701P28180.pdf part of XEROX 701P28180 701P28180.part01.rar, 406 page service manual for Xerox Phaser 7700 color laser printer. text manual preview

Text preview for : 701P28180.pdf part of XEROX 701P28180 406 page service manual for Xerox Phaser 7700 color laser printer.

Back to : 701P28180.part01.rar | Home

Service Manual
701P28180

Phaser 7700 Color Laser Printer
®

Service Manual 701P28180

Phaser®7700
Color Laser Printer

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so. This printing: December 2006

Prepared By: Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville, OR 97070 © 2006 by Xerox Corporation. All rights reserved. Unpublished rights reserved under the copyright laws of the United States.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 and 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. 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®, CentreWare®, Phaser®, PrintingScoutTM, TekColorTM, and Walk-Up® are trademarks of Xerox Corporation in the United States and/or other countries. Adobe Reader®, Adobe Type Manager®, ATMTM, and PostScript® are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple®, AppleTalk®, EtherTalk®, LaserWriter®, LocalTalk®, Macintosh®, Mac OS®, and TrueType® 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. Windows® and Windows ServerTM are trademarks of Microsoft Corporation in the United States and/or other countries. Novell®, NetWare®, NDPS®, NDS®, Novell Directory Services®, IPXTM, and Novell Distributed Print ServicesTM are trademarks of Novell, Incorporated in the United States and/or other countries. SunSM, Sun MicrosystemsTM, and SolarisTM are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries. SWOP® is a trademark of SWOP, Inc. UNIX® is a registered trademark in the US and other countries, licensed exclusively through X/Open Company Limited. 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.

ii

Phaser 7700 Color Printer Service Manual

User Safety Summary
Terms in Manual
Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols and terms when they are used, and always read NOTE, CAUTION and WARNING messages. NOTE: A NOTE may indicate an operating or maintenance procedure, practice or condition that is necessary to efficiently accomplish a task. A NOTE may also provide additional information related to a specific subject or add a comment on the results achieved through a previous action. CAUTION: A CAUTION indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. WARNING: A WARNING indicates an operating, or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.

Terms on Product
CAUTION: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. DANGER: A personal injury hazard exists in the area where you see the sign.

Phaser 7700 Color Printer Service Manual

iii

Power Source
For 110 VAC printers, DO NOT apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 240 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. Refer to a qualified service technician for changes to the cord or connector. WARNING: If the product loses the ground connection, usage of controls and other conductive parts can cause an electrical shock.

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

Mechanical Components
Manually rotate drive assemblies to inspect and gears.
Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running

iv

Phaser 7700 Color Printer Service Manual

Laser Components
WARNING: This printer generates a laser beam as part of the printing process. The laser beam in this printer is invisible. Direct eye exposure to the laser beam may cause eye injury or blindness.

To avoid permanent eye damage, follow these directions:

Before starting any service procedure, switch off the printer power and unplug the power cord from the AC wall outlet. Do not disassemble the Laser Scanner Assembly. Use caution when you are working around the Laser Scanner Assembly or when you are performing laser related troubleshooting or repair procedures. Never place a mirror or a reflective tool or object in the laser beam path. Do not disassemble the printer in such a way that the laser beam can exit the print engine during a print cycle.

Fuser Components
WARNING: This printer uses heat to fuse the toner image to a sheet of paper. The Fuser Assembly is very hot. Turn Off the printer power and wait at least 30 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.

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

Warning Labels
Throughout the printer, warning labels are displayed on potentially dangerous components. When you service the printer, check to make certain that all warning labels are in place. Most importantly, read and obey all posted warning labels. WARNING: Turning the power Off using the On/Off switch does not de-energize the printer. You must remove the power cord to disconnect the printer from the main power source. Keep the power cord accessible for removal in case of an emergency.

Phaser 7700 Color Printer Service Manual

v

Safety Instructions
Read all installation instructions carefully before you plug the product into a power source.

Care of Product
Disconnect the power plug by pulling the plug, not the cord.

Disconnect the power plug if the power cord or plug is frayed or otherwise damaged, Or if any liquid or foreign material is spilled into the case, Or if the printer is exposed to any excess moisture, Or if the printer is dropped or damaged, Or if you suspect that the product needs servicing or repair, And whenever you clean the product.

Ground the Product
Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If necessary, contact a licensed electrician to install a properly grounded outlet.

vi

Phaser 7700 Color Printer Service Manual

Service Safety Summary
General Guidelines
For qualified service personnel only: Refer also to the preceding Users Safety Summary. Do not service 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 on: 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, soldering, or replacing components. Do not wear jewelry: Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into contact with dangerous voltages and currents. Power Source: This product is intended to operate from a power source that does not apply more than 127 or 240 volts AC RMS (depending on printer model) between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Class 1 Laser Product
The Phaser® 7700 Color Printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation. The laser and output of the laser scanner unit produces a beam that, if looked into, could cause eye damage. Service procedures must be followed exactly as written without change. When servicing the machine or laser module, follow the procedures specified in the manual to avoid any hazards from the laser. Laser (FDA): Any laser label visible to service must be reproduced in the service manual with location shown or indicated. Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included.

Phaser 7700 Color Printer Service Manual

vii

Federal Communication Commision Compliance
This equipment has been tested and found to comply with the limits set for a Class B digital device, as stated in 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 may radiate radio frequency energy. If not installed and used in accordance with the instructions provided, this equipment may cause disruptive interference to nearby radio and television communications. Even if the equipment is installed according to the instructions, there is no guarantee of no interference in a particular installation. If this equipment does cause disruptive interference to nearby radio and television reception, switch the equipment off to determine if it is the true cause of the interference. If the equipment is the cause of the interference, the user should try to minimize the interference by taking one or more of the following courses of action: Note

Installation of the Finisher and/or the Token Ring Interface results in an FCC classification change to Class A.

Either reorient or relocate the radio/television receiving antenna. Increase the separation between the equipment and the radio/television receiver. Connect the equipment to an AC outlet that is not on the same circuit as the radio/television receiver. If the previous solutions fail to bring results, you should consult either your equipment dealer or an experienced radio/television technician.

For more information on interference, refer to the Federal Communications Commission's booklet "How to Identify and Resolve Radio-TV Interference Problems." This booklet is available from the U.S. Government Printing Office, Washington D.C. 20402, Stock No. 004-000-00345-4.

viii

Phaser 7700 Color Printer Service Manual

Canadian Notice
This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as described in the radio interference regulations of the Canadian Department of Communications. Note Installation of the Finisher and/or the Token Ring Interface results in a classification change to Class A.

Avis Canadien
Cet appareil numerique est conforme aux limites émission de bruits radioélectriques pour les appareils de classe B stipulés das le réglement sur le brouillage radioéletrique du Ministére des Communcations du Canada.

European Notice
This equipment was tested and is determined to be compliant with VDE requirements for a Class B device.

Hinweis
Hiermit wird bescheinigt, dass der Babe Laserdrucker, in bereinstimmung mit den Betimmunngen der Vfg 104ß 984 funkenstört ist. Der Deutschen Bundespost wurde das Inverkehrbringen dieses Gertëes angqeigt und die Berechtigung zur berprufung der Serie auf Einhaltung der Bestimmungen eingeräumt.

Phaser 7700 Color Printer Service Manual

ix

ESD Precautions
Some semiconductor devices are easily damaged from static electricity. These components are Electrostatically Sensitive Devices (ESDs); examples include integrated circuits (ICs), Large-Scale Integrated circuits (LSIs), some field-effect transistors and semiconductor chip components. The following techniques reduce the occurrence of component damage caused by static electricity: CAUTION: 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 by touching a known earth ground. Alternatively, wear a discharging wrist strap device. (Be sure to remove the strap before applying power to the unit under test to avoid potential shock.) After removing an ESD-equipped assembly, place it on a conductive surface such as aluminum foil or the static bag to prevent accumulation of an electrostatic charge. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage ESDs. Do not remove a replacement ESD from its protective package until you are ready to install it. Most replacement ESDs are packaged with leads that are electrically shorted together by conductive foam, aluminum foil or other conductive materials. Immediately before removing the protective material from the leads of a replacement ESD, touch the protective material to the chassis or circuit assembly into which the device is to be installed. Minimize body motions when handling unpackaged replacement ESDs. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an ESD. Handle ICs and EPROMs carefully to avoid bending a pin. Pay attention to the direction of parts when mounting or inserting them on a PCB.

x

Phaser 7700 Color Printer Service Manual

Contents
User Safety Summary .............................................................................................. 1-iii Terms in Manual ............................................................................................... 1-iii Terms on Product ............................................................................................. 1-iii Power Source ................................................................................................... 1-iv Power Supply and Electrical Components ......................................................... 1-iv Mechanical Components ................................................................................... 1-iv Laser Components ............................................................................................. 1-v Fuser Components ............................................................................................. 1-v Safety Components ............................................................................................ 1-v Warning Labels .................................................................................................. 1-v Safety Instructions ............................................................................................ 1-vi Care of Product ................................................................................................. 1-vi Ground the Product .......................................................................................... 1-vi Service Safety Summary ......................................................................................... 1-vii General Guidelines ........................................................................................... 1-vii Class 1 Laser Product ...................................................................................... 1-vii Federal Communication Commision Compliance ............................................ 1-viii Canadian Notice ................................................................................................ 1-ix Avis Canadien ................................................................................................... 1-ix European Notice ................................................................................................ 1-ix Hinweis ............................................................................................................. 1-ix ESD Precautions ....................................................................................................... 1-x

Contents List of Tables List of Figures

2-xi 2-xxi 1-xxiii

Phaser 7700 Color Laser Printer Service Manual

xi

General Information

1-1

Phaser 7700 Printer Overview .................................................................................. 1-2 Printer RAM and Printer Capabilities ................................................................. 1-4 CRC Life Counter Behavior ................................................................................ 1-5 Engine Control Interface and Power Supply Boards .......................................... 1-6 Power Supplies ................................................................................................. 1-7 Engine Control and Image Processor Boards .................................................... 1-8 Auxiliary Feeder Control Board .......................................................................... 1-9 Print Engine Sensors and Switches ................................................................. 1-10 Print Engine Sensors and Switches (cont'd.) ................................................. 1-11 Auxiliary Feeder Sensors and Switches ........................................................... 1-12 Auxiliary Feeder Actuators and Clutches ......................................................... 1-13 Print Engine Solenoids, Actuators, and Clutches ............................................ 1-14 Print Engine and Auxiliary Feeder Interlocks and Sensors ............................... 1-15 Image Processor Board ................................................................................... 1-16 Assemblies of the Print Engine ........................................................................ 1-17 Assemblies of the Print Engine (cont'd.) ........................................................ 1-18 Assemblies of the Print Engine (cont'd.) ........................................................ 1-19 Auxiliary Feeder Assemblies ........................................................................... 1-20 Front Panel Description .......................................................................................... 1-21 LED indicators ................................................................................................. 1-21 Front Panel Shortcuts ...................................................................................... 1-22 Rear Panel .............................................................................................................. 1-23 Connectors ...................................................................................................... 1-23 Printer Specifications 1-24 Physical Dimensions and Clearances .............................................................. 1-24 Supported Paper Weights, Page Sizes and Print Area ..................................... 1-27

Diagnostics, Error Codes and Messages

2-31

Error Messages 2-31 Troubleshooting Error Codes 2-31 Chain / Link ..................................................................................................... 2-31 Where do they come from? ............................................................................. 2-31 Why are they here? ......................................................................................... 2-31 System Boot Sequence ................................................................................... 2-32 Power On Self Test (POST) ............................................................................. 2-32 POST Faults ..................................................................................................... 2-33 Fault Reporting Devices ................................................................................... 2-33 LED Blink Patterns ........................................................................................... 2-33 POST Diagnostics Test Descriptions ............................................................... 2-34 Service Diagnostics ................................................................................................ 2-35 xii Phaser 7700 Color Laser Printer Service Manual

Entering Service Diagnostics Mode .................................................................2-35 Service Diagnostics Test Menu Functions ........................................................2-36 Error Codes and Messages Troubleshooting ...........................................................2-46 Voltage Measurements ............................................................................................2-46 Fuser Connector Pin Locations ........................................................................2-47

Troubleshooting

3-87

Troubleshooting Network Problems ........................................................................3-88 Operating System and Application Problems ...................................................3-88 Media Jams and the Paper Path .......................................................................3-88 Print Image Quality Problems ..........................................................................3-88 Troubleshooting Power Supplies and Interlocks .....................................................3-89 Troubleshooting AC Power ..............................................................................3-89 Troubleshooting the Low-voltage Power Supplies ...........................................3-89 Troubleshooting the +3.3 VDC and +5 VDC LVPS ............................................3-90 Troubleshooting the +24 VDC LVPS ................................................................3-90 Interlock Circuit Diagram .................................................................................3-91 The +24 VDC Interlock Circuit ..........................................................................3-91 The +5 VDC Interlock Circuit ............................................................................3-92 Troubleshooting When the Printer Does Not Come to a "Ready" State ...................3-93 Printer Does Nothing When Power Switched On .............................................3-93 Fans On, Front Panel LED Never On .................................................................3-93 Fans On, Front Panel LED is Red, No Front Panel message .............................3-93 Front Panel Continually Displays the Xerox Phaser 7700 Splash Screen .........3-93 Front Panel Continually Displays "warming up - please wait" Message ............3-93 Front Panel displays "Fatal Fault Encountered" message .................................3-94 Troubleshooting - Printer Comes to a "Ready" State ..............................................3-94 False LH Door, RH Door, or Front Door Open Messages .................................3-94 False "Load Paper in Tray [1,2,3,4]" Message ..................................................3-94 False "Tray [1,2,3,4] Missing" Message ...........................................................3-94 Tray 1 Will Not Lift ...........................................................................................3-95 Tray 2, 3 or 4 Will Not Lift ................................................................................3-95 Tray 2, 3 and 4 Will Not Lift or Printer Will Not Recognize the Auxiliary Feeder ......................................................3-96 Printer Will Not Recognize the Finisher ............................................................3-96 Troubleshooting the Toner Dispense/Auger/Developer System ..............................3-97 Checking the Toner Cartridge ...........................................................................3-97 Checking the Toner Auger System ...................................................................3-98 Checking the Developer ATC Sensor ..............................................................3-101 Checking the Developer .................................................................................3-102 Tips ................................................................................................................3-102 Operation System and Application Problems ........................................................3-104 Macintosh Printing Problems ........................................................................3-104 Phaser 7700 Color Laser Printer Service Manual xiii

Windows Printing Problems .......................................................................... 3-104 Troubleshooting Network Problems .............................................................. 3-105 Media Jams and the Paper Path ........................................................................... 3-106 Media-based Problems .................................................................................. 3-106 Multiple-sheet Pick ........................................................................................ 3-106 Mis-pick ........................................................................................................ 3-106 Skewed Image ............................................................................................... 3-106 Damaged Prints ............................................................................................. 3-107 Fuser Jams .................................................................................................... 3-107 Exit Jams ....................................................................................................... 3-107 Print Image Quality Problems ............................................................................... 3-108 Light (undertone) Prints (all colors) .............................................................. 3-108 Blank Prints ................................................................................................... 3-108 One Color is Faded or Missing ...................................................................... 3-109 Missing Band in Direction of Paper Travel ..................................................... 3-110 Streaks in Direction of Paper Travel .............................................................. 3-111 Streaks Parallel with the Leading Edge .......................................................... 3-112 Random Missing Spots ................................................................................. 3-113 Random Spotting ......................................................................................... 3-113 Single Color ................................................................................................... 3-113 All Colors ....................................................................................................... 3-114 Repetitive Mark Appears on Each Print ......................................................... 3-114 Background Contamination ........................................................................... 3-115 Unfused Image or Image Easily Rubs Off of Page ......................................... 3-116 Toner on Back of Print ................................................................................... 3-117 Print is Mottled .............................................................................................. 3-118 Image Mis-registered on Paper ..................................................................... 3-119 Residual Image or Ghosting .......................................................................... 3-120 Light Bands, Dark Bands, or Mottled Prints .................................................. 3-121

Adjustments and Calibration

4-123

Internal Hard Drive 4-123 Registration Control (RegiCon) Adjustment Overview .......................................... 4-124 Coarse RegiCon Initialization ......................................................................... 4-124 Coarse and Fine Skew Adjustments ............................................................... 4-125 In/Out Skew Adjustment ................................................................................ 4-125 Center Skew Adjustment ............................................................................... 4-126 Processes of the RegiCon Adjustment .................................................................. 4-127 Check Print-quality ........................................................................................ 4-127 Preparation for RegiCon ................................................................................ 4-127 Registration Control Procedures .......................................................................... 4-130 RegiCon Flowchart ........................................................................................ 4-133 Step 1: Belt Edge Learn ................................................................................. 4-134 xiv Phaser 7700 Color Laser Printer Service Manual

Step 2: RegiCon #4 Coarse Skew Adjustment ...............................................4-135 Step 3: RegiCon #1 Fine Skew Adjustment ....................................................4-137 Step 4: RegiCon #2 In/Out Skew Adjustment .................................................4-138 Step 5: RegiCon #3 Center Skew Adjustment ................................................4-139 Coarse RegiCon Initialization .................................................................................4-140 ATC Sensor Setup .................................................................................................4-142 Additional Information ...................................................................................4-142

Cleaning and Maintenance

5-143

Service Preventive Maintenance Procedure ..........................................................5-143 Recommended Tools .....................................................................................5-143 Cleaning .........................................................................................................5-143

Resetting NVRAM

6-145

PostScript NVRAM Resets ....................................................................................6-145 Restore Factory Settings (color) ....................................................................6-145 Restore Previous Settings (color) ..................................................................6-145 Restore Factory Settings (margins) ...............................................................6-146 Reset Calibrations (color, margins, paper) ....................................................6-146 Resetting All Printer Default Settings (NVRAM) .............................................6-146 Resetting Engine NVRAM ..............................................................................6-146 Resetting Job Defaults ...................................................................................6-147 Resetting Network Setup Values to Default ....................................................6-147 Resetting Accumulator Belt Life .....................................................................6-147 Resetting Belt Cleaner Assembly Life .............................................................6-148 Resetting Transfer Roller Life ........................................................................6-148 Service Diagnostics NVRAM Resets ......................................................................6-149 PostScript NVRAM Reset ...............................................................................6-149 Clear Tech Rep Faults ....................................................................................6-149 Reset CRU Life Counters ...............................................................................6-149 Reset Engine NVRAM ....................................................................................6-150 Store Engine NVRAM .....................................................................................6-150

Phaser 7700 Color Laser Printer Service Manual

xv

Removal and Replacement Procedures

7-151

Rear Cover Assembly 7-154 Right Side Cover Assembly .................................................................... 7-155 Top Cover Assembly .............................................................................. 7-156 Front Panel Assembly ............................................................................. 7-157 Rear Cover, Top Rear Power Switch Cover and LH Rear Mid Cover ....... 7-158 Left-Hand Lower Cover Assembly .......................................................... 7-160 Front Cover Assembly ............................................................................ 7-161 Fuser Front Cover ................................................................................... 7-162 Rear Shield ............................................................................................ 7-163 Rear Shield Bracket ................................................................................ 7-164 24 VDC Power Supply Shield ................................................................. 7-165 Multi-Purpose Tray (MPT) Assembly ..................................................... 7-166 Multi-Purpose Tray Paper Pick Rollers ................................................... 7-167 Left-Hand Cover Assembly (Left-Hand Door) ......................................... 7-168 Duplex Chute .......................................................................................... 7-170 Duplex Unit Assembly ............................................................................ 7-171 Transfer Roller Assembly (2nd BTR) ...................................................... 7-172 Duplex Transport Assembly ................................................................... 7-173 Fuser Unit ............................................................................................... 7-174 Registration Transport Assembly ........................................................... 7-175 Shutter Solenoid Assembly .................................................................... 7-176 Tray 1 Feeder Assembly and Paper Lift Motor ........................................ 7-177 Waste Cartridge Sensor Holder .............................................................. 7-178 Print Cartridge Plate Cover .................................................................... 7-179 Dispense Assembly ................................................................................ 7-180 Print Cartridge Plate Assembly ............................................................... 7-182 Developer Housing Assembly ................................................................. 7-185 New Developer Housing Assembly Charging ......................................... 7-186 Toner Dispense Motor Assembly ........................................................... 7-188 Steering Drive Assembly ........................................................................ 7-189 Waste Toner Agitator Motor Assembly ................................................... 7-190 Mark-On-Belt (MOB) Sensor .................................................................. 7-191 Exit Transport Assembly ........................................................................ 7-192 Fuser Fan Assembly ............................................................................... 7-195 Accumulator Belt Assembly .................................................................. 7-196 Belt Cleaner Assembly ............................................................................ 7-198 Waste Auger Assembly .......................................................................... 7-199 Laser Unit ............................................................................................... 7-200 Image Processor Board Assembly ......................................................... 7-202 Internal Hard Drive ................................................................................. 7-203 Electrical Chassis (Card Cage) Assembly ............................................... 7-204 Engine Control Board ............................................................................ 7-206 Engine Control Interface Board .............................................................. 7-207 xvi Phaser 7700 Color Laser Printer Service Manual

T1 and T3 High-voltage Power Supplies .................................................7-208 3.3 VDC and 5 VDC Low-Voltage Power Supplies and Bracket ...............7-210 LD Power Relay ......................................................................................7-211 +24 VDC Low-voltage Power Supply, Fan and Bracket ...........................7-212 T2 High-Voltage Power Supply ..............................................................7-213 Chassis AC Power Assembly ..................................................................7-214 Main Drive Assembly ..............................................................................7-215 Accumulator Belt Drive Assembly ...........................................................7-217 Developer Drive Assembly ......................................................................7-218 Print Cartridge Drive Assembly ...............................................................7-219 Tray 1 Paper-Select Switches .................................................................7-220 Main Lever Assembly Right and Left-Hand Jacks ....................................................................................7-221 Auxiliary Feeder Covers ..........................................................................7-225 Auxiliary Feeder Cover Assembly ............................................................7-226 High-Capacity Feeder (HCF) Tray 3 .........................................................7-227 High-Capacity Feeder (HCF) Tray 4 and Paper Transport .......................7-228 Auxiliary Feeder Control Boards ..............................................................7-229 Auxiliary Feeders Motor Assemblies ......................................................7-230 Auxiliary Feeder Paper-Select Switches .................................................7-231 Auxiliary Feeder Paper Feed Motor Assembly ........................................7-232 Bracket Assembly, Left-Hand and Right-Hand Gear (HCF) .....................7-233

FRU Parts List

8-235

PL 8-1 Accumulator Belt FRUs ......................................................................8-236 PL 8-2 Left-Hand Door FRUs .........................................................................8-237 PL 8-3 Media Trays FRUs ..............................................................................8-239 PL 8-4 Duplex Unit FRUs ...............................................................................8-240 PL 8-5 Cover FRUs ........................................................................................8-241 PL 8-6 Cover FRUs (cont'd.) ..........................................................................8-242 PL 8-7 Cover FRUs (cont'd.) ..........................................................................8-243 PL 8-8 Switch and Sensor FRUs ....................................................................8-245 PL 8-9 Switch and Sensor FRUs (cont'd.) .....................................................8-247 PL 8-10 Circuit Boards FRUs .........................................................................8-249 PL 8-11 Power Supplies FRUs .......................................................................8-251 PL 8-12 Power Supplies FRUs (cont'd.) ........................................................8-253 PL 8-13 Motors/Drivers FRUs ........................................................................8-255 PL 8-14 Electrophotographic Components FRUs ...........................................8-257 PL 8-15 Electrophotographic Components FRUs (cont'd.) ............................8-259 PL 8-16 Multi-Purpose Tray FRUs .................................................................8-261 PL 8-17 Paper Feed FRUs ..............................................................................8-263 PL 8-18 Paper Feed FRUs (cont'd.) ................................................................8-265 PL 8-19 Fans FRUs ........................................................................................8-267 Phaser 7700 Color Laser Printer Service Manual xvii

PL 8-20 Lift Components FRUs ..................................................................... 8-268 PL 8-21 Wiring FRUs .................................................................................... 8-270 PL 8-22 Auxiliary Feeder FRUs ...................................................................... 8-272 PL 8-23 Lower Tray Deck (LTD) FRUs .......................................................... 8-274 PL 8-24 Lower Tray Deck (LTD) FRUs (cont'd.) ............................................ 8-276 PL 8-25 High-Capacity Feeder FRUs .............................................................. 8-277 PL 8-26 High-Capacity Feeder FRUs (cont'd.) ............................................... 8-278 PL 8-27 High-Capacity Feeder FRUs (cont'd.) ............................................... 8-279 PL 8-28 High-Capacity Feeder FRUs (cont'd.) ............................................... 8-280 PL 8-29 High-Capacity Feeder FRUs (cont'd.) ............................................... 8-281 Kits ................................................................................................................ 8-282 Manual Packs & Service Manual ................................................................... 8-283 Software ........................................................................................................ 8-284 Supplies and Accessories .............................................................................. 8-284 Recommended Service Tools ........................................................................ 8-285

Test Prints

9-287

Analyzing the Test Print ........................................................................................ 9-288 Print Color Test Prints ................................................................................... 9-289 Diagnostics Mode .......................................................................................... 9-291

Wiring Diagrams Phaser 7700 Finisher

10-295 11-313

Finisher Overview 11-314 General Information ............................................................................................ 11-315 Assemblies of the Finisher .................................................................................. 11-317 Internal Assemblies of the Finisher ..................................................................... 11-318 Horizontal Transport Sensor, Interlock, and Switch Locator Map ...................... 11-319 Finisher Sensor, Interlock, and Switch Locator Map ......................................... 11-320 Finisher Sensor, Interlock, and Switch Locator Map .......................................... 11-321

Removal and Replacement Procedures

11-323

Horizontal Transport Assembly ............................................................ 11-324 Horizontal Transport Top Open, Front, and Rear Cover 11-325 Horizontal Transport Entrance Upper Cover Assembly ......................... 11-326 Horizontal Transport Belts .................................................................... 11-327 xviii Phaser 7700 Color Laser Printer Service Manual

Horizontal Transport Entrance Sensor and Top Tray Full Sensor ..........11-328 Gate-In Solenoid Assembly ...................................................................11-329 Finisher Covers .....................................................................................11-330 Stack Height-Sensor Assembly .............................................................11-332 Stacker Paper-Sensor Assembly ...........................................................11-333 Set Clamp Clutch and Gear ...................................................................11-334 Eject Roll Assembly ..............................................................................11-335 Finisher Control Board, Bracket, and Shield .........................................11-336 Stacker Motor Assembly .......................................................................11-338 Paddle Shaft .........................................................................................11-339 Paper Transport Motor (Motor Assembly Main) ...................................11-340 Cam Bracket Assembly .........................................................................11-341 Staple Unit Assembly and Motor ..........................................................11-342 Compiler Tray .......................................................................................11-344

Finisher FRU Parts List Finisher Wiring Diagrams

11-345 12-371

Phaser 7700 Color Laser Printer Service Manual

xix

xx

Phaser 7700 Color Laser Printer Service Manual

List of Tables
Table 1-1 CRC Life .................................................................................................. 1-5 Table 1-2 Front Panel Key Descriptions ................................................................ 1-21 Table 1-3 Front Panel Shortcuts............................................................................ 1-22 Table 1-4 Rear Panel DIP Switch Settings............................................................. 1-23 Table 1-5 Physical Dimensions of the Printer ....................................................... 1-24 Table 1-6 Physical Dimensions of Lower Tray Feeder ........................................... 1-24 Table 1-7 Functional Specifications....................................................................... 1-25 Table 1-8 Electrical Specifications......................................................................... 1-25 Table 1-9 Environmental Specifications ................................................................ 1-26 Table 1-10 Specialty Paper.................................................................................... 1-28 Table 1-11 Print Area ............................................................................................ 1-28 Table 2-1 POST Diagnostics Test Descriptions ..................................................... 2-34 Table 2-2 Service Diagnostics Test Menu Functions ............................................. 2-36 Table 8-1 Accumulator Belt FRUs List ................................................................. 8-236 Table 8-2 Left-Hand Door FRUs List ................................................................... 8-238 Table 8-3 Media Trays FRUs List ....................................................................... 8-239 Table 8-4 Duplex Unit FRUs List ......................................................................... 8-240 Table 8-5 Cover FRUs List................................................................................... 8-241 Table 8-6 Cover FRUs (cont'd.) List .................................................................... 8-242 Table 8-7 Covers FRUs List (cont'd.) .................................................................. 8-244 Table 8-8 Switch and Sensor FRUs List .............................................................. 8-246 Table 8-9 Switch and Sensor FRUs List (cont'd.)................................................ 8-248 Table 8-10 Circuit Board FRUs List ..................................................................... 8-250 Table 8-11 Power Supplies FRUs List ................................................................. 8-252 Table 8-12 Power Supplies FRUs List (cont'd.)................................................... 8-254 Table 8-13 Motors / Drivers FRUs List................................................................ 8-256 Table 8-14 Electrophotographic Components FRUs List ..................................... 8-258 Table 8-15 Electrophotographic Components FRUs List (cont'd.) ...................... 8-260 Table 8-16 Multi-Purpose Tray (MPT) FRUs List ................................................ 8-262 Table 8-17 Paper Feed FRUs List ........................................................................ 8-264 Table 8-18 Paper Feed FRUs List (cont'd.)......................................................... 8-266 Table 8-19 Fans FRUs List .................................................................................. 8-267 Table 8-20 Lift Components FRUs List................................................................ 8-269 Table 8-21 Wiring FRUs List ............................................................................... 8-271 Table 8-22 Auxiliary Feeders FRUs List............................................................... 8-273 Table 8-23 Lower Tray Deck (LTD) FRUs List ..................................................... 8-275 Table 8-24 Lower Tray Deck (LTD) FRUs List (cont'd.)....................................... 8-276 Table 8-25 High-Capacity Feeder FRUs List ........................................................ 8-277 Table 8-26 High-Capacity Feeder FRUs List (cont'd.).......................................... 8-278 Table 8-27 High-Capacity Feeder FRUs List (cont'd.).......................................... 8-279 Phaser 7700 Color Laser Printer Service Manual xxi

Table 8-28 High-Capacity Feeder FRUs List (cont'd.) .......................................... 8-280 Table 8-29 High-Capacity Feeder FRUs (cont'd.) ................................................. 8-281 Table 8-30 Kits .................................................................................................... 8-282 Table 8-31 Manual Packs & Service Manual........................................................ 8-283 Table 8-32 Software ............................................................................................ 8-284 Table 8-33 Supplies............................................................................................. 8-284 Table 8-34 Accessories ....................................................................................... 8-285 Table 8-35 Recommended Tools List .................................................................. 8-285 Table 11-1 Finisher Specifications ..................................................................... 11-315 Table 11-2 Finisher Unit Main Assemblies FRUs List ........................................ 11-346 Table 11-3 Finisher Covers FRUs List................................................................ 11-347 Table 11-4 Finisher Stand FRUs List.................................................................. 11-349 Table 11-5 Gate Unit FRUs List.......................................................................... 11-351 Table 11-6 Horizontal Transport Assembly FRUs List ....................................... 11-353 Table 11-7 Horizontal Transport Assembly FRUs List (cont'd.) ......................... 11-355 Table 11-8 Top Cover and Eject Roll FRUs List ................................................. 11-357 Table 11-9 Paper Transport Assembly FRUs List .............................................. 11-359 Table 11-10 Paper Transport Assembly FRUs List (cont'd.) .............................. 11-361 Table 11-11 Staple Unit Assembly FRUs List..................................................... 11-363 Table 11-12 Compiler Tray Assembly FRUs List................................................ 11-365 Table 11-13 Stacker Elevator Assembly FRUs List ............................................ 11-367 Table 11-14 Exit Assembly FRUs List ................................................................ 11-369 Table 11-15 Electrical FRUs List ........................................................................ 11-370

xxii

Phaser 7700 Color Laser Printer Service Manual

List of Figures
Figure 1-1 The Phaser 7700 Color Laser Printer (shown with the High-Capacity Feeder) 1-1 Figure 1-2 Engine Control Interface and Power Supply Boards ............................... 1-6 Figure 1-3 Power Supplies ...................................................................................... 1-7 Figure 1-4 Engine Control and Image Processor Boards ......................................... 1-8 Figure 1-5 Auxiliary Feeder Control Board ............................................................... 1-9 Figure 1-6 Print Engine Sensors and Switches ..................................................... 1-10 Figure 1-7 Print Engine Sensors and Switches (cont'd.) ....................................... 1-11 Figure 1-8 Auxiliary Feeder Sensors and Switches ................................................ 1-12 Figure 1-9 Auxiliary Feeder Actuators and Clutches .............................................. 1-13 Figure 1-10 Print Engine Solenoids, Actuators, and Clutches ............................... 1-14 Figure 1-11 Print Engine and Auxiliary Feeder Interlocks and Sensors ................. 1-15 Figure 1-12 Image Processor Board ..................................................................... 1-16 Figure 1-13 Assemblies of the Print Engine .......................................................... 1-17 Figure 1-14 Assemblies of the Print Engine (cont'd.) ............................................ 1-18 Figure 1-15 Assemblies of the Print Engine (cont'd.) ............................................ 1-19 Figure 1-16 Auxiliary Feeder Assemblies ............................................................... 1-20 Figure 1-17 Front Panel ......................................................................................... 1-21 Figure 1-18 Printer Rear Connections ................................................................... 1-23 Figure 1-19 Printer Clearances .............................................................................. 1-24 Figure 2-1 Voltage Measurement Point Locations ................................................. 2-46 Fig 2-2 Fuser Connector Pin Locations ................................................................. 2-47 Figure 3-1 Circuit Diagram .................................................................................... 3-91 Figure 3-2 Toner Cartridge Gear ............................................................................ 3-97 Figure 3-3 Toner Cartridge .................................................................................... 3-98 Figure 3-4 Toner Dispense Assembly .................................................................... 3-99 Figure 3-5 Toner Port .......................................................................................... 3-100 Figure 3-6 Developer Housing ............................................................................. 3-103 Figure 4-1 Coarse RegiCon Initialization ............................................................. 4-124 Figure 4-2 Coarse and Fine Skew Adjustments ................................................... 4-125 Figure 4-3 In/Out Skew Adjustment .................................................................... 4-125 Figure 4-4 Center Skew Adjustment .................................................................... 4-126 Figure 4-5 RegiCon Flowchart ............................................................................. 4-133 Figure 4-6 Grid 1-Dot Pattern Orientation for A-size Paper ................................. 4-140 Figure 4-7 Grid 1-Dot pattern annotations .......................................................... 4-141 Figure 7-1 Rear Cover Assembly ......................................................................... 7-154 Figure 7-2 Right Side Cover Assembly ................................................................ 7-155 Figure 7-3 Top Cover Assembly .......................................................................... 7-156 Figure 7-4 Control Panel Assembly ..................................................................... 7-157 Figure 7-5 Top Rear Power Switch Cover and Left-Hand Rear Mid Cover ........... 7-158 Phaser 7700 Color Laser Printer Service Manual xxiii

Figure 7-6 Left-Hand Lower Cover Assembly ...................................................... 7-160 Figure 7-7 Front Cover Assembly ........................................................................ 7-161 Figure 7-8 Fuser Front Cover ............................................................................... 7-162 Figure 7-9 Rear Shield ......................................................................................... 7-163 Figure 7-10 Rear Shield Bracket .......................................................................... 7-164 Figure 7-11 24 VDC Power Supply Shield ........................................................... 7-165 Figure 7-12 MPT Assembly ................................................................................. 7-166 Figure 7-13 Multi-Purpose Tray Pick Rollers ....................................................... 7-167 Figure 7-14 Left-Hand Cover Assembly (Left-Hand Door) ................................... 7-168 Figure 7-15 Damper Teeth Alignment .................................................................. 7-169 Figure 7-16 Duplex Chute .................................................................................... 7-170 Figure 7-17 Duplex Unit Assembly ...................................................................... 7-171 Figure 7-18 Transfer Roller Assembly (2nd BTR) ................................................ 7-172 Figure 7-19 Inverter Transport Assembly ............................................................ 7-173 Figure 7-20 Fuser Unit ......................................................................................... 7-174 Figure 7-21 Registration Transport Assembly ..................................................... 7-175 Figure 7-22 Shutter Solenoid Assembly .............................................................. 7-176 Figure 7-23 Tray 1 Feeder Assembly ................................................................... 7-177 Figure 7-24 Waste Cartridge, Waste Cartridge Cover and Waste Cartridge Sensor Holder 7-178 Figure 7-25 Print Cartridge Plate Cover (plastic) ................................................. 7-179 Figure 7-26 Dispense Assembly .......................................................................... 7-180 Figure 7-27 Print Cartridge Plate Assembly ......................................................... 7-182 Figure 7-28 Print Cartridge Plate Assembly (cont'd.) .......................................... 7-183 Figure 7-29 Developer Housing Assembly ........................................................... 7-185 Figure 7-30 Developer Housing Assembly Recharge ........................................... 7-186 Figure 7-31 Toner Dispense Motor Assembly ...................................................... 7-188 Figure 7-32 Steering Drive Assembly .................................................................. 7-189 Figure 7-33 Waste Toner Agitator Motor Assembly. ............................................ 7-190 Figure 7-34 Mark-On-Belt Sensor ........................................................................ 7-191 Figure 7-35 Exit Transport Assembly ................................................................... 7-192 Figure 7-36 Reconfigured Inverter ....................................................................... 7-193 Figure 7-37 Parts No Longer Installed ................................................................. 7-193 Figure 7-38 Interlock Actuator and Spacers ........................................................ 7-194 Figure 7-39 Fuser Fan Assembly ......................................................................... 7-195 Figure 7-40 Accumulator Belt Assembly .............................................................. 7-196 Figure 7-41 Belt Cleaner Assembly ...................................................................... 7-198 Figure 7-42 Waste Auger Assembly ..................................................................... 7-199 Figure 7-43 Laser Unit Assembly ......................................................................... 7-200 Figure 7-44 Laser Unit Label ............................................................................... 7-201 Figure 7-45 Image Processor Board Assembly. ................................................... 7-202 Figure 7-46 Internal Hard Drive ........................................................................... 7-203 Figure 7-47 Electrical Chassis Assembly ............................................................. 7-204 Figure 7-48 Engine Control Board ....................................................................... 7-206 Figure 7-49 Engine Control Interface Board ......................................................... 7-207 Figure 7-50 T1 and T3 High-voltage Power Supplies ........................................... 7-208 xxiv Phaser 7700 Color Laser Printer Service Manual

Figure 7-51 3.3 VDC and 5 VDC Low-Voltage Power Supplies ............................ 7-210 Figure 7-52 LD Power Relay ............................................................................... 7-211 Figure 7-53 Low-voltage Power Supply, Fan and Bracket ................................... 7-212 Figure 7-54 T2 High-Voltage Power Supply ........................................................ 7-213 Figure 7-55 Chassis AC Power Assembly ............................................................ 7-214 Figure 7-56 Main Drive Assembly ....................................................................... 7-215 Figure 7-57 Accumulator Belt Drive Assembly .................................................... 7-217 Figure 7-58 Developer Drive Assembly ............................................................... 7-218 Figure 7-59 Print Cartridge Drive Assembly ........................................................ 7-219 Figure 7-60 Tray 1 Paper-Select Switches .......................................................... 7-220 Figure 7-61 Main Lever, Right-Hand and Left-Hand Jacks .................................. 7-221 Figure 7-62 Lift Pin Alignment ............................................................................ 7-223 Figure 7-63 Cover Screw Location ...................................................................... 7-223 Figure 7-64 Cover Removed ................................................................................ 7-224 Figure 7-65 Tension Spring Location .................................................................. 7-224 Figure 7-66 Front and Rear Gears Aligned .......................................................... 7-224 Figure 7-67 Auxiliary Feeder Covers .................................................................... 7-225 Figure 7-68 High-Capacity Feeder (HCF) Cover Assembly ................................... 7-226 Figure 7-69 High-Capacity Feeder (HCF) Tray 3 .................................................. 7-227 Figure 7-70 High-Capacity Feeder (HCF) Tray 4 and Paper Transport ................. 7-228 Figure 7-71 LTD Control or HCF Control Board ................................................... 7-229 Figure 7-72 Transport Motor Assembly .............................................................. 7-230 Figure 7-73 Paper-Select Switches ..................................................................... 7-231 Figure 7-74 Paper Feed Motor Assembly and Chute (LTA & HCF) ...................... 7-232 Figure 7-75 Bracket Assembly, Gear RH & Gear LH (HCF) .................................. 7-233 Figure 8-1 Accumulator Belt FRUs ........................................................................8-236 Figure 8-2 Left-Hand Door FRUs ......................................................................... 8-237 Figure 8-3 Media Trays FRUs .............................................................................. 8-239 Figure 8-4 Duplex Unit FRUs ..................................................................