XEROX PHASER 8860, PHASER 8860MFP User Manual
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
Acrobat®, Adobe® Reader®, Adobe Type Manager®, ATM™, Illustrator® PageMaker®, Photoshop®, PostScript®, Adobe Brilliant® Screens, Adobe Garamond®, Adobe Jenson™,
Birch®, Carta®, IntelliSelect®, Mythos®, Quake®, and Tekton® are trademarks of Adobe Systems Incorporated in the United States and/or other countries.
Apple®, AppleTalk®, Bonjour®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac
OS®, TrueType®, Apple Chancery®, Chicago®, Geneva®, Monaco®, New York® , and QuickDraw® are trademarks of Apple Computer, Inc. in the United States and/or other countries.
HP-GL®, HP-UX®, and PCL® are trademarks of Hewlett-Packard Corporation in the United
States and/or other countries.
Xerox Corporation
XOG Worldwide Product Training & Information
26600 Parkway - Bldg. 60
P.O. Box 1000, M/S 7060-776
Wilsonville, OR 97070-1000
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.
Unpublished rights reserved under the copyright laws of the United States. Contents of this
publication may not be reproduced in any form without permission of Xerox Corporation.
Copyright protection claimed includes all forms of matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such
as styles, templates, icons, screen displays, looks, etc.
IBM® and AIX® are trademarks of International Business Machines Corporation in the United
States and/or other countries.
Windows®, Vista™, Windows Server™, and Wingdings® are trademarks of Microsoft Corporation in the United States and/or other countries.
Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services®, IPX™, and Novell Distributed Print Services™ are trademarks of Novell, Incorporated in the United States and/or other
countries.
SunSM, Sun Microsystems™, and Solaris™ are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries.
SWOP® is a trademark of SWOP, Inc.
UNIX® is a trademark in the United States and other countries, licensed exclusively through X/
Open Company Limited.
As an ENERGY STAR® partner, Xerox Corporation has determined that this product meets the
ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
PANTONE® Colors generated may not match PANTONE-identified standards. Consult current
PANTONE Publications for accurate color. PANTONE® and other Pantone, Inc. trademarks are
the property of Pantone, Inc. © Pantone, Inc., 2000.
Xerox technical training materials and service manuals are intended for use by authorized
Xerox service technicians and service partners only and are not for resale. These materials
may not be distributed, copied or otherwise reproduced without prior written consent from
Xerox Corporation.
XEROX®, The Document Company®, the digital X®, CentreWare®, infoSMART®, Made For
Each Other®, PagePack™, Phaser®, PhaserSMART®, and Walk-Up™ are trademarks of
Xerox Corporation in the United States and/or other countries.
Introduction
09/2007
Initial Issue
ii
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
iii
Introduction
Introduction
09/2007
iv
Initial Issue
Phaser 8860/8860MFP Service Manual
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.
Initial Issue
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.
09/2007
v
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.
Introduction
Power Safety, Service Safety Summary
09/2007
vi
Initial Issue
Phaser 8860/8860MFP Service Manual
• 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.
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
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.
09/2007
viii
Phaser 8860/8860MFP Service Manual
Initial Issue
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
ix
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
09/2007
x
Initial Issue
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xi
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
Regulatory Specifications, Phaser 8860/8860MFP
09/2007
xii
Figure 1 Phaser 8860MFP Multifunction Product with Optional Trays
Initial Issue
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xiii
Introduction
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
Introduction
Parts of the 8860MFP
09/2007
xiv
Initial Issue
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xv
Introduction
Parts of the 8860MFP
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
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.
Introduction
09/2007
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.
Initial Issue
xvi
Phaser 8860/8860MFP Service Manual
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.
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xvii
Introduction
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
09/2007
xviii
Phaser 8860/8860MFP Service Manual
Initial Issue
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
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.
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xix
Introduction
Parts of the 8860
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..
Introduction
8860 Control Panel Layout
09/2007
xx
Initial Issue
Phaser 8860/8860MFP Service Manual
8860 Menu Map
NOTE: Maps vary by model.
Figure 1 8860 Menu Map (1/2)
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xxi
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
2
75-255* g/m
2
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.)
Introduction
System Specifications
09/2007
xxii
Initial Issue
Phaser 8860/8860MFP Service Manual
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.
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xxiii
Introduction
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.
º
- 32º C / 50º - 90º F operating
10
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.
Introduction
System Specifications
09/2007
xxiv
Initial Issue
Phaser 8860/8860MFP Service Manual
• 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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
xxv
Introduction
System Specifications
Introduction
System Specifications
09/2007
xxvi
Initial Issue
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
1-1
Service Call Procedures
Service Call Procedures
09/2007
1-2
Initial Issue
Phaser 8860/8860MFP Service Manual
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
Initial Issue
Phaser 8860/8860MFP Service Manual
09/2007
1-3
Service Call Procedures
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
09/2007
1-4
Initial Issue
Phaser 8860/8860MFP Service Manual
Loading...