure applies to these errors:

PEST Heater Faults

37,017.44 The Head Maintenance Clutch is drawing less power than expected.

37,018.45 The Deskew Clutch is drawing less power than expected.

37,019.46 The Pick Clutch is drawing less power than expected.

37,020.48 The Tray 1 Pick Solenoid is drawing less power than expected.

37,021.42 The Strip Solenoid is drawing less power than expected.

37,022.4x The Preheater Lift Solenoid is drawing less power than expected.

37,023.4x The Head Tilt Solenoid is drawing less power than expected.

Initial Actions

• Check the indicated component for damage, wear, or obstructions.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

37,024.48 PEST Tray 2 Lift Motor Fault

An error has occurred related to the Tray 2 Lift Motor. The following troubleshooting procedure applies to this error:.

Tray 2 Lift Motor Fault

37,024.48 The Tray 2 Lift Motor is drawing less power than expected.

Initial Actions

• Check the Tray 2 Lift Plate for damage or obstructions.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,024.48 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Tray 2 Lift Motor, PL 4.0 Left Side Harness (1/2) - Figure 6

Electronics Module, PL 4.0 Left Side Harness (1/2) - Figure 6

Table 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

Pick Clutch, PL 4.0 Left Side Harness (1/2) - Figure 6

Tray 1 Pick Solenoid, PL 4.0 Left Side Harness (1/2) - Figure 6

Strip Solenoid, PL 3.0 I/O Board (1/2) - Figure 11

Preheater Lift Solenoid, PL 4.0 Left Side Harness (2/2) - Figure 7

Head Tilt Solenoid, PL 4.0 Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 PEST Clutch/Solenoid Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the component indicated by the error.

Run the Service Diagnostics test for the affected component. Does the component operate correctly?

2 Check wiring to the affected component.

Is the wiring damaged?

Go to Step 2. Replace the affected

Repair or replace the harness.

component.

Replace the affected component.

Troubleshooting Procedure

Table 2 PEST Tray 2 Lift Motor Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Tray 2 Lift Motor.

Run the Service Diagnostics Tray 2 Lift Motor test. Does the motor operate correctly?

2 Check the motor connection to the Left

Side Harness. Is the connection secure and the harness undamaged?

Replace the Electronics Module (REP

5.0.5).

Replace the motor (REP 4.0.10).

Go to Step 2.

Repair of replace the Left Side Harness.

Error Messages and Codes

37,0XX.4x, 37,024.48

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Initial Issue

Phaser 8860/8860MFP Service Manual

37,026.44 PEST Purge Pump Fault

An error has occurred related to the Purge Pump. The following troubleshooting procedure applies to this error:.

37,02X.4x PEST Relay Board Faults

An Relay Board error has occurred. The following troubleshooting procedure applies to these errors:

Tray 2 Lift Motor Fault

37,026.44 The Purge Pump purge valve is drawing less power than expected.

Initial Actions

• Check the Purge Pump for damage or obstructions.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,026.44 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Purge Pump, PL 2.0 Left Side Harness (2/2) - Figure 7

Electronics Module, PL 4.0 Left Side Harness (2/2) - Figure 7

Troubleshooting Procedure

Table 2 PEST Purge Pump Fault Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Purge Pump.

Run the Service Diagnostics Purge Vent Solenoid test. Does the pump operate correctly?

2 Check the pump connection to the Left

Side Harness. Is the connection secure and the harness undamaged?

Go to Step 2. Replace the Purge

Replace the Purge Pump (REP 2.0.7).

Pump (REP 2.0.7).

Repair of replace the Left Side Harness.

PEST Relay Board Faults

37,027.45 Both relay coils are drawing less power than expected.

37,028.46 The A coil is drawing less power than expected.

37,029.47 The B coil is drawing less power than expected.

Initial Actions

• Check the Relay Board’s power connection.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,02X.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Relay Board, PL 5.0 I/O Board (1/2) - Figure 11

Electronics Module, PL 5.0 Electronics Module Power - Figure 9

Troubleshooting Procedure

Table 2 PEST Relay Board Faults 37,02X.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Relay Board.

Run the Service Diagnostics Drum Heater Relay test. Does the Relay Board operate correctly?

2 Check wiring to the affected component.

Is the wiring damaged?

Replace the Electronics Module (REP

5.0.5).

Repair or replace the harness.

Go to Step 2.

Replace the Relay Board (REP 5.0.19).

Initial Issue

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Error Messages and Codes

37,026.44, 37,02X.4x

37,03X.4x PEST X-Axis Motor Faults

An X-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:

37,035.44 and 37,036.45 PEST Y-Axis Motor Faults

A Y-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:

PEST X-Axis Motor Faults

37,030.45 The X-Axis Motor is drawing less power than expected.

37,031.46 The X-Axis Motor first phase is drawing less power than expected.

37,032.47 The X-Axis Motor first phase is drawing too much power.

37,033.48 The X-Axis Motor second phase is drawing less power than expected.

37,034.40 The X-Axis Motor second phase is drawing too much power.

Initial Actions

• Check the X-Axis Motor connection.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,03X.4x Troubleshooting Reference Table

Applicable 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

Troubleshooting Procedure

Table 2 PEST X-Axis Motor Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the X-Axis Motor.

Run the Service Diagnostics X-Axis Drive test. Does the motor operate correctly?

2 Check wiring to the motor.

Is the wiring damaged?

Replace the Electronics Module (REP

5.0.5).

Repair or replace the harness.

Go to Step 2.

Replace the X-Axis Motor (REP 4.0.5).

PEST Y-Axis Motor Faults

37,035.44 The Y-Axis Motor is drawing less power than expected.

37,036.45 The Y-Axis Motor is drawing too much power.

Initial Actions

• Check for obstructions to Drum rotation.

• Check the condition of the Y-Axis Drive Belt.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,03X.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Y-Axis Motor, PL 4.0 Electronics Module Power - Figure 9

Drum Assembly, PL 2.0

Electronics Module, PL 5.0 Electronics Module Power - Figure 9

Troubleshooting Procedure

Table 2 PEST Y-Axis Motor Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check the Drum rotation.

Does the Drum rotate smoothly?

2 Check the Y-Axis Motor.

Remove the Y-Axis Belt (REP 2.0.4). Does the Y-Axis Motor shaft rotate freely?

3 Replace the Y-Axis Belt and test the Y-

Axis Motor. Run the Service Diagnostics Y-Axis Drive test. Does the motor operate correctly?

4 Check wiring to the motor.

Is the wiring damaged?

Go to Step 2. Replace the Drum

Go to Step 3. Replace the Y-Axis

Replace the Electronics Module (REP

5.0.5).

Repair or replace the harness.

Assembly (REP

2.0.3).

Motor (REP 4.0.11).

Go to Step 4.

Replace the Y-Axis Motor (REP 4.0.11).

Error Messages and Codes

37,03X.4x, 37,035.44 and 37,036.45

09/2007

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Initial Issue

Phaser 8860/8860MFP Service Manual

37,037.46 and 37,038.47 PEST Media Drive Faults

A Media Drive Assembly error has occurred. The following troubleshooting procedure applies to these errors:

37,039.48 and 37,040.40 PEST Process Drive Faults

A Y-Axis Motor error has occurred. The following troubleshooting procedure applies to these errors:

PEST Media Drive Faults

37,037.46 The Media Drive Motor is drawing less power than expected.

37,038.47 The Media Drive Motor is drawing too much power.

Initial Actions

• Check for obstructions to Media Drive rotation.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,037.46 and 37,038.47 Troubleshooting Reference Table

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

Troubleshooting Procedure

Table 2 PEST Media Drive Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Media Drive Motor.

Run the Service Diagnostics Media Path Motor test. Does the motor operate correctly?

2 Check wiring to the motor.

Is the wiring damaged?

Replace the Electronics Module (REP

5.0.5).

Repair or replace the harness.

Go to Step 2.

Replace the Media Drive (REP 4.0.14).

PEST Process Drive Faults

37,039.48 The Process Drive Motor is drawing less power than expected.

37,040.40 The Process Drive Motor is drawing too much power.

Initial Actions

• Check for obstructions to Process Drive rotation.

• Check the rotation of the Drum Maintenance and Transfix Roller shafts.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,039.48 and 37,040.40 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Process Drive, PL 4.0 Right Side Harness / I/O Control - Figure 10

Electronics Module, PL 5.0

Troubleshooting Procedure

Table 2 PEST Process Drive Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Check shaft rotation.

Do the Process Drive gears, Transfix Shaft, and Drum Maintenance shaft rotate freely?

2 Test the Process Drive Motor.

Run the Service Diagnostics Process Motor test. Does the motor operate correctly?

3 Check wiring to the motor.

Is the wiring damaged?

Go to Step 2. Repair or replace

Replace the Electronics Module (REP

5.0.5).

Repair or replace the harness.

affected parts.

Go to Step 3.

Replace the Process Drive (REP

4.0.7).

Initial Issue

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Error Messages and Codes

37,037.46 and 37,038.47, 37,039.48 and 37,040.40

37,0XX.4x PEST Power Supply Faults

An Power Supply error has occurred. The following troubleshooting procedure applies to these errors:

PEST Power Supply Faults

37,041.41 The Power Supply failed to reset.

37,043.43 The Power Supply 2.5 V source over limit.

37,044.44 The Power Supply 2.5 V source under limit.

37,045.45 The Power Supply 3.3 V source over limit.

37,046.46 The Power Supply 3.3 V source under limit.

37,047.47 The Power Supply 12 V source over limit.

37,048.48 The Power Supply 12 V source under limit.

37,049.40 The Power Supply -12 V source over limit.

37,050.41 The Power Supply -12 V source under limit.

37,051.42 The Power Supply current over limit.

37,052.43 The Power Supply current under limit.

37,053.44 The Power Supply 50 V source 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 source over limit.

37,058.40 The Power Supply 15 V source under limit.

37,059.41 The Power Supply -15 V source over limit.

37,060.42 The Power Supply -15 V source under limit.

37,061.43 The Power Supply 5 V source over limit.

37,062.44 The Power Supply 5 V source under limit.

37,063.45 The Power Supply high switch not activated. Electrical short or missing reset line.

37,064.46 Vss too low. The Printhead power harness may be disconnected.

37,065.47 Vpp too low. The Printhead or Wave Amp may be disconnected.

37,066.48 The Wave Amplifier s drawing too much power. Possible short.

Troubleshooting Procedure

Table 2 PEST Power Supply Faults 37,0XX.4x Troubleshooting Procedure

Step Questions or Actions Yes No

1 Test the Power Supply.

Run the Service Diagnostics Voltages test. Does the Power Supply operate correctly?

2 Check the Printhead Power connection.

Is the wiring disconnected or damaged?

Go to Step 2. Replace the Elec-

Repair or replace the harness.

tronics Module (REP

5.0.5).

Replace the Electronics Module (REP

5.0.5).

Initial Actions

• Check the component power connections and harness condition.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 37,0XX.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Electronics Module, PL 5.0

Error Messages and Codes

37,0XX.4x

09/2007

2-48

Initial Issue

Phaser 8860/8860MFP Service Manual

39,002.40 and 39,003.41 Scanner Subsystem Test Faults

A Scanner DRAM or Optical self test error has occurred. The following troubleshooting procedure applies to these errors:

39,004.42 Scanhead Locked or Shipping Restraint Faults

A Scanner self test determined the Scanhead was either locked, or the shipping restraint remained. The following troubleshooting procedure applies to these errors:

Scanner Subsystem Test Faults

39,002.40 The Scanner DRAM test failed.

39,003.41 The Scanner Optical Test failed.

Initial Actions

• Cycle system power and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,00X.4x Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Scanner Assembly, PL 1.0

Troubleshooting Procedure

Table 2 Scanner Subsystem Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Cycle system power and retest.

Does this correct the problem?

2 Replace the Scanner Assembly (REP

1.0.11).

Complete. Go to Step 2.

Complete.

Scanhead Lock or Shipping Restraint Faults

39,004.42 The Scanhead did not reach Home position. Release Scanner Shipping Restraint

or Scanhead Locked appears on the Control Panel display.

Initial Actions

• Check the Scanhead lock.

• Check for packaging.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,004.42 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Scanner Assembly, PL 1.0

Troubleshooting Procedure

Table 2 Scanhead Locked Troubleshooting Procedure

Step Questions or Actions Yes No

1 Cycle system power and retest.

Does this correct the problem?

2 Replace the Scanner Assembly (REP

1.0.11).

Complete. Go to Step 2.

Complete.

Initial Issue

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Error Messages and Codes

39,002.40 and 39,003.41, 39,004.42

39,005.43 Scanner Missing Fault

A Scanner was not detected. The following troubleshooting procedure applies to these errors:

Scanner Missing Fault

39,005.43 The system did not detect the Scanner Assembly.

Initial Actions

• Reseat the Scanner connection to the Electronics Module.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,005.43 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Scanner Assembly, PL 1.0

Scanner Power Supply, PL 5.0 Exit Module Control Board - Figure 13

DADF, PL 1.0

Exit Module Control Board, PL 5.0 Exit Module Control Board - Figure 13

Exit Roller Motor, PL 4.0 Exit Module Control Board - Figure 13

Elevator Motor, PL 4.0 Exit Module Control Board - Figure 13

Troubleshooting Procedure

Table 2 Scanhead Missing Troubleshooting Procedure

Step Questions or Actions Yes No

1 Cycle system power and retest.

Does this correct the problem?

2 Check the Scanner Power Supply status

LED (see Figure 2). Is the Status LED blinking?

3 Remove the Output Tray and Side Covers.

Disconnect the Elevator (P/J303) and Exit Roller (P/J309) motors. Does the Status LED stop blinking and remain On?

4 With the Exit Module motors discon-

nected, disconnect the DADF from the Scanner. Does the Status LED stop blinking and remain On?

Complete. Go to Step 2.

Go to Step 3. Go to Step 5.

Replace the defective motor or the Exit Module (REP 3.0.7)

Replace the DADF (REP 1.0.15).

Go to Step 4.

Go to Step 5.

Table 2 Scanhead Missing Troubleshooting Procedure

Step Questions or Actions Yes No

5 Is the Status LED Off? Replace the Scanner

6 Disconnect the Scanner Assembly from

the Electronics Module. Does the Status LED light?

Power Supply (REP

5.0.2). If the error

persists, replace the Electronics Module (REP 5.0.5).

Replace the Scanner Assembly (REP

1.0.11).

Go to Step 6.

Replace the Exit Module Control Board (REP 5.0.1). If the error persists, replace the Scanner Power Supply (REP

5.0.2). If the Status

LED remains Off, replace the Electronics Module (REP

5.0.5).

Error Messages and Codes

39,005.43

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Initial Issue

Phaser 8860/8860MFP Service Manual

39,010.8 Document Feeder Disconnected or Missing

The system could not detect the DADF. The following troubleshooting procedure applies to this error:

39,011.40 and 39,012.40 DADF Subsystem Test Faults

The DADF DRAM or Optical self test error has occurred. The following troubleshooting procedure applies to these errors:

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 display.

Initial Actions

• Check the DADF connection to the Scanner Assembly.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,010.8 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

DADF, PL 1.0

Troubleshooting Procedure

Table 2 DADF Disconnected or Missing Troubleshooting Procedure

Step Questions or Actions Yes No

1 Reseat the DADF connection to the Scan-

ner Assembly. Wait at least one minute. Does the problem persist?

2 Cycle system power and retest.

Does this correct the problem?

Go to Step 2. Complete.

Complete. Replace the DADF

(REP 1.0.15).

DADF Subsystem Faults

39,011.40 The DADF DRAM Test failed.

39,012.40 The DADF Optical Test failed.

Initial Actions

• Cycle system power and retest.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,011.40 and 39, 012.40 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

Document Feeder, PL 1.0

Troubleshooting Procedure

Table 2 DADF Subsystem Faults Troubleshooting Procedure

Step Questions or Actions Yes No

1 Cycle system power and retest.

Does this correct the problem?

2 Replace the DADF (REP 1.0.15). Complete.

Complete. Go to Step 2.

Initial Issue

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Error Messages and Codes

39,010.8 , 39,011.40 and 39,012.40

39,013.42 Document Feeder Jam

A media Jam is detected in the DADF. The following troubleshooting procedure applies to this error:

39,014.43 Document Feeder Calibration Fault

A calibration faults is detected in the DADF. The following troubleshooting procedure applies to this error:

Document Feeder Disconnected or Missing Faults

39,013.42 Media Jam in the DADF was detected. Jam at Document Feeder appears on the

Control Panel display.

Initial Actions

• Check that the media is supported by the system.

• Check the pick rollers and separator pad.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,004.42 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

DADF Pick Roller and Pad, PL 1.0

DADF, PL 1.0

Troubleshooting Procedure

Table 2 Scanhead Locked Troubleshooting Procedure

Step Questions or Actions Yes No

1 Clean or replace the DADF Pick Rollers

and Separator Pad. Does the problem persist?

2 Remove all media, open and close the

DADF Front Cover, and retest. Does this correct the problem?

Go to Step 2. Complete.

Complete. Replace the DADF

(REP 1.0.15).

Document Feeder Calibration Fault

39,014.43 DADF calibration fault.

Initial Actions

• Check that the media is supported by the system.

• Check the pick rollers and separator pad.

• If the problem persists, follow the procedure below.

Primary Causes

The troubleshooting table lists parts and wiring referenced in the troubleshooting procedure.

Table 1 39,004.42 Troubleshooting Reference Table

Applicable Parts Wiring and Plug/Jack References

DADF, PL 1.0

Troubleshooting Procedure

Table 2 Scanhead Locked Troubleshooting Procedure

Step Questions or Actions Yes No

1 Cycle system power and retest.

Does this correct the problem?

Complete. Replace the DADF

(REP 1.0.15).

Error Messages and Codes

39,013.42 , 39,014.43

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Jam Codes

The system stores the most recent 20 events in Jam History. To access this information, press and hold the Up Arrow button, then scroll to Jam History and press OK. Jam codes for Process Events differ between models. Tables 1 and 2 list the code keys for each model. Ta ble 3 provides troubleshooting information for the most common jams.

Table 1 8860 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 Front Door G Tray 2 Media H Tray 3 Media J Tray 4 Media M Media Drive N Y-Axis Motor P Process Drive T Exit Door V Tray 2 Event W Tray 3 Event X Tray 3 Pick Flag Y Tray 4 Event Z Tray 4 Pick Flag

2 Sensor Event 3 Timeout 4 Motor Stall 5 Motor Position 6 Length Short 7 Length Long

A Abnormal shutdown B Normal shutdown C Mechanical recovery D Warmup E Ready F Fault G Auto Drum Maintenance H Printhead Maintenance J Printhead purge K Oil Transfix Roller L Standby M Pick from Tray 2 N Pick from Tray 3 P Pick from Tray 4 Q Pick from Tray 1 R Pick from Duplex S Stage for transfix T Transfix V Drum Maintenance 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

NOTE: The following table defines the first 3-digits. The 4th digit represents the tray number (1~4), 5 represents a chase page, and 6 represents duplex. Numbers following the 4th digit are the system page count:

Code Description / Procedure

A2C Deskew sensor in unexpected state during mechanical recovery.

1. Check the Drum Maintenance Kit NVRAM contacts during oiling for continuity.

2. Instruct customer to remove media from Tray 1 before opening the front door.

3. Replace the pivot arm.

A2E Deskew sensor in unexpected state at ready.

1. Check system grounding.

2. Replace Tray 1 Pick Solenoid.

A2F Deskew sensor in unexpected state.

1. Check system grounding.

2. Verify all doors and covers are fully closed and not moving during printing.

A2J Deskew flag sensor event during head purge.

A2K Deskew sensor in an unexpected state during a Transfix Roller oiling.

2 Sensor Event 3 Timeout 4 Motor Stall 5 Motor Position 6 Length Short 7 Length Long

Table 3 Jam Code Troubleshooting

A Abnormal shutdown B Normal shutdown C Mechanical recovery D Warmup E Ready F Fault G Auto Drum Maintenance H Printhead Maintenance J Printhead purge K Oil Transfix Roller L Standby M Pick from Tray 2 N Pick from Tray 3 P Pick from Tray 4 Q Pick from Tray 1 R Pick from Duplex S Stage for transfix T Transfix V Drum Maintenance W Imaging X Exit Z Shutdown

1 Tray 1 2 Tray 2 3 Tray 3 4 Tray 4 5 Chase Page 6 Duplex

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Error Messages and Codes

Jam Codes

Table 3 Jam Code Troubleshooting

Code Description / Procedure

A2M

The deskew flag tripped unexpectedly while picking paper from Tray 2.

A2N

The deskew flag tripped unexpectedly while picking paper from Tray 3.

A2P

The deskew flag tripped unexpectedly while picking paper from Tray 4.

A2S

Deskew sensor in unexpected state during media stage for transfix.

A2Q

The deskew flag tripped unexpectedly while the printer was picking paper from Tray 1.

1. Try using different, supported media

2. Ensure the paper guides are snug against the media in the tray

3. Push up on Tray {2 - 4} Nudger Roller until it is captured by actuator arm.

4. Run the following diagnostic tests, Deskew Flag, Tray {2-4} Pick Clutch and the Tray {2-4} Solenoid.

5. Check system grounding.

6. Verify all doors and covers are fully closed and not moving during printing.

7. Replace the Tray {2 - 4} Pick Clutch.

8. Replace the Retard Roller (REP 3.0.18).

9. Replace the Preheater (REP 2.0.17).

A3G

Deskew Sensor time-out event during an auto drum maintenance cycle.

A3M

The deskew flag timed out waiting for the paper picked from Tray 2.

A3N

The deskew flag timed out waiting for the paper picked from Tray 3.

A3P

The deskew flag timed out waiting for the paper picked from Tray 4.

A3Q

The deskew flag timed out waiting for the paper picked from Tray 1.

1. Verify media is appropriate for the tray.

2. Verify the tray is not overfilled and the guides are positioned correctly.

3. Check for obstructions in the paper path.

4. Test the appropriate Tray Solenoid.

5. Test the appropriate Tray Pick Clutch.

6. Ensure the take away rollers are in good condition.

7. Test the take away roller using the diagnostic Paper Path Drive test.

8. Replace the appropriate Separator Pad Assembly.

9. Replace the Pick Assembly (REP 3.0.18).

A3R Deskew sensor time-out during movement from exit roller to deskew roller when

duplexing print.

1. Ensure the media is appropriate for two-sided printing. Not too short, not too smooth.

2. Check the condition of the Exit Roller and the Duplex Roller.

3. Check the Front Door for obstructions or damage, replace the Front Door if necessary.

4. Test the operation of the exit roller and the duplex roller using diagnostic Duplex Paper Lead Edge Times test.

5. Test the deskew sensor using the diagnostic Sensors test.

B2C Preheat exit sensor unexpected state during mechanical recovery.

1. Clear jam and let printer finish mechanical recovery.

2. Check system grounds.

Table 3 Jam Code Troubleshooting

Code Description / Procedure

B2F

Preheater exit sensor in unexpected state during fault.

B2S

Preheater exit sensor in unexpected state during stage.

1. Check system grounds.

2. Check the Drum Maintenance Kit NVRAM contacts during oiling for continuity.

3. Check the waste tray.

4. Replace the Preheater (REP 2.0.17).

B2M

The preheat flag tripped unexpectedly while picking paper from Tray 2.

B2N

The preheat flag tripped unexpectedly while picking paper from Tray 3.

B2P

The preheat flag tripped unexpectedly while picking paper from Tray 4.

B2Q

The preheat flag tripped unexpectedly while picking paper from Tray 1.

1. Test the Preheater Sensor using Service Diagnostics.

2. Check system grounds.

B3M

The preheat flag timed out waiting for the paper picked from Tray 2.

B3N

The preheat flag timed out waiting for the paper picked from Tray 3.

B3P

The preheat flag timed out waiting for the paper picked from Tray 4.

B3Q

The preheat flag timed out waiting for the paper picked from Tray 1.

B3S

Preheater sensor timed out during stage.

B3T

Preheater Exit Sensor timed out during transfix.

1. Verify media is appropriate for the tray.

2. Check for paper path obstructions, ensure the Preheater plate moves freely.

3. Replace the Tray 1 Separator Pad Assembly.

4. Test the Preheater Exit Sensor using Service Diagnostics.

5. Check the condition of the Deskew Rollers.

6. Test the Deskew Clutch using Service Diagnostics.

7. Run the Paper Path Drive test from Service Diagnostics.

8. Replace the Preheater (REP 2.0.17), then retest.

C2C

Strip flag unexpected event during mechanical recovery.

C2D

Strip flag unexpected state during warm-up.

C2E

Strip flag unexpected event during system ready.

C2F

Strip flag unexpected event during fault.

C2K

Strip flag unexpected event during Transfix Roller oiling.

C2M

The strip flag actuated unexpectedly when paper was picked from Tray 2.

C2N

The strip flag actuated unexpectedly when paper was picked from Tray 3.

C2P

The strip flag actuated unexpectedly when paper was picked from Tray 4.

C2Q

The strip flag actuated unexpectedly when paper was picked from Tray 1.

C2R

Strip flag unexpected event during pick from the duplex path.

C2T

Strip flag unexpected event during transfix.

1. Check system grounds.

2. Check for paper tray overfill.

3. Test the Strip Sensor using Service Diagnostics.

4. Check the Stripper Blade for damage or debris.

5. Run the Paper Lead Edge Times test using Service Diagnostics.

6. Test the Deskew Clutch using Service Diagnostics.

7. Replace the Stripper Carriage Assembly (REP 2.0.12), then retest.

Error Messages and Codes

Jam Codes

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Table 3 Jam Code Troubleshooting

Code Description / Procedure

C2X Strip flag unexpected event during exit.

1. Check that the media is not too thick and is supported by the system.

2. Use a less glossy media.

3. Check that the guides in the tray are snug against the media.

4. If the Drum Maintenance Kit is near end of life, replace it.

5. Clean and inspect the exit rollers.

6. Test the Paper Path Drive using Service Diagnostics.

C3M

The strip flag timed out waiting for the paper picked from Tray 2.

C3N

The strip flag timed out waiting for the paper picked from Tray 3.

C3P

The strip flag timed out waiting for the paper picked from Tray 4.

C3Q

The strip flag timed out waiting for the paper picked from Tray 1.

C3T

Strip flag time-out during transfix.

1. Check that the media is the correct size and type for the tray. If envelope jam, try a different style.

2. Check the Drum Maintenance Kit for proper operation, replace if necessary.

3. Check that the Process Drive is correctly homed (ADJ 4.7.1).

4. Test the Stripper Carriage using the Stripper Contact test in Service Diagnostics.

5. Test the Transfix Drive using the Transfix Drive Slow and Transfix Drive Fast tests.

C3X Strip flag time-out during exit.

1. Open the Exit Door and ensure the springs for the idler rollers are present and installed correctly (they should be the same for all 5 rollers).

2. Verify the metal bar is installed on top of the Exit Guide.

C5X Print pulled back into transfix nip during exit.

1. Check that the media is not too thick and is supported by the system.

2. Use a less glossy media.

3. If the Drum Maintenance Kit is near end of life, replace it.

4. Clean and inspect the exit rollers.

5. Check that the Process Drive is correctly homed (ADJ 4.7.1).

6. Test the Paper Path Drive using Service Diagnostics.

7. Replace the Lower Exit Guide.

D2D

Exit flag unexpected event during warm-up.

D2M

The exit flag actuated unexpectedly when paper was picked from Tray 2.

D2N

The exit flag actuated unexpectedly when paper was picked from Tray 3.

D2P

The exit flag actuated unexpectedly when paper was picked from Tray 4.

D2Q

The exit flag actuated unexpectedly when paper was picked from Tray 1.

D2R

The exit flag actuated unexpectedly when duplexing

D2T

The exit flag actuated unexpectedly when transfixing

1. Check system grounds.

2. Test the Exit Sensor using Service Diagnostics.

3. Run the Paper Lead Edge Times test using Service Diagnostics.

4. Replace the problem component, then retest.

Table 3 Jam Code Troubleshooting

Code Description / Procedure

D2X The exit flag actuated unexpectedly exit.

1. Check that the media is not too thick and is supported by the system.

2. Use a less glossy media.

3. If the Drum Maintenance Kit is near end of life, replace it.

4. Clean and inspect the exit rollers.

5. Check that the Exit Sensor Flag for proper installation or damage. Replace if necessary.

6. Test the Paper Path Drive using Service Diagnostics.

7. Replace the problem component.

D3C

Exit flag time-out during mechanical recovery.

D3M

Exit flag timed out following Tray 2 Pick.

D3N

Exit flag timed out following Tray 3 Pick.

D3P

Exit flag timed out following Tray 4 Pick.

D3Q

Exit flag timed out following Tray 1 Pick.

D3R

Exit flag timed out during duplexing.

D3T

Exit flag time-out during transfix.

1. Check that the media is not too thick and is supported by the system.

2. Check that the exit path is free of obstructions.

3. If the Drum Maintenance Kit is near end of life, replace it.

4. Clean and inspect the Stripper Blade.

5. Clean and inspect the exit rollers. Check that the rollers rotate freely.

6. Check the Exit Sensor Flag for proper installation or damage. Replace if necessary.

7. Test the Paper Path Drive using Service Diagnostics.

8. Replace the problem component.

E2D

Tray 1 width sensor during warm-up.

E2E

Tray 1 width sensor during operation.

E2Q

Tray 1 width sensor during Tray 1 pick

1. Check the Tray 1 width guides for proper operation. Verify the guides are not moving during printing.

2. Check the Front Door is closed and the wiring is properly connected and seated.

3. Test the Tray 1 Width Sensor using Service Diagnostics.

4. Check the Tray 1 wiring to the I/O board.

5. Replace the I/O Board (REP 5.0.13), then retest.

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Error Messages and Codes

Jam Codes

Table 3 Jam Code Troubleshooting

Code Description / Procedure

F2D

The Front Door Interlock tripped during warming up.

F2F

The Front Door Interlock tripped during fault state.

F2M

The Front Door Interlock tripped during a pick from Tray 2.

F2N

The Front Door Interlock tripped during a pick from Tray 3.

F2P

The Front Door Interlock tripped during a pick from Tray 4.

F2Q

The Front Door Interlock tripped during a pick from Tray 1.

F2R

The Front Door Interlock tripped during duplexing.

F2S

The Front Door Interlock tripped while the paper was staged for transfix.

F2T

The Front Door Interlock tripped during transfix.

F2V

The Front Door Interlock tripped during Drum oiling.

F2W

The Front Door Interlock tripped during imaging.

F2X

The Front Door Interlock tripped during exit.

1. Check the Front Door for damaged hinges, latch, or interlock actuator.

2. Check the covers for proper alignment and fit.

3. Test the Interlock Switch (Door Sensor test) using Service Diagnostics.

4. Check the Front Door Interlock Switch installation and wiring.

5. Replace the switch, then retest.

G2M Tray 2 removed during pick from Tray 2.

H2N Tray 3 removed during pick from Tray 3.

J2M Tray 4 removed during pick from Tray 4.

J2P Tray 4 Media Present Sensor event pick from Tray 4.

Table 3 Jam Code Troubleshooting

Code Description / Procedure

M2C

Media Drive motor had an unexpected event during mechanical recovery.

M4A

Media Drive motor stalled during an abnormal printer shutdown.

M4B

Media Drive motor stalled during a normal printer shutdown.

M4C

Media Drive motor stalled during mechanical recovery.

M4D

Media Drive motor stalled during printer warm-up.

M4E

Media Drive motor stalled during ready state.

M4F

Media Drive motor stalled during a fault state.

M4G

Media Drive motor stalled during an auto drum maintenance cycle.

M4H

Media Drive motor stalled during printhead maintenance.

M4J

Media Drive motor stalled during printhead purge.

M4K

Media Drive motor stalled during an oil Transfix Roller cycle.

M4L

Media Drive motor stalled during standby mode.

M4M

Media Drive motor stalled during pick from Tray 2.

M4N

Media Drive motor stalled during pick from Tray 3.

M4P

Media Drive motor stalled during pick from Tray 4.

M4Q

Media Drive motor stalled during pick from Tray 1.

M4R

Media Drive motor stalled during duplex.

M4S

Media Drive motor stalled during transfix stage.

M4T

Media Drive motor stalled during transfix.

1. Check that the media is supported by the system.

2. Check that the exit path is free of obstructions.

3. Check system grounds.

4. Test the Media Drive motor using the Paper Path Drive test.

5. If necessary, retest using the Media Path Motor and Shafts tests.

6. Check the condition and movement of the rollers and gears.

7. Replace the Media Drive Assembly (REP 4.0.14).

N2T Y-Axis motor event during transfix (Tray 1 only - probably a multi-pick).

1. Check that the media is supported by the system.

2. Try a heavier media.

3. Send a snippet to turn off the multi-pick detection code.

4. Test the Y-Axis Motor using Service Diagnostics, replace if necessary (REP

4.0.11).

5. Run the Voltages test, replace the Electronics Module if necessary (REP 5.0.5).

N2W Y-Axis motor event during imaging. Probably a software fault. Check system grounds.

Error Messages and Codes

Jam Codes

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Table 3 Jam Code Troubleshooting

Code Description / Procedure

N4A

Y-Axis motor stalled on power-up following an abnormal shutdown.

N4B

Y-Axis motor stalled on power-up following a normal shutdown.

N4C

Y-Axis motor stalled during mechanical recovery

N4D

Y-Axis motor stalled during warm-up.

NFE

Y-Axis motor stalled during ready state.

N4F

Y-Axis motor stalled during a fault state.

N4G

Y-Axis motor stalled during an auto drum maintenance cycle.

N4H

Y-Axis motor stalled during printhead maintenance.

N4J

Y-Axis motor stalled during printhead purge.

N4K

Y-Axis motor stalled during an oil Transfix Roller cycle.

N4L

Y-Axis motor stalled during standby mode.

N4S

Y-Axis motor stalled during staging for transfix.

N4T

Y-Axis motor stalled during transfixing.

N4V

Y-Axis motor stalled during a print drum maintenance cycle.

N4W

Y-Axis motor stalled during drum imaging.

N4X

Y-Axis motor stalled during paper exit.

1. Check for supported media, generally label, trifold or envelopes cause this error.

2. Try running fewer sheets through the tray.

3. Check that the Process Drive is correctly homed (ADJ 4.7.1).

4. Test theY-Axis Motor using Service Diagnostics, replace if necessary (REP

4.0.11).

5. Test for Y-Axis Belt slippage using the Belt Slip test.

6. Replace the Tray 1 Separator Pad assembly.

7. Replace the Process Drive (REP 4.0.7).

N5T

Y-Axis motor out of position during transfixing.

N5W

Y-Axis motor out of position during drum imaging.

1. Check the Y-Axis drive belt.

2. Run the Check Drum Y-Axis Encoder test.

3. Run the Check Drum Y-Axis Drive test.

4. Test for Y-Axis Belt slippage using the Belt Slip test.

5. Replace the Y-Axis Motor (REP 4.0.11), or Drum Assembly (REP 2.0.3) if necessary.

N6T Y-Axis Motor media short during transfix. The media was shorter than expected. Legal

size paper from Tray 4 in standard print mode may buckle. Use slower print mode.

1. Check for supported media.

2. Check 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 Code Troubleshooting

Code Description / Procedure

N7T Y-Axis Motor media long during transfix. The media was longer than expected.

1. Check for supported media.

2. Try heavier media.

3. Try loading only a few sheets. Some photo media may require running one sheet at a time.

4. Run the diagnostic Check Drum Y-Axis Encoder test.

5. Replace the Pick Assembly and Retard Roller (REP 3.0.18).

6. Run the clean ink smears and check the Preheater exit flag for debris.

7. Remove the Preheater (REP 2.0.17), and check the Preheater flag for ink or paper interference.

8. Replace the Preheater (REP 2.0.17) if the error persists.

P4A

Process Drive stalled on power-up following an abnormal shutdown.

P4B

Process Drive stalled on power-up following a normal shutdown.

P4C

Process Drive stalled during mechanical recovery

P4D

Process Drive stalled during warm-up.

PFE

Process Drive stalled during ready state.

P4F

Process Drive stalled during a fault state.

P4G

Process Drive stalled during an auto drum maintenance cycle.

P4H

Process Drive stalled during printhead maintenance.

P4J

Process Drive stalled during printhead purge.

P4K

Process Drive stalled during an oil Transfix Roller cycle.

P4L

Process Drive stalled during standby mode.

P4S

Process Drive stalled during staging for transfix.

P4T

Process Drive stalled during transfixing.

P4V

Process Drive stalled during a print drum maintenance cycle.

P4W

Process Drive stalled during drum imaging.

P4X

Process Drive stalled during paper exit.

1. Check for supported media.

2. Check that the Process Drive is correctly homed (ADJ 4.7.1).

3. Test the Process Drive using Service Diagnostics.

4. Replace the Process Drive (REP 4.0.7) if necessary.

5. Run the Transfix Fast and Slow tests.

6. Replace the Transfix Camshaft (REP 2.0.10) and load arms if necessary.

7. Run the Tilt Drive test, replace if necessary.

8. Replace the Process Drive (REP 4.0.7).

Initial Issue

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Error Messages and Codes

Jam Codes

Table 3 Jam Code Troubleshooting

Code Description / Procedure

T2A

Exit Door Interlock tripped following an abnormal shutdown.

T2B

Exit Door Interlock tripped following a normal shutdown.

T2C

Exit Door Interlock tripped during mechanical recovery

T2D

Exit Door Interlock tripped during warm-up.

T2E

Exit Door Interlock tripped during ready state.

T2F

Exit Door Interlock tripped during a fault state.

T2G

Exit Door Interlock tripped during an auto drum maintenance cycle.

T2H

Exit Door Interlock tripped during Printhead maintenance.

T2J

Exit Door Interlock tripped during Printhead purge.

T2K

Exit Door Interlock tripped during an oil Transfix Roller cycle.

T2L

Exit Door Interlock tripped during standby mode.

T2M

Exit Door Interlock tripped during pick from Tray 2.

T2N

Exit Door Interlock tripped during pick from Tray 3.

T2P

Exit Door Interlock tripped during pick from Tray 4.

T2Q

Exit Door Interlock tripped during pick from Tray 1.

T2R

Exit Door Interlock tripped during duplexing.

T2S

Exit Door Interlock tripped during transfix staging.

T2T

Exit Door Interlock tripped during transfixing.

T2X

Exit Door Interlock tripped during paper exit.

T2Z

Exit Door Interlock tripped during shutdown.

1. Check for supported media.

2. Check system grounds.

3. Run the Monitor Sensors test using Service Diagnostics.

4. Check the Exit Door Interlock Switch. Replace if necessary (REP 6.0.2).

5. Check the Drum Maintenance Kit is functioning properly and the blade is not covered with ink debris. Replace if necessary

6. Replace the Transfix Roller (REP 2.0.12).

V2D

Tray 2 Paper Size Switch activated during warm-up.

V2E

Tray 2 Paper Size Switch activated during ready state.

V2F

Tray 2 Paper Size Switch activated during a fault state.

V2K

Tray 2 Paper Size Switch activated during an oil Transfix Roller cycle.

V2L

Tray 2 Paper Size Switch activated during standby mode.

V2M

Tray 2 Paper Size Switch activated during pick from Tray 2.

V2N

Tray 2 Paper Size Switch activated during pick from Tray 3.

V2P

Tray 2 Paper Size Switch activated during pick from Tray 4.

V2Q

Tray 2 Paper Size Switch activated during pick from Tray 1.

V2R

Tray 2 Paper Size Switch activated during duplexing.

V2S

Tray 2 Paper Size Switch activated during transfix staging.

V2T

Tray 2 Paper Size Switch activated during transfixing.

V2X

Tray 2 Paper Size Switch activated during paper exit.

1. Check system grounds.

2. Check that the Tray 2 media guides are set correctly.

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 / Procedure

W2D

Tray 3 Paper Size Switch activated during warm-up.

W2E

Tray 3 Paper Size Switch activated during ready state.

W2F

Tray 3 Paper Size Switch activated during a fault state.

W2L

Tray 3 Paper Size Switch activated during standby mode.

W2M

Tray 3 Paper Size Switch activated during pick from Tray 2.

W2N

Tray 3 Paper Size Switch activated during pick from Tray 3.

W2P

Tray 3 Paper Size Switch activated during pick from Tray 4.

W2Q

Tray 3 Paper Size Switch activated during pick from Tray 1.

W2R

Tray 3 Paper Size Switch activated during duplexing.

W2V

Tray 3 Paper Size Switch activated during an auto drum maintenance cycle.

W2S

Tray 3 Paper Size Switch activated during transfix staging.

W2T

Tray 3 Paper Size Switch activated during transfixing.

W2X

Tray 3 Paper Size Switch activated during paper exit.

1. Check system grounds.

2. Check that the Tray 3 media guides are set correctly.

3. Run the Monitor Sensors test using Service Diagnostics.

4. Replace the 525-Sheet Feeder.

W4N

Tray 3 Paper Size Switch activated during pick from Tray 3.

W4P

Tray 3 Paper Size Switch activated during pick from Tray 4.

W2S

Tray 3 Paper Size Switch activated during pick from Tray 1.

1. Check system grounds.

2. Check that the Tray 3 media guides are set correctly.

3. Run the Monitor Sensors test using Service Diagnostics.

4. Replace the 525-Sheet Feeder.

X2A

Tray 3 pick flag actuated during an abnormal shutdown.

X2B

Tray 3 pick flag actuated during a normal shutdown.

X2C

Tray 3 pick flag actuated during mechanical recovery

X2D

Tray 3 pick flag actuated during warm-up.

X2E

Tray 3 pick flag actuated during ready state.

X2F

Tray 3 pick flag actuated during a fault state.

X2L

Tray 3 pick flag actuated during standby mode.

X2M

Tray 3 pick flag actuated during pick from Tray 2.

X2N

Tray 3 pick flag actuated during pick from Tray 3.

X2P

Tray 3 pick flag actuated during pick from Tray 4.

X2Q

Tray 3 pick flag actuated during pick from Tray 1.

X2R

Tray 3 pick flag actuated during duplexing.

X2S

Tray 3 pick flag actuated during transfix staging.

X2V

Tray 3 pick flag actuated during an auto drum maintenance cycle.

X2W

Tray 3 pick flag actuated during drum imaging.

X2X

Tray 3 pick flag actuated during paper exit.

1. Check system grounds.

2. Check that the Tray 2 media guides are set correctly

3. Run the Monitor Sensors test using Service Diagnostics.

4. Replace the 525-Sheet Feeder.

5. Replace the Pivot Arm.

Error Messages and Codes

Jam Codes

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Table 3 Jam Code Troubleshooting

Code Description / Procedure

X3D

Tray 3 pick flag timed-out during warm-up.

X3E

Tray 3 pick flag timed-out during ready state.

X3F

Tray 3 pick flag timed-out during a fault state.

X3K

Tray 3 pick flag timed-out during an oil Transfix Roller cycle.

X3L

Tray 3 pick flag timed-out during standby mode.

X3M

Tray 3 pick flag timed-out during pick from Tray 2.

X3N

Tray 3 pick flag timed-out during pick from Tray 3.

X3P

Tray 3 pick flag timed-out during pick from Tray 4.

X3Q

Tray 3 pick flag timed-out during pick from Tray 1.

X3R

Tray 3 pick flag timed-out during duplexing.

X3S

Tray 3 pick flag timed-out during transfix staging.

X3T

Tray 3 pick flag timed-out during transfixing.

X3V

Tray 3 pick flag timed-out during a drum maintenance cycle.

X3W

Tray 3 pick flag timed-out during drum imaging.

X3X

Tray 3 pick flag timed-out during paper exit.

1. Check for supported media.

2. Reduce the amount of media loaded in the tray and reposition the guides to fit snugly against the media.

3. Check the rollers for damage, debris or excessive wear. Clean or replace as necessary.

4. Run the Tray 3 Pick Shaft test using Service Diagnostics.

5. Check system grounds.

6. Push up on the Nudger Roller until it is captured by the Actuator Arm.

7. Run the Pick Clutch test using Service Diagnostics. Replace if necessary.

8. Run the Media Path Drive test using Service Diagnostics.

9. Replace the Pick Roller Assembly (REP 3.0.18).

10. Replace the 525-Sheet Feeder.

Y2D

Tray 4 Paper Size Switch activated during warm-up.

Y2E

Tray 4 Paper Size Switch activated during ready state.

Y2F

Tray 4 Paper Size Switch activated during a fault state.

Y2L

Tray 4 Paper Size Switch activated during standby mode.

Y2M

Tray 4 Paper Size Switch activated during pick from Tray 2.

Y2N

Tray 4 Paper Size Switch activated during pick from Tray 3.

Y2P

Tray 4 Paper Size Switch activated during pick from Tray 4.

Y2Q

Tray 4 Paper Size Switch activated during pick from Tray 1.

Y2R

Tray 4 Paper Size Switch activated during duplexing.

Y2S

Tray 4 Paper Size Switch activated during transfix staging.

Y2T

Tray 4 Paper Size Switch activated during transfixing.

Y2V

Tray 4 Paper Size Switch activated during a drum maintenance cycle.

Y2W

Tray 4 Paper Size Switch activated during Drum imaging.

Y2X

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 Switch.

4. Replace the Tray 4 525-Sheet Feeder.

5. Replace the pivot arm.

Table 3 Jam Code Troubleshooting

Code Description / Procedure

Z2A

Tray 4 pick flag actuated during an abnormal shutdown.

Z2B

Tray 4 pick flag actuated during a normal shutdown.

Z2C

Tray 4 pick flag actuated during mechanical recovery

Z2D

Tray 4 pick flag actuated during warm-up.

Z2E

Tray 4 pick flag actuated during ready state.

Z2F

Tray 4 pick flag actuated during a fault state.

Z2L

Tray 4 pick flag actuated during standby mode.

Z2M

Tray 4 pick flag actuated during pick from Tray 2.

Z2N

Tray 4 pick flag actuated during pick from Tray 3.

Z2P

Tray 4 pick flag actuated during pick from Tray 4.

Z2Q

Tray 4 pick flag actuated during pick from Tray 1.

Z2R

Tray 4 pick flag actuated during duplexing.

Z2S

Tray 4 pick flag actuated during transfix staging.

Z2T

Tray 4 pick flag actuated during transfix.

Z2V

Tray 4 pick flag actuated during an auto drum maintenance cycle.

Z2W

Tray 4 pick flag actuated during drum imaging.

Z2Z

Tray 4 pick flag actuated during paper exit.

1. Check system grounds.

2. Run the Monitor Sensors test using Service Diagnostics.

3. Replace the 525-Sheet Feeder.

4. Replace the Pivot Arm.

Z3B

Tray 4 pick sensor timed-out during a normal shutdown.

Z3D

Tray 4 pick sensor timed-out during warm-up.

Z3E

Tray 4 pick sensor timed-out during ready state.

Z3F

Tray 4 pick sensor timed-out during a fault state.

Z3L

Tray 4 pick sensor timed-out during standby mode.

Z3M

Tray 4 pick sensor timed-out during a pick from Tray 2.

Z3N

Tray 4 pick sensor timed-out during a pick from Tray 3.

Z3P

Tray 4 pick sensor timed-out during a pick from Tray 4.

Z3Q

Tray 4 pick sensor timed-out during a pick from Tray 1.

Z3R

Tray 4 pick sensor timed-out during duplexing.

Z3S

Tray 4 pick sensor timed-out during transfix staging.

Z3T

Tray 4 pick sensor timed-out during transfix.

Z3V

Tray 4 pick sensor timed-out during an auto drum maintenance cycle.

Z3W

Tray 4 pick sensor timed-out during drum imaging.

Z3Z

Tray 4 pick sensor timed out while exiting print

1. Check the paper loaded in Tray 4 is the correct size and type.

2. Check the rollers for damage, debris or excessive wear. Clean or replace as necessary.

3. Run the Tray 4 Pick Shaft test.

4. Replace the Tray 4 525-Sheet Feeder.

Initial Issue

Phaser 8860/8860MFP Service Manual

09/2007

2-59

Error Messages and Codes

Jam Codes

Error Messages and Codes

Jam Codes

09/2007

2-60

Initial Issue

Phaser 8860/8860MFP Service Manual

IQ1 IOT Image Quality Entry RAP .................................................................................. 3-3

IQ2 Dark Streaks on Copied Image ................................................................................ 3-4

IQ3 Voids in the Copied Image ....................................................................................... 3-4

IQ4 Skewed Copy Image ................................................................................................ 3-5

IQ6 Fuzzy Text or Image................................................................................................. 3-5

IQ5 Copy Image is Lighter or Darker than the Original ................................................... 3-6

IQ7 Copied Image Colors Do Not Match the Original ..................................................... 3-6

IQ8 Dark Streaks on Copied Image ................................................................................ 3-7

IQ9 Copy Image is Skewed............................................................................................. 3-7

IQ10 Copy Image is Lighter or Darker than the Original................................................. 3-8

IQ11 Copied Image Colors Do Not Match the Original ................................................... 3-8

IQ12 Fuzzy Text or Image............................................................................................... 3-9

IQ13 Random Light Stripes............................................................................................. 3-9

IQ14 Predominate Light Stripes...................................................................................... 3-10

IQ15 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 Scratches or Marks Parallel to the Long Axis of Printing ....................................... 3-14

IQ21 Ink on the White Portion of the Printed Page......................................................... 3-15

IQ22 Fuzzy Text .............................................................................................................. 3-16

IQ23 Poor Primary Color Fill ........................................................................................... 3-17

IQ24 Ghosting................................................................................................................. 3-18

IQ25 Poor Small Text Resolution.................................................................................... 3-19

IQ26 Vertical Lines Appear Wavy ................................................................................... 3-20

IQ27 Oil Streaks on Print ................................................................................................ 3-20

IQ28 Incomplete Image Transfer .................................................................................... 3-21

IQ29 Ink Smears on First Side of Duplex Print ............................................................... 3-22

IQ30 Repeating Print Defects ......................................................................................... 3-23

IQ31 White Stripes (Pinstripes)....................................................................................... 3-23

IQ32 Wrinkling................................................................................................................. 3-24

IQ33 Image is Offset or Cut-Off ...................................................................................... 3-24

IQ34 Poor Ink Adhesion, Poor Image Durability ............................................................. 3-25

IQ35 Massive Jet Loss.................................................................................................... 3-25

Analyzing Service Test Prints ......................................................................................... 3-26

Jet Substitution Mode...................................................................................................... 3-31

3 Image Quality

Initial Issue

Phaser 8860/8860MFP Service Manual

09/2007

3-1

Image Quality

09/2007

3-2

Initial Issue

Phaser 8860/8860MFP Service Manual

IQ1 IOT Image Quality Entry RAP

The purpose of this RAP is to establish the source of the imaging defect. After following the Initial Actions, select the RAP that best describes the observed defect.

Table 2 Scanner Image Quality Problems

Symptom RAP

Fuzzy Text or Image IQ12

Initial Actions

Computer applications, hardware malfunctions, or communication between the IIT and IOT can cause scan/copy or print-quality issues. Hardware failures that result in image quality problems can occur in the DADF, Scanner Assembly or Print Engine. Use the following steps to determine which part of the system is at fault.

1. Ensure the DADF and Scanner connectors are securely connected.

2. Cycle power to the system.

3. Print the 2-sided demo page from the Control Panel. If the image defect appears on the printed page, the problem is within the Print Engine. When analyzing a print-quality defect from a Print Engine malfunction, determine if the defect occurs:

• in all colors

• in only one color

• as a repeating or random defect

4. Copy a page directly from the platen.

5. Copy a page from the DADF, selecting 2-sided copy to see if the defect is on the 1st, 2nd or both sides of the page.

6. If the image defect appears on the 1st side, the problem is within the Scanner Assembly.

7. If the image defect appears on the 2nd side of the page, the problem is the DADF.

NOTE: To aid in troubleshooting image quality issues, print the Paper Tips page. The paper should be from an unopened ream that has been acclimated to room temperature.

Procedure

After determining the source of the image quality problem, examine the image and select the relevant corrective procedure from one of the following tables.

Table 1 DADF Image Quality Problems

Symptom RAP

Dark Streaks on the Copied Image IQ2

Voids in the Copied Image IQ3

Skewed Copy Image IQ4

Copied Image is Lighter or Darker than the Original IQ5

Fuzzy Text or Image IQ6

Copy Image Colors Do Not Match Original IQ7

Table 2 Scanner Image Quality Problems

Symptom RAP

Dark Streaks on the Scanned Image IQ8

Skewed Scan Image IQ9

Scanned Image is Lighter or Darker than the Original IQ10

Scan Image Colors Do Not Match Original IQ11

Table 3 Print Engine Image Quality Problems

Symptom RAP

Random Light Stripes IQ13

Predominate Light Stripes IQ14

Smudges or Smears IQ15

The printed Image is too Light or Dark IQ16

No Image is Printed IQ17

Color is Uneven or Wrong IQ18

Streaks or Lines Down the Print IQ19

Scratches or Marks Parallel to the Long Printing Axis IQ20

Ink on the White Portion of the Page IQ21

Fuzzy Text IQ22

Poor Primary Color Fills IQ23

Ghosting IQ24

Poor Small Text Resolution IQ25

Vertical Lines Appear Wavy IQ26

Oil Streaks on Print IQ27

Incomplete Image Transfer IQ28

Ink Smears on First Printed Side of Duplex Print IQ29

Repeating Defects IQ30

White Stripes IQ31

Wrinkling IQ32

Image if Offset or Cutoff IQ33

Poor Ink Adhesion, Poor Image Durability IQ34

If a print 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 Eliminate Light Stripes test print. The Eliminate Light Stripes test print indicates individual weak or missing jets or an obstruction in the imaging path that produces a vertical band down the entire page. You may also see color variations from jet to jet on the Eliminate Light Stripes test print. Some variation is normal and usually self corrects within a few printed pages.

Initial Issue

Phaser 8860/8860MFP Service Manual

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3-3

Image Quality

IQ1

IQ2 Dark Streaks on Copied Image

This RAP addresses image quality problems associated with the DADF.

IQ3 Voids in the Copied Image

This RAP addresses image quality problems associated with the DADF.

Initial Actions

1. Check that supported media is being used.

2. Check for Ink build-up or debris. Clean if necessary.

3. Copy another page. If the problem persists, perform the following corrective actions.

4. Reseat all DADF connections.

Procedure

Table 1 IQ2 Dark Streaks on Copied Image

Step Questions and Actions Yes No

1 Check the DADF for ink build up.

Open the DADF Front Cover. Clean the inside of the DADF Front Cover, including the ribs, rollers and separator pad. Does the problem persist?

2 Check the CVT Window for ink build up.

Clean the CVT Window. Does the problem persist?

3 Check DADF calibration.

Perform the DADF to Scanner Calibration adjustment procedure (ADJ 1.15.1). Does the problem persist?

4 Replace the DADF (REP 1.0.15).

Does the problem persist?

Go to Step 2. Complete.

Go to Step 3. Complete. Advise

the customer that periodic cleaning of the CVT window may be necessary.

Go to Step 4. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Complete.

Initial Actions

1. Check that supported media is being used.

2. Reseat all DADF connections.

Procedure

Table 1 IQ3 Voids in the Copied Image

Step Questions and Actions Yes No

1 Does the void run the entire length of one

side of the image.

2 Open the DADF and check that the Calibra-

tion Strip extends fully. The Lamp should be completely covered by the strip. Block the DADF Cover Sensor, select 2-sided copy, and then feed media through the DADF. Does the strip extend and retract properly?

3 Remove any debris obstructing the Lamp.

Does the problem persist?

Go to Step 2. Go to Step 3.

Go to Step 3. Replace the DADF.

Replace the DADF. Complete.

Image Quality

IQ2, IQ3

09/2007

3-4

Figure 1 DADF Calibration Strip

Initial Issue

Phaser 8860/8860MFP Service Manual

IQ4 Skewed Copy Image

This RAP addresses image quality problems associated with the DADF. See the Skew and

Margins test print discussion.

Initial Actions

1. Reset the Media Guides on the DADF Input Tray.

2. Check that supported media is being used.

3. Check that image skew exceeds specifications.

4. Reseat all DADF connections.

IQ6 Fuzzy Text or Image

This RAP addresses image quality problems associated with the DADF.

Initial Actions

1. Check that supported media is being used.

2. Reseat all DADF connections.

3. Cycle power to the system.

Procedure

Table 1 IQ4 Skewed Copy Image

Step Questions and Actions Yes No

1 Check that the original is printed on sup-

ported media and is undamaged. Is the original supported?

2 Check that the paper guides are correctly

adjusted, and clean the Pick Roller and Separator Pad. Does the problem persist?

3 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

Go to Step 2. Use the Platen.

Go to Step 3. Complete.

Replace the DADF (REP 1.0.15).

Complete.

Table 1 IQ6 Fuzzy Text or Image

Step Questions and Actions Yes No

1 Print the Graphics Demo page for fuzzy

image or the Configuration page for fuzzy text. Does the text appear fuzzy?

2 Make a copy of the page printed in Step 1.

Does the image still appear fuzzy?

3 Check and/or adjust the Control Panel copy

settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Use Text or Mixed print mode to evaluate text. Graphics lose image quality in these two modes. If the system is set to Photo or Graphics mode, text quality decreases. Does the problem persist after making the adjustments?

4 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

5 Scan a copy of the page printed in Step 2.

Does the problem persist?

The problem is with the Print Engine. See IQ22.

Go to Step 3. Go to Step 4.

Go to Step 4. Complete.

Go to Step 5. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Go to Step 2.

Replace the DADF (REP 1.0.15).

Initial Issue

Phaser 8860/8860MFP Service Manual

09/2007

3-5

Image Quality

IQ4, IQ6

IQ5 Copy Image is Lighter or Darker than the Original

This RAP addresses image quality problems associated with the DADF.

IQ7 Copied Image Colors Do Not Match the Original

This RAP addresses image quality problems associated with the DADF.

Initial Actions

1. Check that supported media is being used.

2. Reseat all DADF connections.

Procedure

NOTE: The Control Panel settings for Color Mode, Document Type, Output Quality, and Lighten/Darken influence the output in different ways. Finding a satisfactory combination of these settings for a particular original might require several attempts. In some cases, these controls may not completely compensate for artifacts introduced in the scanning process.

Table 1 IQ5 Copy Image is Lighter or Darker than the Original

Step Questions and Actions Yes No

1 Check and/or adjust the Control Panel copy

settings.

1. Print the Troubleshooting Print Quality 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 Standard.

Does the problem persist after making the adjustments?

2 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

Go to Step 2. Complete.

Replace the DADF. Complete.

Initial Actions

1. Check that supported media is being used.

2. Test output using Laser Original Mode.

3. Reseat all DADF connections.

4. Cycle power to the system.

NOTE: There can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.e., ink jet copy, laser toner copy, etc.). A Laser Original Mode is also available to adjust the imaging system to more accurately produce copies of laser originals. Color matching varies because the reflective characteristics of the original vary.

The Control Panel settings for Color Mode, Document Type, Output Quality, and Lighten/ Darken influence the output in different ways. Finding a satisfactory combination of these settings for a particular original might require several attempts. In some cases, these controls may not completely compensate for artifacts introduced in the scanning process.

Procedure

Table 1 IQ7 Copied Image Colors Do Not Match the Original

Step Questions and Actions Yes No

1 Print the Graphics Demo page.

Make a copy of the Graphics Demo page. Do the colors vary between the two?

2 Check and/or adjust the Control Panel copy

settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Does the problem persist after making the adjustments?

3 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

4 Replace the DADF.

Does the problem persist?

5 Check the cabling between the Scanner and

Print Engine. Is the cabling damaged?

Go to Step 2. Complete.

Go to Step 3. Complete.

Go to Step 4. Complete.

Go to Step 5. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Replace the Electronics Module. If the problem persists, replace the Scanner Assembly (REP 1.0.11).

Image Quality

IQ5, IQ7

09/2007

3-6

Initial Issue

Phaser 8860/8860MFP Service Manual

IQ8 Dark Streaks on Copied Image

This RAP addresses image quality problems associated with the Scanner Assembly.

IQ9 Copy Image is Skewed

This RAP addresses image quality problems associated with the Scanner Assembly.

Initial Actions

1. Check that supported media is being used.

2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.

3. Check for Ink build-up or debris. Clean if necessary.

4. Copy another page. If the problem persists, perform the following corrective actions.

Procedure

Table 1 IQ8 Dark Streaks on Copied Image

Step Questions and Actions Yes No

1 Check the CVT Window for ink build up.

Clean the CVT Window. Scan another page. Does the problem persist?

2 Check DADF calibration.

Perform the DADF to Scanner Calibration adjustment procedure (ADJ 1.15.1). Does the problem persist?

Go to Step 2. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Complete.

Initial Actions

1. Check that supported media is being used.

2. Adjust the guides on the DADF Input Tray.

3. Check that image skew exceeds specifications.

4. Reseat all DADF connections.

Procedure

Table 1 IQ9 Copy Image is Skewed

Step Questions and Actions Yes No

1 Check that the original is printed on sup-

ported media and is undamaged. Print the Paper Tips page for a listing of supported media. Is the original supported?

2 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

Go to Step 2. Use the Platen.

Replace the Scanner Assembly (REP 1.0.11).

Complete.

Initial Issue

Phaser 8860/8860MFP Service Manual

09/2007

3-7

Image Quality

IQ8, IQ9

IQ10 Copy Image is Lighter or Darker than the Original

This RAP addresses image quality problems associated with the DADF.

IQ11 Copied Image Colors Do Not Match the Original

This RAP addresses image quality problems associated with the DADF.

Initial Actions

1. Check that supported media is being used.

2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.

Procedure

Table 1 IQ10 Copy Image is Lighter or Darker than the Original

Step Questions and Actions Yes No

1 Check and/or adjust the Control Panel copy

settings.

1. Print the Troubleshooting Print Quality 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 Standard.

Does the problem persist after making the adjustments?

2 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

Go to Step 2. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Complete.

Initial Actions

1. Check that supported media is being used.

2. Reseat all cable connections between the Scanner Assembly and the Electronics Module.

3. Cycle power to the system.

NOTE: There can be slight color variations from an original copy to a solid ink print resulting from the physical properties of the original, (i.e., ink jet copy, laser toner copy, etc.). Reds may never match the original. A Laser Original Mode is also available to adjust the imaging system to more accurately produce copies of laser originals. Color matching varies because the reflective characteristics of the original vary.

Procedure

Table 1 IQ11 Copied Image Colors Do Not Match the Original

Step Questions and Actions Yes No

1 Print the Graphics Demo page.

Make a copy of the Graphics Demo page. Do the colors vary between the two?

2 Check and/or adjust the Control Panel copy

settings. Print the Troubleshooting Print Quality page and evaluate the Output Quality and Color Settings section. Does the problem persist after making the adjustments?

3 Adjust the Original Type and Output Quality

modes and monitor how the copy changes with different combinations of settings. Does the problem persist?

4 Perform the DADF to Scanner Calibration

adjustment procedure (ADJ 1.15.1). Does the problem persist?

5 Replace the DADF (REP 1.0.15).

Does the problem persist?

6 Check the cabling between the Scanner and

Print Engine. Is the cabling damaged?

Go to Step 2. Complete.

Go to Step 3. Complete.

Go to Step 4. Complete.

Go to Step 5. Complete.

Go to Step 6. Complete.

Replace the Scanner Assembly (REP 1.0.11).

Replace the Electronics Module (REP 5.0.5). If the problem persists, replace the Scanner Assembly.

Image Quality

IQ10, IQ11

09/2007

3-8

Initial Issue

Phaser 8860/8860MFP Service Manual

XEROX PHASER 8860, PHASER 8860MFP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

About This Manual

Organization

Power Safety

Service Safety Summary

Moving the System

Symbology and Nomenclature

Electrostatic Discharge Precautions

Regulatory Specifications

Phaser 8860/8860MFP Overview

System Configurations

Parts of the 8860MFP

8860MFP Control Panel Layout

Parts of the 8860

8860 Control Panel Layout

8860 Menu Map

System Specifications

1 Service Call Procedures

Service Call Procedures

Initial Actions

Routine Maintenance Activities

Cleaning Procedures

Final Actions

2 Error Messages and Codes

Power On Self Tests

NVRAM Reset

Error Message Troubleshooting

1,00X.4x 525-Sheet Feeder Faults

1,000.6x 525-Sheet Feeder Program Faults

2,00X.xx I/O Board Errors

2,006.xx I/O Board Program Faults

2,0XX.6x Configuration Card Faults

3,0XX.6x IPC Program Faults

4,0xx.4x Process Control Errors

4,024.42 Wiper Alignment Fault

4,025.46 Drum Transfix Fault

4,0xx.6x Process Control Program Faults

5,0xx.4x Y-Axis Sub-System Faults

5,0xx.6x Y-Axis Sub-System Program Faults

6,0xx.4x X-Axis Fault

6,0xx.6x X-Axis Program Faults

7,002.44 Process Drive Fault

7,006.4x Head Tilt Solenoid Fault

7,007.49 Process Drive Fault

7,008.41 Printhead Tilt Fault

7,009.42 Printhead Restraint Fault

7,01X.4x Process Faults

7,0xx.6x Program Faults

8,0XX.4x Wiper or Media Drive Faults

8,0xx.6x Media Drive Program Faults

9,0XX.4x Ink Loader Faults

9,009.44 and 9,00X.6x Ink Loader Program Faults

11,0XX.xx Electronics Module Interface Faults

11,100.60 Electronics Module Temperature Fault

11,300.6x EMC Motor Control Faults

12,000.60 Program Faults

13,000.48 Printhead Thermal Fault

13,003.42 and 13,007.46 Thermal Faults

13,008.47 and 13,010.49 Drum Thermal Faults

13,067.43, 13,069.45, 13,071.47 Drum Temp Sensor Faults

13,XXX.4x Preheater Thermal Faults

13,1XX.4x Left Jetstack Thermal Faults

13,2XX.4x Right Jetstack Thermal Faults

13,XXX.xx Printhead Reservoir Thermal Faults

13,XXX.xx Ink Loader Thermal Faults

13,00x.6x Thermal Program Faults

19,0XX.4x Printhead Calibration Faults

19,0XX.6x Waveform Program Faults

21,000.69 Diagnostic Firmware Version Mismatch

22,0XX.6x Jam Fault

23,0XX.6x NVRAM Faults

23,133.4x RAM Faults

26,0XX.6x Printing Faults

27,0XX.6x Profile Library

29,0XX.6x Jam Manager Faults

31,001.40 Mechanical Initialization Jam