Brother MFC-5860CN User manual

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FACSIMILE EQUIPMENT
SERVICE MANUAL
MODELS: MFC5860CN
MFC5460CN

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How this manual is organized
This manual is made up of nine chapters and appendices.
CHAPTER 1 PARTS NAMES AND FUNCTIONS
Contains external views and names of components and describes their functions. Information about
the keys on the control panel is included to help you check operation or make adjustments.
CHAPTER 2 SPECIFICATIONS
Lists the specifications of each model, which enables you to make a comparison of different models.
CHAPTER 3 THEORY OF OPERATION
Gives an overview of the scanning and printing mechanisms as well as the sensors, actuators, and
control electronics. It aids in understanding the basic principles of operation as well as locating
defects for troubleshooting.
CHAPTER 4 ERROR INDICATION AND TROUBLESHOOTING
Details error messages and codes that the incorporated self-diagnostic functions display if any error
or malfunction occurs. If any error message appears, refer to this chapter to find which components
should be checked or replaced.
The latter half of this chapter provides sample problems that could occur in the main sections of the
machine and related troubleshooting procedures. This will help service personnel pinpoint and repair
defective components.
CHAPTER 5 TRANSFER OF DATA LEFT IN THE MACHINE TO BE SENT FOR REPAIR
Describes how to transfer data left in the machine to be sent for repair. The service personnel should
instruct end users to follow the transfer procedure given in this chapter if the machine at the user site
cannot print received data due to the printing mechanism defective. End users can transfer received
data to another machine to prevent data loss.
CHAPTER 6 DISASSEMBLY/REASSEMBLY AND LUBRICATION
Details procedures for disassembling and reassembling the machine together with related notes. The
disassembly order flow provided enables you to see at a glance the quickest way to get to
component(s) involved.
At the start of a disassembly job, you check the disassembly order flow that guides you through a
shortcut to the target components.
This chapter also covers screw tightening torques and lubrication points to which the specified
lubricants should be applied during reassembly jobs.
CHAPTER 7 ADJUSTMENTS AND UPDATING OF SETTINGS, REQUIRED AFTER PARTS
REPLACEMENT
Details adjustments and updating of settings, which are required if the head/carriage unit, main PCB
and some other parts have been replaced.
CHAPTER 8 CLEANING
Provides cleaning procedures not covered by the User's Guide. Before starting any repair work, clean
the machine as it may solve the problem concerned.

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CHAPTER 9 MAINTENANCE MODE
Describes the maintenance mode which is exclusively designed for the purpose of checks, settings
and adjustments of the machine using the keys on the control panel.
In the maintenance mode, you can update memory (EEPROM: electrically erasable programmable
read-only memory) contents for optimizing the drive conditions of the head/carriage unit or the paper
feed roller and paper ejection roller in the engine unit, if those units have been replaced, or for setting
the CIS scanner area, for example. You can also customize the EEPROM according to the shipment
destination of the machine concerned. In addition, you can perform operational checks of the LCD,
control panel PCB or sensors, perform a print test, display the log information or error codes, and
modify firmware switches (WSW).
Appendix 1 Reading Labels
Shows the location of labels put on some parts and describes the coding information for serial
number, property data, and manufacturing information.
Appendix 2 Firmware Installation
Provides instructions on how to change firmware stored in the flash ROM on the main PCB or load
firmware to a new main PCB from the host PC.
Appendix 3 EEPROM Customizing Codes
Provides instructions on how to set up the EEPROM customizing codes for the various preferences
exclusively designed for each destination. The specified customizing code is stored in the EEPROM
mounted on the main PCB. If the main PCB is replaced, therefore, you need to set up the proper
customizing code with the machine in the maintenance mode.
Customizing codes customize firmware for individual models, enabling the common firmware to be
used for various models. A list of EEPROM customizing codes comes with the firmware data
provided by Brother Industries.
Appendix 4 Firmware Switches (WSW)
Describes the functions of the firmware switches, which can be divided into two groups: one is for
customizing preferences designed for the shipping destination (as described in Appendix 3) and the
other is for modifying preferences that match the machine to the environmental conditions. Use the
latter group if the machine malfunctions due to mismatching.
Appendix 5 Wiring Diagrams
Provides the wiring diagrams that help you understand the connections between PCBs.
Appendix 6 Circuit Diagrams
Provides the circuit diagrams of the MJ PCB and power supply PCB.
Appendix 7 Deletion of Personal Information
Provides instructions on how to delete personal information recorded in the machine.

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CHAPTER 4 ERROR INDICATION AND TROUBLESHOOTING
This chapter details error messages and codes that the incorporated self-diagnostic functions
display if any error or malfunction occurs. If any error message appears, refer to this chapter to
find which components should be checked or replaced.
The latter half of this chapter provides sample problems that could occur in the main sections of
the machine and related troubleshooting procedures. This will help service personnel pinpoint and
repair defective components.
CONTENTS
4.1 ERROR INDICATION..................................................................................................4-1
4.1.1 Equipment Errors.............................................................................................4-1
[ 1 ] Error messages appearing on the LCD.....................................................4-1
[ 2 ] Error codes contained in "MACHINE ERROR X X" messages ..................4-6
4.1.2 Communications Errors..................................................................................4-20
4.2 TROUBLESHOOTING ..............................................................................................4-27
4.2.1 Introduction....................................................................................................4-27
4.2.2 Precautions....................................................................................................4-27
4.2.3 Checking Prior to Troubleshooting..................................................................4-27
4.2.4 Troubleshooting Based on Problem Type.......................................................4-29
[ 1 ] Control panel and LCD problems............................................................4-29
[ 2 ] FAX problems........................................................................................4-29
[ 3 ] Communications problems.....................................................................4-30
[ 4 ] Paper/document feeding problems.........................................................4-30
[ 5 ] Print-image problems.............................................................................4-31
[ 6 ] PC-driven printing problems...................................................................4-36
[ 7 ] Printing from memory cards--Compact Flash, Memory Stick,
SD Memory Card, or xD-Picture Card ....................................................4-36
[ 8 ] Others....................................................................................................4-36
4.2.5 Problems Encountered Frequently in the Past................................................4-37
[ 1 ] Paper jams.............................................................................................4-37
[ 2 ] "MACHINE ERROR 4F" error message..................................................4-38
[ 3 ] Ink-related problems...............................................................................4-38
[ 4 ] Auto document feeder (ADF) malfunction...............................................4-39
4.2.6 Possible Component Defects and Resulting Problems ...................................4-41

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[ 1 ] ADF mechanism.....................................................................................4-41
[ 2 ] Scanner mechanism...............................................................................4-42
[ 3 ] Head/carriage unit drive and purge mechanisms....................................4-43
[ 4 ] Print head mechanism............................................................................4-44
[ 5 ] Sheet feeder (SF) mechanism................................................................4-45
[ 6 ] Paper feeding mechanism......................................................................4-45
[ 7 ] Speaker..................................................................................................4-45
[ 8 ] Control panel..........................................................................................4-46
[ 9 ] PCBs......................................................................................................4-46
[ 10 ] Adjustments/data in the memories..........................................................4-47

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CHAPTER 6 DISASSEMBLY/REASSEMBLY AND LUBRICATION
This chapter details procedures for disassembling and reassembling the machine together with
related notes. The disassembly order flow provided enables you to see at a glance the quickest
way to get to component(s) involved.
At the start of a disassembly job, you check the disassembly order flow that guides you through
a shortcut to the target components.
This chapter also covers screw tightening torques and lubrication points to which the specified
lubricants should be applied during reassembly jobs.
CONTENTS
6.1 DISASSEMBLY/REASSEMBLY..................................................................................6-1
Safety Precautions...................................................................................................6-1
Tightening Torque....................................................................................................6-2
Preparation..............................................................................................................6-3
How to Access the Target Component.....................................................................6-4
Disassembly Flowchart............................................................................................6-5
6.1.1 Jam Clear Cover..............................................................................................6-6
6.1.2 Scanner Cover (Scanner Unit), Scanner Cover Support and Damper................6-7
6.1.3 ADF & Document Cover ASSY.......................................................................6-12
6.1.4 Disassembly of ADF & Document Cover ASSY ..............................................6-14
6.1.5 Control Panel ASSY, Scanner Cover Sensor Actuator, Ink Cartridge
Cover Sensor Actuator, and Cover Sensor PCB .............................................6-26
6.1.6 Disassembly of Control Panel ASSY...............................................................6-28
6.1.7 Upper Cover...................................................................................................6-30
6.1.8 Speaker .........................................................................................................6-32
6.1.9 Ink Cartridge Cover and Media Module Cover.................................................6-33
6.1.10 Main PCB.......................................................................................................6-34
6.1.11 High Yield Ink Cartridge Sensor PCB..............................................................6-38
6.1.12 LT Cover, LT Front Cover, LT Paper Pull-in Roller and Gear...........................6-39
6.1.13 MJ/PS Shield Unit and Power Supply PCB.....................................................6-41
6.1.14 Head/Carriage Unit and Ink Refill ASSY .........................................................6-44
6.1.15 Ink Absorber Box, Ink Absorber Felt, and PF Encoder Disk.............................6-56
6.1.16 Engine Unit and Flushing Box.........................................................................6-58

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6.1.17 Components on the Engine Unit (Maintenance unit, Mode switching lever &
clutch gear ASSY, Carriage motor, Inner chute ASSY, Registration sensor
PCB, PF encoder PCB, Paper feed motor, Paper pull-in gear shaft, and
Paper pull-in roller holder) ..............................................................................6-62
6.1.18 Paper Tray ASSY...........................................................................................6-68
6.1.19 Paper Tray ASSY #2 (For models with paper tray #2).....................................6-70
6.1.20 Routing of the Harnesses, Flat Cables, and Ink Supply Tubes........................6-72
6.2 LUBRICATION..........................................................................................................6-80

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6.1 DISASSEMBLY/REASSEMBLY
Safety Precautions
To prevent the creation of secondary problems by mishandling, observe the following precautions
during maintenance work.
(1) Before replacing parts or units, unplug the power cord and telephone line.
In particular, when having access to the power supply inside the machine, make sure that the
power cord is unplugged from the electrical outlet; when having access to the main PCB or MJ
PCB, make sure that both the power cord and telephone line are unplugged from the electrical
outlet.
(2) Be careful not to lose screws, washers, or other parts removed for parts replacement.
(3) When using soldering irons and other heat-generating tools, take care not to damage the resin
parts such as wires, PCBs, and covers.
(4) Static electricity charged in your body may damage electronic parts.
Before handling the PCBs, touch a metal portion of the machine to discharge static electricity
charged in your body. When transporting PCBs, be sure to wrap them in conductive sheets.
When replacing the head/carriage unit, put on a grounding wrist band and perform the job on a
static mat. Also take care not to touch the conductor sections on the flat cables.
(5) Be sure to reinsert self-tapping screws correctly, if removed.
(6) Tighten screws to the torque values listed on the next page.
(7) When connecting or disconnecting cable connectors, hold the connector bodies not the wires. If
the connector has a lock, always slide the connector lock to unlock it.
(8) Before reassembly, apply the specified lubricant to the specified points. (Refer to Section 6.2 in
this chapter.)
(9) After repairs, check not only the repaired portion but also that the connectors and other related
portions function properly before operation checks.
(10) Once the head/carriage unit prints, it will start head locking operation after five seconds from
the end of printing. The head locking operation will take 5 to 10 seconds. NEVER unplug the
power cord before the machine completes the head locking operation; doing so will make the
head/carriage unit unusable and require replacement with a new head/carriage unit.
When you receive the machine from the user or when you pack it for sending it back to the
user, check the head locking state.

Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual
Brother MFC-5460CN MFC-5860CN service manual