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Phaser 7400 Color Printer Options Service Manual

1. Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Door D Detect Sensor Actuator m Door D Detect Sensor m Door D Is there any damage or misalignment 2 Test the Door D Detect Sensor Replace the Engine Go to Step 3 Run the Service Diagnostics Door D test Control Board see for the appropriate tray Book 1 NOTE Door sensor tests are located under the Interlock Switches sub menu Does the switch function correctly 3 Replace the Door D Detect Sensor Replace the Complete Does the error persist DUPLEX Harness if the error persists replace the Duplex Unit 3 34 Phaser 7400 Color Printer Options Service Manual Close Finisher Door F The Door F Interlock Switch indicates that Door F is open Initial Actions Ensure that the door is free of obstructions and fully closed Verify that the actuator is not broken Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Door F Interlock Switch and actuator m Options Inverter Sensors Diagram Troubleshooting Procedure Table m Options Map 9 Inverter Sensor Locations Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the parts Go to Step 2 damage concerned m Door F Interlock Switch m Switch actuator 2
2. 1 25 Inverter Sensors Wiring Diagram 000 7 26 Inverter Motors Solenoids and Clutch Wiring Diagram 1 21 Duplex Unit Wiring Diagrams 0 cee ee 1 28 Duplex Unit Sensors and Interconnect Wiring 1 28 Duplex Unit Motors and Solenoids 0005 1 29 Optional Tray Wiring Diagrams 0 0 cee ee 7 30 Paper Tray Sensors and Interconnect Wiring 7 30 Paper Tray Motors Clutches and Interconnect Wiring 1 31 Index Phaser 7400 Color Printer Service Manual General information In this chapter m Printer Introduction and Overview m Printer Configurations m Printer Options m Specifications Section i Printer Introduction and Overview The Xerox Phaser 7400 Color Printer Service Manual is the primary document used to repair maintain and troubleshoot this printer For manual updates Service Bulletins knowledge base etc see www xerox com office 7400support For further technical support contact your assigned Xerox Technical Support for this product 400 301 The Xerox Phaser 7400 Color Printer is a single pass electrophotographic design using light emitting diodes LED for image exposure The Phaser 7400 supports PostScript 3 and PCL5c page description languages Print performance for A4 paper is 40 pages per minute ppm monochrome 36 ppm for full color in 1 sided or 2 sided modes Resolutions of up to 600 x 12
3. 4 N 57400 133 The position of the stapler depends on the staple mode E Front 1 point stapling The stapler moves to the front stapling position of the paper for stapling and then returns to the standby position Rear 1 point stapling The stapler moves to the opposite end rear of it s travel length for stapling and then returns to the standby position m Middle 2 point stapling The stapler moves to the rear stapling position first then to the front stapling position and then returns to the standby position The Staple Empty Sensor detects the presence of a staple cartridge in the machine as well as the presence of staples in the cartridge A Staple Top Position Sensor determines when to push staples up to the top of the staple cartridge Theory of Operation 2 23 Delivery The Finisher Unit includes a Delivery Tray and the Saddle Unit includes a Bind Tray The Bind Tray is a fixed unit where all folded paper stacks are delivered The Bind Tray includes a Bind Tray Sensor to detect the presence of paper The delivery tray in the finisher unit moves up and down using a Lift Motor The Paper Surface Sensor detects the home position of the delivery tray If paper is already stacked on the delivery tray the home position is sensed on the top surface of the stacked paper When the paper coming from the processing tray stacks on the Delivery Tray the Lift Motor receives a specified number of pulses which causes t
4. 0 0 cece ee eee 4 2 Registering Punch Holes 0 0 cc cece eee eee 4 2 Adjusting Sensor Output After Sensor Replacement 4 4 Adjusting Sensor Output After EE PROM Replacement 4 5 Stapler Unit Adjustments 0 0 0 0 eee 4 6 Adjusting the Saddle Stitch Double Stapling Position 4 6 Adjusting the Stapler Phase 0 0 00 e eee eae 4 7 Saddle Unit Adjustments 0 0 00 c cece eee 4 17 Adjusting the Folding Position 0058 4 17 Adjusting the Phase of the Saddle Unit Gear 4 18 5 Service Parts Disassembly OVANVIEW areara r TiSi ETE E ERARA oh ee ee 5 2 General Notes on Disassembly 0 0 a 5 2 PreparallON es criti dnie een EEEE E e i 5 2 Notations in the disassembly text 0 0000s 5 3 Fastener VDCS sian are wcie 24 Sede eS 4 Ke ee Re 5 3 Standard Orientation o uaua aeaa 5 4 Finisher Disassembly 0 0 0 0 0 c cee eee eee 5 5 Removing Inverter Base Unit from Finisher 5 5 Undocking Inverter from Printer 0 000 5 6 Trays and Covers 0 ce eee teens 5 7 Paper Exit Tray 0 eee eee 5 7 Front Door Door J ananannannnanannnnannnaananae 5 8 Right Side Door Door Q 0 eee eee 5 10 Rear COVG ovis cde wa dots aaa 5 11 Upper Cover Door H 1 eee 5 13 Processing Tray Upper Cover 0 00 e eee 5 15 Inverter Front Covers 0 0 0
5. 006 Printer Error Contact Service report fault n Finisher Punch Unit Counter at End of Life Finisher Staple Unit Counter at End of Life Finisher Interface Error 0 0 ccc cece eee ees Inverter Power Supply Failure 0 0 00 00 00 ee Tray 3 4 5 6 Firmware Error 0 00 00 008 Duplex Unit Firmware Error 0c c eee eee ees Finisher Inverter Firmware Error 0 0 0 e eee Tray 3 4 5 6 Flash Memory Failure Duplex Unit Flash Memory Failure 06 Finisher Inverter Flash Memory Failure Tray 3 4 5 6 Lift Motor Failure 0 Duplex Unit Fan Failure 0 0 ccc cee eee 24V Not Available to the Duplex Unit 24 V Not Available to Tray 3 4 5 6 Duplex Unit Clock Frequency Error 0 00008 Finisher Inverter Clock Frequency Error 6 Tray 3 4 5 6 Feeder Board Clock Frequency Error Table of Contents XV No Paper in Tray 2 S 4 5 6 0008 3 87 Staple Cartridge Is Empty 0 0 c cece eee 3 88 Punch Waste Box is Full or Missing 06 3 89 Finisher Away From BaSe 0 cee ee eee 3 90 Finisher Away From Printer 0 2 0 0 c eee eee 3 91 4 Adjustments and Calibrations Punch Unit Adjustments
6. Circuit Breaker CB1 Finisher Host Controller PCB Machine Regulator IC IC1 a Logic System Punch Controller PCB Puncher Unit Motors Finisher Controller PCB Punch Controller PCB Sensors jee ee ee ee Be ee ee ee ee ee HK HK Logic System e en oe o ke a o e o a o a i i i kl a Ci ys ad s7400 157 Theory of Operation 2 41 Finisher Power Supply Protection A circuit breaker CB1 is available to protect the 24 VDC system that drives the motors against overcurrent conditions The 24 VDC system drives the feed motor paddle motor and delivery motor Punch Unit Power Supply Protection After the printer is powered ON the Finisher Controller Board supplies the punch unit with 24 VDC and 5 VDC power The 24 VDC power drives the motors while the 5 VDC power supplies the associated sensors and ICs on the Punch Controller Board The 24VDC power to the motors is removed if the joint switch MS2 or the Front Door Door J switch MS1 of the Finisher is open 2 42 Phaser 7400 Color Printer Options Service Manual General Troublesnooting In this chapter m Power On Self Test POST m Service Diagnostics m Error Message Table m Troubleshooting the Options Section 3 Introduction This section covers the startup Service Diagnostics and power supply operations of the Finisher Inverter Duplex Unit and Paper Tray options to aid in troubleshooting pr
7. RON AJS Na 5 119 Hook Service Parts Disassembly 6 Repeat Step 5 for the Front Guide Bushing 7400 246 Lower Stack Delivery Roller Assembly DS sue 7 Remove the two stop rings and move the two bushings to the inside 8 Remove the four screws metal flange 6 mm then lift the Lower Stack Delivery Roller Assembly to detach 5 120 Phaser 7400 Color Printer Options Service Manual 9 Remove the two delivery belts Note Be sure to mount the belts so that the edges of the claws of the belts are flush Sg Delivery Belts AE ae W N ap r mau OS stack Delivery Roller SS NES OS Y s7400 248 xg Delivery Belt Hooks s7400 249 Service Parts Disassembly 5 121 Duplex Unit Disassembly To view sensors motors solenoids gears belts and boards in the Duplex Unit you must first remove the following m Front Cover Assembly m Bottom Plate m Side Rails Note If you need to remove the Duplex Unit Controller Board for any of the following procedures disconnect all connectors and remove one screw self tapping 6 mm securing the board to the frame and then pull free from the mounting post Front Cover Assembly From the front assembly you can see three sensors and the connector to the Duplex Unit Controller board To remove the Front Cover assembly 1 Remove two screws metal flange 6 mm from the front cover A IW T Duplex Unit Front Cover
8. 7400 610 Parts List 6 4 Optional Tray Parts Diagram 2 of 2 9D vs T 76 ws gt 86 3 7400 592 6 42 Phaser 7400 Color Printer Options Service Manual Parts List 1 15 Optional Tray Parts List Optional Tray Parts List ID Part Number Name Description 0 059K51750 Optional Tray Assembly Single Tray i 059K52510 LTD Assembly High capacity feeder 050K61900 Optional feeder Note The LTD assembly and optional feeders are not referenced in the preceding diagram Parts List 6 43 6 44 Phaser 7400 Color Printer Options Service Manual Wiring Diagrams In this chapter m Plug Jack Designators m Plug Jack Locators m Wiring Diagrams Section Plug Jack Locator Diagrams The P J Locator diagrams show the location of primary connections within the option devices Use these illustrations to locate connections called out in the troubleshooting procedures presented in Section 3 To find the location of a Plug or Jack 1 Locate the P J connector designator in the first column of the table 2 With this information go to the map listed in the second column 3 Use the coordinates to quickly locate the connection indicated on the map with its P J designation number Print Options Plug Jack Designators Finisher Plug Jack Designators P J Map Coord Remarks CN1 1 A 835 Receives 24 volt from the printer CN2 1 A 837 Monitors transmit and receive voltage le
9. Feeder Assembly 7400 69 5 136 Phaser 7400 Color Printer Options Service Manual Registration Motor Remove the Tray Feeder page 5 136 Release the motor harness from the clamp Disconnect the Registration Motor connector P J40 from the harness Aa N Remove two metal 6 mm screws that secure the Registration Motor to the Feeder Registration Motor 7400 647 Service Parts Disassembly 5 137 Feed Motor 1 Remove the Tray 2 Feeder page 5 136 2 Release the motor harness from the clamp 3 Disconnect the Feed Motor connector P J30 from the harness 4 Remove two metal 6 mm screws that secure the Feed Motor to the Feeder Feed Motor 7400 648 5 138 Phaser 7400 Color Printer Options Service Manual Lift Motor 1 Remove the tray 2 Remove the Right Rear Cover page 5 134 3 Disconnect the Lift Motor connector GDDC from the Motor Driver Board 4 Remove the two metal 6 mm screws that secure the Lift Motor to the frame K s7400 690 Service Parts Disassembly 5 139 Registration Clutch 1 Remove the Tray Feeder page 5 136 2 Remove the E clip that secures the clutch to the Registration Roller Z i o Mo Registration Clutch ZN 6S oY fe OS a JILL mn O y s7400 682 3 While holding the anti rattle spring remove the clutch from the roller shaft 5 140 Phaser 7400 Color Printer Options Service Manual Door C Detect Sensor The Door C Detec
10. 2 6 Phaser 7400 Color Printer Options Service Manual The slide motor is then driven a specified number of pulses until the stapler reaches the rear standby position at the back of the machine At this point the unit enters the standby state Stapler Light Shielding Plate Slide Home Position Sensor Slide Motor 7400 132 Staple Unit Components Component Function Staple Fold Motor Rotates the cam in the appropriate direction for the stapling process Stapler sensors Detects the absence of and or the position of the stapling mechanism and motors Finisher Slide Motor Moves the Stapler Unit to the appropriate location on the paper stack for stapling Theory of Operation 2 7 Saddle Unit The Saddle Unit stitches center staples up to 50 sheets middle 2 point then folds the stack in two in the Finisher The Finisher Controller Board receives commands from the printer to control the following operations a Paper feed in After alignment on the processing tray the feed drive system inserts a stack of sheets between the stack delivery rollers As the stack delivery rollers rotate the stack is fed toward the saddle unit b Stitching When the center of the paper stack stitching position reaches the stapler s staple position the unit staples the paper stack When only one sheet is fed from the printer the next step stack feed occurs without performing the stitching operation c Stack Feed The s
11. 3 For DIP switch SW1001 on the Punch Controller Board press shift bits 1 through 4 as follows 7400 537 m Press switches SW1002 and SW1003 on the Punch Controller Board simultaneously m The presses will initialize the EEP ROM At the end all LEDs LED1001 LED1002 LED1003 will go ON 4 Adjust the sensor output page 4 4 and register the number of punch holes page 4 2 Adjustments and Calibrations 4 5 Stapler Unit Adjustments Adjusting the Saddle Stitch Double Stapling Position To adjust the stapling position for middle 2 point stapling you must match it with the folding position If you have replaced the Finisher Controller Board you must transfer the existing settings to the new board Note Both the folding and stapling positions may vary for some types of paper In these cases change the middle stapling position in the user mode of the printer Use the following steps 1 Locate DIP switch SW1 on the Finisher Controller Board LED3 LED2 LED1 o O oO PSW3 PSW2 PSW1 2 Set switch SW1 on the Finisher Controller Board as follows eee 7400 533 4 6 Phaser 7400 Color Printer Options Service Manual 3 Press switches PSW1 or PSW2 on the Finisher Controller Board as necessary to move the stapling position to the proper location pressing the switch once moves the stapling position about 0 14 mm To move the stapling position in the direction press switch PSW1 m To move the staplin
12. 6 Finisher Internal Parts Diagram 1 of 2 08 6 9 Finisher Internal Parts Diagram 2 of 2 0 6 10 Parts List 1 3 Finisher Internal Parts List 6 11 Stack Lift Motor Drive Assembly Parts Diagram 6 12 Parts List 1 4 Stack Lift Motor Drive Assembly Parts List 6 13 Staple Fold Drive Assembly Parts Diagram 6 14 Parts List 1 5 Staple Fold Drive Assembly Parts List 6 15 Bundle Support Cover Assembly Parts Diagram 6 16 Parts List 1 6 Bundle Support Cover Parts List 6 17 Dispose Assembly Processing Tray Parts Diagram 6 18 Parts List 1 7 Dispose Assembly Processing Tray Parts List 6 19 Paper Feeder Paddle Assembly Parts Diagram 6 20 Parts List 1 8 Paper Feeder Paddle Assembly Parts List 6 21 Puncher Assembly Parts Diagram 00005 6 22 Parts List 1 9 Puncher Assembly Parts List 6 23 Punch Total Assembly Diagram 000 eae 6 24 Parts List 1 10 Punch Total Assembly Parts List 6 25 Staple Unit Diagram 1 of 2 nanana eee 6 27 Staple Unit Diagram 2 of 2 0 0 eee 6 28 Parts List 1 11 Staple Unit Parts List 6 29 Fold Unit Diagram 1 of 3 eee 6 30 Fold Unit Diagram 2 of 3 eee 6 31 Fold Unit Diagram 3 of 3 eee 6 32 Parts List 1 12 Fold Unit Parts List 6 33 Inverter Part
13. 6 Remove the two screws metal flange 6 mm and the anti vibration spring from the motor 7 Pull the motor and its associated gear free from the gear assembly 5 68 C amp A LD O gy stot MOP Lower Roller Motor s7400 494 Phaser 7400 Color Printer Options Service Manual Inverter Feeder Clutch Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Rear Covers page 5 19 Remove the Inverter Top Cover page 5 23 Aa O N Disconnect the two wire connector from connector plug FAN on the Inverter Controller Board Make sure you also pull the wires free from the cable guides 5 Remove the screw metal flange 6 mm and anti vibration spring from the lower left side of the clutch 6 Remove the e clip from the end of the clutch 7 With the anti vibration spring and e clip removed you can pull the clutch and its gear free from the roller gear assembly 4 Ay v Anti Vibration Spring s7400 495 Service Parts Disassembly 5 69 Inverter Upper Roller Solenoid Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Rear Covers page 5 19 Remove the Top Cover page 5 23 Aa O N a Disconnect the cable from the connector CL2 on the Inverter Controller Board Be sure you also free the cable harness from the cable guide Carefully remove the tension spring from the solenoid and swing plate From
14. Inverter Upper Paper Detects the leading edge of the selected paper size Present Sensor Inverter Lower Paper Detects the trailing edge of the selected paper size Present Sensor Inverter Paper in Sensor Detects the presence of media in the Inverter Duplex Sensors The Duplex Unit receives media diverted to the Side Exit by the Exit Gate The media is detected by the Duplex Entrance Sensor and drawn into the Duplex Unit The media is inverted and exits the Duplex Unit just above Registration Roller 2 Media moves through the Duplex Unit as follows 1 2 After Side 2 is printed the Exit Gate Solenoid switches the Exit Gate to its side output position This directs the sheet downwards toward the Duplex Unit As the sheet reaches the Duplex Entrance Sensor roller 1 turns drawing the media into the lower portion of the Duplex Unit After the trailing edge of the media clears the Duplex Entrance Sensor and with the Duplex Reverse Sensor High the Entrance Roller is reversed and the Duplex Solenoid is activated to position the Duplex Gate to direct the inverted media into the upper portion of the Duplex Unit The Duplex Rollers transport the media out of the Duplex Unit and into the printer where Side 1 is printed This portion of the duplex path is monitored by the Front and Rear Duplex Sensors Duplex Rear Sensor Paper End Sensor Duplex Entrance Sensor Duplex Reverse N y4 sensor Nh Duplex Front S
15. N a Remove the Processing Tray Upper Cover page 5 15 Remove the Upper Right Cover Assembly page 5 37 Remove the Side Guide page 5 107 Remove the two screws metal 10 mm and disconnect the following four connectors CN36 to Clutch CN85 to Rear Alignment Motor CN63 to Front Alignment Motor CN57 to Delivery Motor Rear Alignment Motor Delivery Motor CN57 Front Alignment Motor 5 38 7400 218 Phaser 7400 Color Printer Options Service Manual 5 Pull the Processing Stopper Base to the front and free the hooks at the front and rear of the Processing Stopper NA Hook lt Pa NG Processing Stopper p ae _ Processing Stopper _ s7400 219 Service Parts Disassembly 5 39 6 Release the two hooks of the harness retainer remove three connectors and detach the motor harness Wwe BOTs ZY s Wo Ds NANAK Connectors 7400 220 5 40 Phaser 7400 Color Printer Options Service Manual 7 Remove the Stop Ring and detach the Timing Belt Caution A free floating pin is inserted in the gear shaft that can easily fall into the chassis Be careful when loosening or removing the belt from the gear 8 Disconnect the connector and free the harness from the Edge Saddle Free floating Pin IX Timing Belt T Stop Ring No 7 Edge Saddle 7400 221 Service Parts Disassembly 5 4 9 Remove the two screws metal flange 6 mm slide the Processing Tray As
16. F186 Finisher interface error Communications lost with Finisher 3 70 3 8 Phaser 7400 Color Printer Options Service Manual Error Control Panel Message Page 197 Inverter Power Supply Error 3 71 221 Tray 3 Firmware Error Firmware error in Tray 3 Flash Memory 3 72 222 Tray 4 Firmware Error Firmware error in Tray 4 Flash Memory 3 72 223 Tray 5 Firmware Error Firmware error in Tray 5 Flash Memory 3 72 224 Tray 6 Firmware Error Firmware error in Tray 6 Flash Memory 3 72 225 Duplex Unit Firmware Error Firmware error in Duplex Unit Flash Memory 3 73 227 Finisher Inverter Firmware Error Firmware error in Inverter Flash Memory 3 74 242 Tray 3 Flash Memory Failure Hardware error in the Tray 3 Flash Memory device 3 75 243 Tray 4 Flash Memory Failure Hardware error in the Tray 4 Flash Memory device 3 75 244 Tray 5 Flash Memory Failure Hardware error in the Tray 5 Flash Memory device 3 75 245 Tray 6 Flash Memory Failure Hardware error in the Tray 6 Flash Memory device 3 75 246 Duplex Unit Flash Memory Failure Hardware error in the Flash Memory device 3 76 248 Finisher Inverter Flash Memory Error Inverter Flash Memory device error 3 77 911 The Tray 3 Lift Motor has failed 3 78 912 The Tray 4 Lift Motor has failed 3 78 913 The Tray 5 Lift Motor has failed 3 78 914 The Tray 6 Lift Motor has failed 3 78 918 The Duplex Unit Fan has failed 3 80 919 24 V not avail
17. For diagnostic purposes you may be instructed to open or close the Right Side Door on the Finisher The illustration below identifies the location of the Right Side Door Door G Finisher Right Side Door Door G Bi 7400 719 5 10 Phaser 7400 Color Printer Options Service Manual Rear Cover 1 Remove the Paper Exit Tray page 5 7 2 Press the release latch and slide the Finisher away from the base 3 Detach the cable from the Finisher to the Inverter at the rear of the Finisher Service Parts Disassembly 5 11 4 Remove two screws metal 6 mm on the left side of the rear cover Rear Cover n M UDT S E Rear Cover 7400 162 5 Remove one screw metal 6 mm on the right side of the rear cover 6 Slide the Rear Cover towards the right side of the Finisher and remove 5 12 Phaser 7400 Color Printer Options Service Manual Upper Cover Door H 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Open the Upper Cover and turn the stopper strap retainer clip counter clockwise then remove the strap from the cover Upper Cover Retainer Clip stopper Strap 7400 163 4 Remove the screw metal 6 mm and detach the Processing Tray Rear Cover Service Parts Disassembly 5 13 5 Detach the Upper Cover Upper Cover Processing Tray Rear Cover 7400 164 5 14 Phaser 7400 Color Printer Options Service Manual Processing Tray Upper Cove
18. Remove the Upper Cover page 5 13 Remove the Upper Right Cover Assembly page 5 37 Remove the Feed Motor Unit page 5 62 Remove the Feed Roller page 5 109 oF O N Remove the screw metal flange 6 mm and detach the Inlet Sensor Bushing 7400 234 Service Parts Disassembly 5 75 Tray Paper Sensor The Tray Paper Sensor detects when the paper tray is removed from the Finisher To remove and replace the Tray Paper Sensor Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 2 3 4 Remove the Upper Cover page 5 13 5 Remove the Side Guide page 5 107 6 To locate the sensor look through the top of the side area where you removed the Side Guide and press the paper tray activator a few times see illustration You will see the activator as it enters the sensor below Tray Paper Sensor Delivery Belt Home Position Sensor 7400 700 7 To remove the sensor first remove the 4 wire connector CN32 from the sensor and then using small needle nose pliers pinch the plastic tabs to pull one side of the sensor free 5 76 Phaser 7400 Color Printer Options Service Manual Paper Surface Sensor The Paper Surface Sensor detects media in the home position of the delivery tray To remove and replace the Paper Surface Sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cove
19. m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Are there any defects or misalignment 2 Test the Folding Position Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the at the Finisher Control Board Finisher Control harness Actuate the sensor Does the voltage across CN16 2 lt gt ground change when the sensor is actuated Board page 5 46 General Troubleshooting 3 27 Jam at Finisher Upper Output Tray Media remains in the Compiler Tray This error represents a jam in the Finisher eject path Applicable Status Code Code FN10 Jam at Finisher Upper Output Tray Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 m Options Finisher Controller to Sensors 2 3 Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Compiler Tray
20. s7400 612 5 122 Phaser 7400 Color Printer Options Service Manual 2 Slide the front assembly mounting rod out of the slot Caution Be careful not to lose the retaining springs when you remove the assembly mounting rod Front Assembly Mounting Rod 7400 613 3 From the remaining plastic piece carefully loosen the plastic from the metal support bar This exposes two support screws metal flange 6 mm from the lower metal cover plate Service Parts Disassembly 5 123 Bottom Cover Plate Removing the Bottom Cover Plate will expose the Duplex Controller Board the fan the two motors five sensor switches three belts and the door solenoid To remove the Bottom Cover Plate 1 Remove the Front Cover Assembly page 5 122 2 Turn the Duplex unit over so that the bottom plate is facing up 3 Remove four black screws self tapping 10 mm and one silver screw metal 10 mm fastening the plate to the chassis 4 From the front end of the assembly remove two black screws self tapping 10 mm from the folded end of the bottom plate 5 124 Phaser 7400 Color Printer Options Service Manual 5 Lift the bottom plate free from the chassis Caution Be careful to keep the unit upside down so that you do not lose any of the retaining springs from the unit F Bottom Plate N 7 y N N ml IN Duplex Unit s7400 501 5 125 Service Parts Disassembly Side Rails Removing the Side Rails exposes ge
21. 1 Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Front Covers page 5 17 Remove the Inverter Rear Covers page 5 19 Remove the Top Cover page 5 23 Remove the Inverter Controller Board page 5 55 O a A O N Remove the Inverter Power Supply Board page 5 56 Note Both Inverter boards must be removed in order to access one of the side screws in the metal plate 7 Remove seven screws metal flange 6 mm from the front metal cover plate one from each side near the top and five from the front of the plate 8 Slide the front metal plate away from the chassis to expose the Lower Paper Present Actuator 9 Disconnect the 3 wire cable from the actuator Note The other end of this cable connects to connector SNSCNO on the Inverter Controller Board 5 104 Phaser 7400 Color Printer Options Service Manual 10 To remove the actuator from the top paper guide pinch the plastic release tab to free the actuator OF Inverter Lower Paper present Sensor 7400 607 Service Parts Disassembly 5 105 Inverter Paper in Sensor The Inverter Paper in Sensor detects the presence of media in the Inverter To remove the sensor 1 Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Front Covers page 5 17 Remove the Inverter Rear Covers page 5 19 Remove the Top Cover page 5 23 Remove six screws metal flange 6 mm fr
22. 2 Remove the Registration Clutch 2 page 5 140 3 Remove the Feeder Board Cover 4 Remove 4 metal 6 mm screws that secure the feeder top Feeder Assembly s7400 685 Service Parts Disassembly 5 143 5 Separate the feeder top and then turn the top over to remove 2 black plastic 10 mm screws that secure the sensor housing to the feeder s7400 486 5 144 Phaser 7400 Color Printer Options Service Manual 6 Turn the feeder top upright and release the 2 hooks that secure the sensor housing to the top of the feeder Feed Out 2 Sensor Feeder Assembly 7400 529 7 Release the hooks that secure the sensor in the housing 8 Disconnect the sensor connector P J42 and then remove the sensor Replacement Note Use care when replacing the feeder top Make sure the Level and Low Paper Sensor flags operate properly before tightening the screws Service Parts Disassembly 5 145 Feed Out Sensor 2 1 Remove the Tray Feeder page 5 136 2 Remove the Registration Clutch 2 page 5 140 3 Remove the Feeder Board Cover 4 Remove 4 metal 6 mm screws that secure the feeder top Feeder Assembly 7400 485 5 146 Phaser 7400 Color Printer Options Service Manual 5 Separate the feeder top and then turn the top over to remove 2 black plastic 10 mm screws that secure the sensor housing to the feeder s7400 486 6 Turn the feeder top upright and the release the 2 hooks that secure the
23. 848K00040 Bundle Support Cover Paper Detection Parts List 6 17 Dispose Assembly Processing Tray Parts Diagram s7400 6 6 18 Phaser 7400 Color Printer Options Service Manual Parts List 1 7 Dispose Assembly Processing Tray Parts List Dispose Assembly Processing Tray Parts List ID Part Number Name Description 0 054K37780 Dispose Assembly Processing Tray Parts List 6 19 Paper Feeder Paddle Assembly Parts Diagram g a 57400 636 6 20 Phaser 7400 Color Printer Options Service Manual Parts List 1 8 Paper Feeder Paddle Assembly Parts List Paper Feeder Paddle Assembly Parts List ID Part Number Name Description 0 059K52480 Paper Feeder Paddle Assembly Parts List 6 21 Puncher Assembly Parts Diagram s7400 642 6 22 Phaser 7400 Color Printer Options Service Manual Parts List 1 9 Puncher Assembly Parts List Puncher Assembly Parts List ID Part Number Name Description 1 109K02020 Puncher Controller Board Assy 11 848E05300 Dust LED Board Unit 12 848E05310 Dust PTR Board Unit 16 137E16140 IC TLP1241 Photo Interrupter 17 848E05320 Panel Dust Box 18 848E05330 Cover Dust Box 19 127E15510 Motor Stepping Parts List 6 23 Punch Total Assembly Diagram 7400 643 6 24 Phaser 7400
24. Actions and Questions Yes No 6 Replace the Finisher Control Board Replace the Complete page 5 46 Engine Control Does the error still occur General Troubleshooting Board see Book 1 3 67 Printer Error Contact Service report fault n The following procedures apply to codes associated with the Printer Error message Finisher Punch Unit Counter at End of Life The Punch Count indicates that Punch Unit has reached its end of life Applicable Status Code Code F141 Punch Unit at End of Life Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Punch m Options Map 2 Punch Controller Board m Punch Control Board m Options Punch Controller to Sensor and Motors m Options Map 1 Finisher Controller Board m Options Finisher Controller to Printer Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Replace the Punch page 5 24 Replace the Engine Complete Cycle printer power Control Board Does the error persist NVRAM If the error persists replace the Engine Control Board see Book 1 3 68 Phaser 7400 Color Printer Options Service Manual Finisher Staple Unit Counter at End of Life Applicable Status Code Code F142 Staple Unit at End of Life Initial Actions m Cycle the printer s power m If the problem persists follow the
25. Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Control Board m Print Engine Map 3 see Book 1 m Engine Control Board m Print Engine Motor Driver Board 6 6 see Book 1 m Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option connection Reconnect or Go to Step 2 Is the Option connection from the Inverter replace the cable to the Printer damaged or disconnected 2 Check all pins on the Option Harness for Go to Step 3 Replace the continuity Option harness Disconnect OPTIF from the Engine Control Board and the Option connector Is the harness conductive 3 Check the Inverter Control Board POWER Replace or Replace the connection reconnect the Inverter Control Is POWER disconnected or damaged harness Board page 5 55 If the error persists replace the Engine Control Board see Book 1 General Troubleshooting 3 85 Tray 3 4 5 6 Feeder Board Clock Frequency Error The clock frequency on the indicated Feeder Board is inaccurate Applicable Status Codes Code 933 Tray 3 Feeder Board CPU clock frequency is inaccurate Code 934 Tray 4 Feeder Board CPU clock frequency is inaccurate Code 935 Tray 5 Feeder Board CPU clock frequency is inaccurate Code 936 Tra
26. Mythos Quake and Tekton are trademarks of Adobe Systems Incorporated in the United States and or other countries Apple AppleTalk 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 IBM and AIX are trademarks of International Business Machines Corporation in the United States and or other countries Windows Windows NT 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 Sun 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 loreei PANTO
27. Punch mechanism Function When sensor detects proper paper position the punch blade punches holes in with paper stack following 180 degree rotation of the punch shaft Punch Controller Board Receives instructions from the printer and converts them to control all punch unit operations Horizontal Registration System Detects the home position of the punch slide unit to move it to the appropriate position of the selected paper size Photo sensors Theory of Operation Five LED s mount over the inlet paper path to detect the leading and trailing edges of the paper 2 5 Staple Unit The Staple Unit receives instructions from the printer through the Finisher Controller Board to initiate staple operation and deliver up to 50 sheets of paper depending on the paper size to the finisher staple subassembly The unit mounts in the Finisher and depending on the media selection provides front stapling rear stapling dual stapling and saddle stitching center stapling with fold Staple Clincher stapler Frame Shafts ikea i Sek Q Sain The stapling position depends on the staple mode and paper size After power on the Finisher Controller Board drives the Finisher Slide Motor to place the Staple Unit in the home position The stapler starts moving toward the front of the stapler frame and stops when the Slide Home Position Sensor detects the home position Staple Driver m n i D 7400 201
28. Run the Service Diagnostics Upper Cover Control Board see test Book 1 Does the sensor function correctly 3 Check the sensor connection Go to Step 4 Reconnect the Is CN4 on the Finisher Control Board sensor connected 4 Check the Door H signal Replace the Replace the Does the voltage change on CN4 6 of the Finisher Control harness Finisher Control Board when the switch is Board page 5 46 activated 3 36 Phaser 7400 Color Printer Options Service Manual Close Finisher Door J The Front Cover Door J Sensor indicates that Door J is open Initial Actions Ensure that the door is free of obstructions and fully closed Verify that the actuator is not broken Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Door J Actuator m Door J Switch Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 7 Finisher Sensor Locator 1 2 m Options Finisher Controller to Sensors 1 8 Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the parts Go to Step 2 damage concerned m Door J Actuator m Door J Switch 2 Test the Door J Switch Replace the Engine Go to Step 3 Run the Service Diagnostics Front Cover Control Board see test Book 1 Does the sensor function correctly 3 Check the sensor connection Go to Step 4 Reconnect the Is CN4 on the F
29. Swing Guide Home Position Sensor Stack Feed Roller Home Position Sensor Folding Home Position Sensor 7400 659 7 To remove the sensor disconnect CN41 from the sensor remove one screw metal 4 mm and then pull the sensor free 5 86 Phaser 7400 Color Printer Options Service Manual Waste Full Sensor Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Remove the Punch Control Board page 5 50 oF O N Remove the two screws metal flange 6 mm to remove the controller board film TA Board Cover aa 7400 266 Service Parts Disassembly 5 87 6 Disconnect the connector to remove the Waste full Sensor Board Connector Waste Full Photosensor Board 7400 267 5 88 Phaser 7400 Color Printer Options Service Manual Swing Guide Home Position Sensor The Swing Guide Home Position Sensor detects the home position for the Swing Guide To remove the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove two screws metal 6 mm and remove the swing guide cover oF O N Locate the sensor see illustration and disconnect connector CN41 Swing Guide Home Position Sensor Stack Feed Roller Home Position Sensor poo VSS 2 Folding Home Position Sensor Folding Position Sensor 7400 659 6 To remove the sensor pinch th
30. Tray 3 4 5 6 paper type mismatch error The Paper Size Switch indicates that the media loaded in the source tray does not match the size specified by the print job Initial Actions Inspect the tray to ensure that it is free of obstructions is loaded with the expected media and the guides are adjusted correctly Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Paper Size Switch m Paper Tray m SIZE Harness Troubleshooting Procedure Table Wiring and Plug Jack References m Paper Size Switch Signal Definitions table see Book Step Actions and Questions Yes No 1 Check the paper in the affected tray Go to Step 2 Reload the Is paper loaded in the tray properly paper 2 Check the tray paper guides Go to Step 3 Reset the Are the paper guides set correctly guides 3 Check the Paper Size Switch for the affected Go to Step 4 Correct the tray installation Is the switch installed correctly 4 Test the Paper Size Switch for the affected tray Go to Step 7 Go to Step 5 Run the Service Diagnostics Size Sensor test for the affected tray Does the sensor state change each time the loaded tray is moved in or out 5 Check the Paper Size Switch connection Go to Step 6 Connect the Is the switch connected at either end switch 6 Check continuity between the affected Paper Go to Step 7 Repair the
31. cee ee 5 17 Inverter Rear Covers 0 0 ccc cee ee eee 9 19 Inverter Left Side Door Door F 00 00a 5 21 Inverter Right Side Door Doorl 000 5 22 Inverter Top Cover 0 0 cee eee 9 23 MG tuk eae ne wd eed oe eee sue ee eee eae ed 5 24 Punch Unit 0 0 2 0 eee ees 5 24 Staple Unites reiri awww aod 4 eves serii doe dees irai 9 29 Staple Fold Drive Unit 0 0 00 cece eee 5 30 DOCCIC WHI Ciao senses oepheveruw it bade ehe eee ees 5 34 Assemblies 0 eee nents 5 37 Phaser 7400 Color Printer Options Service Manual Upper Right Cover Assembly 0 0 00 eee 5 37 Processing Tray Assembly 0 cc eee eee eee 5 38 Paddit ASSCINDIV rerin e a a a eats 5 43 BOIS eaea a a a A E a ie 5 46 Finisher Controller Board 0 0 00 eee eee 5 46 Home Position Board 0 0 cee ee eee 5 47 Punch Control Board 0 00 00 cee eee eee 5 50 Photo Sensor Board 0c eee eee eee ee 5 51 PUNCH LED BOAO cc sick w olckc 2a och We naka e bie arene es 5 53 Waste Full LED Board 000 5 54 Inverter Controller Board 00 0 0 eee eee 5 55 Inverter Power Supply Board 0 0 0 ee eee 5 56 Motors Clutches and Solenoids nnana nananana 5 57 PUNCA MOO erenn ana na ae eae Ane Means eae 5 57 Finisher Punch Transfer Motor 20000 5 58 PHU WOO 2 2 t45 355445 9455
32. lt SF Position Sensor eo P a Horizontal Registration Home Position Sensor Feed Motor lt Punching Controller Board 1 SIS A Photo Dust Full Photo Sensor Circuit board Prato Sensor Circuit board LED Circuit Board Punch Dust Full LED Circuit Board 7400 544 2 34 Phaser 7400 Color Printer Options Service Manual Inverter Solenoids and Motors The Inverter motors move the rollers to move the media throughout the paper path The Feeder Clutch on command from the printer engages the motors The Inverter Solenoids also on command from the printer energize the upper and lower paper rollers Upper Roller Solenoid PA Feeder Clutch 4 j Upper Roller Motor T Lower Roller Motor Lower Roller Solenoid s7400 679 Theory of Operation 2 35 Duplex Solenoids Rollers and Motors The Duplex Unit receives media diverted to the Side Exit by the Exit Gate The media is detected by the Duplex Entrance Sensor and drawn into the Duplex Unit The media is inverted and exits the Duplex Unit just above Registration Roller 2 Media moves through the Duplex Unit using the following solenoids rollers and motors m Duplex Solenoid Activates the Duplex Gate directing media to the Duplex Transport Rollers m Duplex Entrance Roller Drive the media into the Duplex Unit m Duplex Transport Rollers Transport the media through the Duplex Unit and drive the sheet into the primary paper
33. s7400 505 5 128 Phaser 7400 Color Printer Options Service Manual Diverter Solenoid The Diverter Solenoid re routes the paper in the opposite direction on its paper path during duplex operation To remove the solenoid 1 Remove the Front Door and Front Cover Assembly page 5 122 Remove the Left Side Rail page 5 126 Disconnect the solenoid connector CL1 from the Duplex Controller Board Remove the solenoid plastic cover oF O N Remove the single metal flange 6 mm screw from the solenoid and lift the solenoid free from the chassis QO Diverter A Service Parts Disassembly 5 129 Duplex Unit Sensors and Switches There are a total of five sensors for the various duplex interlocks and paper paths Refer to the sensor locator illustration to locate the appropriate sensor To remove any of the sensors 1 Remove the Front Cover Assembly page 5 122 2 Disconnect the sensor connector either SNSCNO or SNSCN1 from the Duplex Unit Controller Board 3 Pinch the plastic insert pins on the connector together and lift free from the chassis Caution Be careful not to lose any of the retainer springs Duplex Rear Sensor Paper End sensor Duplex Entrance Sensor tg S oi Sei Duplex Front Sensor s7400 676 5 130 Phaser 7400 Color Printer Options Service Manual Duplex Fan To remove the Duplex Fan 1 Remove the Front Cover Assembly page 5 122 2 Disconnect the fan connector FAN from
34. 117 Ib 550 Sheet Feeder Value Height 109 mm 4 3 in Optional Paper Tray Assembly Width 597 mm 23 5 in Depth 599 mm 23 6 in Weight 16 kg 36 lb Surface Value Tilt tolerance Within 50 mm side to side Finisher Functional Specifications Functional Specifications Characteristic Specification Transport Speed 34 45 PPM Transport Reference Center Reference Tray Type Upper Tray Lift up down offset tray number of trays Lower tray Book tray for saddle stitch Non staple 1 000 sheets Small size 500 sheets Large size Capacity of paper exit Staple sort 30 sheets and load Max 1 000 sheets Small size 500 sheets Large size Large size A3 B4 11 x 17 8 5 x 11 Small size A4R B5 B5R A5R 8 5 x 11 R and Executive 1 8 Phaser 7400 Color Printer Options Service Manual Functional Specifications Continued Characteristic Specification 50 sheets Small size 128 g m x 48 Quantity of paper to pe ctaniee Large size 128 g m x 25 25 sheets 2 Large size 128 g m x 25 Stapling Two positions A3 B4 11 x 17 8 5 x 14 8 5 x 13 A4 8 5 x 11 R and Executive One at the back A3 B4 A4 A4R B5 11x 17 8 5 x 14 8 5 x 13 8 5 x 11 8 5 x 11R Executive One in the front Paper exit direction Face down Paper Exit Paper size A3 B4 A4 A4R B5 B5R A5R 11 x 17 8 5 x 14 8 5 x 13 8 5 x 11 8 5 x 11 R 5 5 x 8
35. 35 3 36 3 37 3 38 3 39 3 41 3 41 3 41 3 42 3 44 3 7 Error Control Panel Message Page Fatal Errors U12 Duplex Interface Failure 3 45 U14 Tray 3 Interface Failure 3 46 U13 Tray 4 Interface Failure 3 46 U16 Tray 5 Interface Failure 3 46 U17 Tray 6 Interface Failure 3 46 U51 Inverter Unit Interface Failure 3 47 U34 Unsupported Duplex Unit ROM 3 48 U35 Unsupported Tray 3 ROM 3 49 U36 Unsupported Tray 4 ROM 3 49 U37 Unsupported Tray 5 ROM 3 49 U38 Unsupported Tray 6 ROM 3 49 U50 Unsupported Inverter Unit ROM 3 50 U55 Unsupported Finisher Unit ROM 3 51 F131 Finisher Folder Sensor Failure 3 52 F103 Finisher Paddle Failure 3 53 F106 Finisher Stapler Swing Motor Failure 3 54 F111 Finisher Stapler Stack Handling Motor Failure 3 55 F110 Finisher Staple Motor Failure 3 54 F93 Finisher Jog Motor Failure 3 56 F115 Finisher Tray Lift Motor Failure 3 58 F116 Finisher Exit Failure 3 60 F138 Finisher Punch Backup RAM Failure 3 61 F132 Finisher Punch Communications Failure 3 62 F181 Finisher Punch Transfer Motor Failure 3 63 F134 Finisher Punch Motor Failure 3 64 F137 Finisher Backup RAM Failure 3 65 F139 Finisher Punch Dust Sensor Failure 3 66 Printer error Contact service report fault nnn Where nnn is one of the codes described below F141 Finisher Punch Unit counter at end of life The Punch count exceeds life limit 3 68 F142 Finisher Staple Unit counter at end of life The Staple count exceeds life limit 3 69
36. 50 2A5s Beinn ae RE ees 5 59 Staple POM MOTO aune a ole da ohana Yate a Mesa Y 5 60 DICE MOOK Goce twas aera ar a T TLE ERES a eee 5 61 Feed Motor 0 00 ee eae 5 62 Paddle MOTOL s0s62 656044259 445 sce bones ateeetnkent 5 63 DOVE MOOT saneret rtan oa see nea ete evacs Date at 5 64 Alignment Front and Rear Motors n nananana 5 65 Binding Clutch 0 0 0 eee 5 66 Inverter Upper Roller Motor 0 0 e eee 5 67 Inverter Lower Roller Motor 00 5 68 Inverter Feeder Clutch 0 0 0 cee eee eee ee 5 69 Inverter Upper Roller Solenoid 0 0 00 008 5 70 Inverter Lower Roller Solenoid n on nananana naaa 5 71 Finisher Sensors and Switches 00 00 eee eee ee 5 72 SOM OWEN carne ch adios SAE oe we eee ones oh ewan a 5 73 Front Door Switch and Sensor 00 ee eee 5 74 INJEC SCNSON 3 io5 c0 teen goer Gan dese EE eeneehes 5 75 Iray Paper SenSOr shdcetie te okcks otenh eo at a aa o i 5 7 6 Paper Surface Sensor 0 eee 5 77 Upper Cover Sensor 0 ee eee 5 78 SALIMI SENS ONS 0 22 02 5240459 reed a a 5 79 Lift Motor Clock Sensor 0 ccc eee eee eee 5 80 Stack Full Sensor lt iuiiec3 Pi gee irs dw ie onna dea neawah ace 5 81 Processing Tray SenSOr 0 0 ce eee 5 82 Aligning Plate Home Position Sensors 06 5 83 Stack Feed Roller Home Position Sensor 5 85 Waste Full Sensor
37. Color Printer Options Service Manual Parts List 1 10 Punch Total Assembly Parts List Punch Total Assembly Parts List ID Part Number Name Description 0 084K35580 Puncher 2 3 holes XC 084K35590 Punch Unit 4 hole F XC 6 137E16140 IC TLP1241 Photo Interrupter 13 180K00230 Punch Unit 2 3H XC 108K00240 Punch Unit 4H F XC 14 127K55160 Motor DC 16 960K32910 PCB Unit1 17 960K32920 PCB Unit2 Parts List 6 25 6 26 Phaser 7400 Color Printer Options Service Manual Staple Unit Diagram 1 of 2 33 s7400 640 Parts List 6 27 Staple Unit Diagram 2 of 2 501 40 s7400 641 6 28 Phaser 7400 Color Printer Options Service Manual Parts List 1 11 Staple Unit Parts List Staple Unit Parts List ID Part Number Name Description 0 029K04400 Staple Assembly Parts List 6 29 Fold Unit Diagram 1 of 3 A A mB B amp RON A er w c oo CC s7400 637 6 30 Phaser 7400 Color Printer Options Service Manual Fold Unit Diagram 2 of 3 Parts List 7400 638 6 31 Fold Unit Diagram 3 of 3 7400 639 6 32 Phaser 7400 Color Printer Options Service Manual Parts List 1 12 Fold Unit Parts List Fold Unit Parts List ID Part Number Name Description 0 054K37
38. Cover page 5 11 3 Remove the Upper Cover page 5 13 4 Disconnect connector CN57 from motor wiring Paddle Motor s7400 674 5 To remove the motor remove two screws metal 6 mm and list the unit free from the chassis Service Parts Disassembly 5 63 Delivery Motor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Remove the Side Guide page 5 107 4 Refer to the illustration below to locate the Delivery Motor Delivery Motor 7400 698 5 Slide the belt off of the motor gear 6 To remove the motor first remove the 6 wire connector CN59 from the motor and then remove two small screws metal 4 mm holding the motor to the chassis 5 64 Phaser 7400 Color Printer Options Service Manual Alignment Front and Rear Motors Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 Refer to the illustration below to locate both Alignment Motors O ao fF O N Rear Alignment Motor Front Alignment Motor CN65 CN63 7400 702 7 To remove either motor first remove the 5 wire connector CN63 Front and CN65 Rear from the motor and then remove two screws metal 6 mm and a washer holding the motor to the paper guide Service Parts Disassembly 5 65 Binding Clutch Remove the Paper Exit Tray page 5 7 Remove t
39. Finisher Away From Printer The Inverter Docking Joint Switch indicates that the Finisher is detached from the printer Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Docking Sensor m Options Map 9 Inverter Sensor Locator m Inverter Control Board m Options Inverter Sensors diagram Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Inverter Docking Sensor m Finisher Base Are there any defects or misalignment 2 Test the Inverter Joint Sensor Replace the Engine Go to Step 3 Run the Service Diagnostics Inverter Joint Control Board see Sensor test Book 1 Does the switch function correctly 3 Check the Inverter Docking Sensor signal Replace the Inverter Replace the Disconnect SNSCN1 from the Inverter Control Board sensor Control Board page 5 55 page 5 100 Ifthe Does the voltage change between 0 and error persists 5vdc on connector SNSCN1 2 when the replace the sensor is actuated harness General Troubleshooting 3 9 3 92 Phaser 7400 Color Printer Options Service Manual Adjustments and Calibrations In this chapter Section 4 Punch Unit Adjustments Registering Punch Holes Per
40. GUO S saena tester esos het se eesd a eae da cme ir 5 127 Duplex Motor Assembly 0 0 0 0 cee eee 9 128 Diverter Solenoid 1 0 cee ee eee 9 129 Duplex Unit Sensors and Switches 048 5 130 Bae a en ee re 5 131 Interconnect Gonnector 0 0 0 cee eee 9 132 Paper Tray Disassembly 0 0 0 ccc ee ee eee 9 133 Options Connector sasssa nanana 5 133 Tray Covers and Tray Door Door C 8 9 134 EVEEN 320 448 tie cee nee ean ahead eh ata beaks 9 136 Registration Motor 0 0 ce ce eee ee 5 137 OO C IV OLO s iaa a tcp Merk cre A E a a a e 5 138 LEMO es sanna depp a a E 5 139 Registration Clutch 0 0 ccc ee eee 9 140 Door C Detect Sensor 0 0 ccc ee eee 5 141 No Paper Sensor niko bia we td ae ie eat ea eee 5 142 Registration Sensor 2 2 een 9 143 Feed Out Sensor 2 66 iia e eee eee ee eee 9 146 Feeder BOAO arse c s os we aiterdews gf Ap dow a ee be aceon DTA OEE A 5 148 Tray Feed Rollers 0 00 c cee eee eee eee 9 150 Phaser 7400 Color Printer Options Service Manual 6 Parts List Using the Parts List 1 0 ccc cee eee nee eee ne nens 6 2 AEA IE otras inn tren gaa eto g eh ee han Gees bone ees 6 3 Finisher Unit Assembly Diagram 000 00 ae 6 4 Parts List 1 1 Finisher Unit Assembly Parts List 6 5 Finisher External Parts Diagram 0 000 6 6 Parts List 1 2 Finisher External Parts List
41. LED2 LED1 o 0 o0 O Q Q PSW3 PSW2 PSW1 Wiring Diagrams 7400 269 7 8 Map 2 Punch Controller Board Locator Diagram SW1001 E O sw1002 O sw1 003 LED1001 LED1002 LED1003 7400 716 Phaser 7400 Color Printer Options Service Manual Map 3 Inverter Controller Board Locator Diagram POWER FAN SNSCNI 835 MOTOR B MOTOR A SNSCN2 CL1 Hi MAIN2 MAINI SNSCNO Wiring Diagrams s7400 711 7 9 Map 4 Duplex Unit Controller Board Locator Diagram POWER FAN SNSCN1 CLI FLASH MOTOR B MOTORA SNSCN2 MAUNE MAINI SNSCNO s7400 711 7 10 Phaser 7400 Color Printer Options Service Manual Map 5 Paper Tray Controller Board Locator Diagram POWER FAN SNSCN1 835 MOTOR B MOTOR A SNSCN2 CL1 ai MAIN2 MAINI SNSCNO Wiring Diagrams s7400 711 7 11 Map 6 Paper Tray Feeder Board Locator Diagram Oo oO e Oo 0 0 0 Oo O oO PAPEND pe RYN 7400 603 7 12 Phaser 7400 Color Printer Options Service Manual Map 7 Finisher Sensor Locator Diagram 1 of 2 Wiring Diagrams 7400 733 Map 8 Finisher Sensor Locator Diagram 2 of 2 gt CNM Z J2006 s7400 734 7 14 Phaser 7400 Color Printer Options Service Manual Map 9 Inverter Sensor Locator Diagram Wiring Diagrams ONSCN2 400 722 Finisher Wiring Diagrams Finisher Punch Power Supply Wiring Diagram Front Door Switch Stapler Safety Joint Switch JS FDSW Swit
42. Options Map 5 Paper Tray Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Option Connector Is there any damage 2 Check that the optional tray is correctly Go to Step 3 Reseat the option installed and fully seated tray 3 Check the Option Control Board version Replace the Engine Replace the using the Service Diagnostics General Control Board see Option Control Status menu Book 1 Board Is the version current General Troubleshooting 3 49 Unsupported Inverter Unit ROM The printer has detected an incompatible Inverter assembly Applicable Status Code Code U50 Unsupported Inverter ROM Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Control Board m Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Inverter firmware version using Replace the Engine Replace the the Service Diagnostics General Status Control Board see Inverter Control menu Book 1 Board page 5 55 Is the version current 3 50 Phaser 7400 Color Printer Options Service Manual Unsupported Finisher Unit ROM The printer has detected an incom
43. Parts List Only those parts listed with part numbers are available for order Parts listed without part numbers are only available as part of a parent assembly or Service Kit 1 2 3 6 2 No The callout number from the exploded part diagram Part Number The material part number used to order specific parts Name Description Name of the part and number supplied per order Note In some cases the Name Description will be followed with a different name in parentheses This indicates the same part but with a different name in the disassembly section Parts throughout this manual are referenced PL For example PL3 1 10 means the part is item 10 of Parts List 3 1 A black triangle preceding a number followed by a parenthetical statement indicates the item is a parent assembly made up of the parts listed in parentheses and enclosed by a dashed line The notation with X Y following a part name indicates an assembly includes components X through Y For example 1 with 2 4 means part 1 consists of parts 2 3 and 4 The notation J1l lt gt J2 and P2 is attached to a wire harness It indicates that connector Jack 1 is attached to one end of the wire harness and connector J2 is attached to the other end that is plugged into P2 Phaser 7400 Color Printer Options Service Manual Finisher Parts The following pages show a parts locator diagram and parts list table for each unit of the Finish
44. Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Saddle Stitch Bind tray m Bind Tray Sensor Flag m Stapler Are there any defects or misalignment 2 Test the Binding Sensor Replace the Engine Go to Step 3 Run the Service Diagnostics Bookbinding Control Board see Sensor tests Book 1 Does the Binding Sensor function correctly 3 Test the sensor signal Replace the Either the sensor Does the voltage change on CN15 3 Finisher Control or the wiring is connector of the Finisher Control Board Board page 5 46 defective Check when the sensor is actuated the resistance of the wires and if no problem is found replace the sensor 3 40 Phaser 7400 Color Printer Options Service Manual Finisher Upper Output Tray is Full Unload Paper Initial Actions Ensure that the output tray is empty and the actuator is in the correct position Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Stack Full Sensor m Options Map 7 Finisher Sensor Locator 1 2 m Options Finisher Controller to Sensors 3 3 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Test the Upper Tray Stack Full Sensor Replace the Go to Step 2 Run the Service Diagnostics Upper Tray Finisher Control Full Sensor test Bo
45. Remove the Paddle Assembly page 5 46 2 Place the assembly as shown 3 Turn the gear in the direction of the arrow to move the upper stack delivery roller assembly upwards 4 Push up the safety guide from below to free one side of the safety guide from the shaft Safety Guide 7400 239 5 Push up the Safety Guide from below to free it from the shaft Service Parts Disassembly 5 115 of the arrow see the following illustrations the direction 6 Remove the Paddle in safety Guide Is Sey ae gt SP SO cae X ff yf _ 9 op O Paddle LG we Options Service Manual Phaser 7400 Color Printer 5 116 Lower Stack Delivery Roller Belt 1 Remove the Paddle Assembly page 5 46 and separate it from the Processing Tray Assembly 2 Slide the front and rear tamper plate of the processing tray to the outside 3 Remove the processing tray stopper Processing Tray Assembly Rear Aligning Plate Front Aligning Plate 7400 242 Service Parts Disassembly 5 117 4 Remove the screw metal flange 6 mm and detach the Front Paper Guide while freeing the two tabs aN O 7 Processing Tray Stopper DS AK 5 x lt 7N P s7400 243 5 118 Phaser 7400 Color Printer Options Service Manual 5 Remove the screw metal flange 6 mm and while freeing the tab remove the Rear Paper Guide ES Ry H Ay O AA Ty LN N Front Paper Guide
46. Sensor persists go to Run the appropriate Service Diagnostics Step 2 sensor test Do the sensors operate 2 Test the Staple Motor Replace the Go to Step 3 1 Close the Interlock Switches for test Finisher Control 2 Run the Service Diagnostics Staple sate page 3 46 Motor tests the error persists go to Step 4 Does the motor operate 3 Check for 24 V to the Staple Motor Replace the Staple Replace the Disconnect CN71 Motor page 5 60 harness If the Is there 24 V across CN71 1 and 2 lt gt error persists go ground to Step 4 4 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Power Supply Disconnect CN1 and CN2 from the Finisher page 5 56 Control Board and the opposite end from the Inverter Is the cable conductive 3 56 Phaser 7400 Color Printer Options Service Manual Finisher Jog Motor Failure An error was detected in either the Front or Rear Alignment Motor Applicable Status Code Code F93 Jog Motor Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Paddle Assembly m Options Map 1 Finisher Controller Board m Alignment Motors m Options Finisher Controller to Motors Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace
47. Size Switch and the Option Control Board wiring Is the harness conductive 7 Check for 5 V to the Paper Size Switch Replace the Replace the Is there 5 V across each switch lt gt ground Paper Size Switch Option Control when the switch is actuated for the affected Board tray page 7 30 3 44 Phaser 7400 Color Printer Options Service Manual Duplex Interface Failure Error occurs only after the detection of a properly installed and functioning Duplex Unit Applicable Status Code Code U12 Communication lost with Duplex Unit Initial Actions m Reseat the Duplex Unit m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Duplex Unit m Print Engine Map 5 see Book 1 Motor Driver Board m Print Engine Motor Driver Board 5 6 see Book 1 m Options Duplex Unit Sensors and Interconnect Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Replace the damage connector Duplex Unit Is the connector damaged page 5 122 Ifthe error persists go to Step 2 2 Check all pins on the DUPLEX Harness for Replace the Motor Replace the continuity Driver Board see DUPLEX Harness Disconnect the DUPLEX Harness Book 1 If the error Is the DUPLEX Harness conductive persists go to Step 3 3 Check all pins of the DRV1 ha
48. Slide motor CN19 1 1 839 Connects to the full stack sensor SWw1 1 C 841 Folding position adjustment middle 2 point stapling PSW3 1 B 840 Factory mode PSW2 1 C 840 Folding position adjustment middle 2 point stapling PSW1 1 D 840 Folding position adjustment middle 2 point stapling LEDS 1 B 839 LED for PSW1 LED2 1 C 839 LED for PSW2 LED1 1 D 839 LED for PSW3 CB1 1 B 835 Circuit breaker between Joint Switch and 24 volts from the printer Punch Controller Board Plug Jack Designator P J Map Coord Remarks J1001 2 H 838 Connects to Finisher Punch Transfer Motor J1002 2 H 840 Connects to Punch Motor J1003 2 D 842 Connects to CN12 of Finisher Unit J1004 2 G 842 Connects to CN14 of Finisher Unit J1005 2 H 835 Connects to waste full photosensor board and the Waste full LED board J1006 2 H 836 Connects to punch motor clock punch home and punch home position sensors J1007 2 D 834 Connects to the photosensor and LED boards SW1001 2 E 837 Punch hole count registration sensor output adjustment etc SW1002 2 E 838 Punch hole count registration sensor output adjustment etc SW1003 2 E 839 Punch hole count registration sensor output adjustment etc LED100 2 E 839 Determines number of punch holes see page 4 2 LED100 2 E 840 Determines number of punch holes see page 4 2 2 LED100 2 840 Determines number of punch holes see page 4 2 3 Wiring Diagrams Inverter Cont
49. Tray Feeder Board m Options Paper Tray Sensors and Interconnect Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Fill the tray Go to Step 2 Complete Does the error occur even if the tray is full 2 Check the following for evidence of fault or Replace any Go to Step 3 damage damaged parts m No Paper Sensor and actuator Is there any damage 3 Test the No Paper Sensor for the affected Replace the Engine Go to Step 4 tray Control Board see Run the Service Diagnostics No Paper Book 1 Sensor test Does the sensor function correctly 4 Check the No Paper Sensor signal Go to Step 5 Replace the No Does the voltage level change when the Paper Sensor sensor is actuated page 5 142 5 Check all pins on the TRYSNS1 Harness Replace the Engine Replace the for continuity Control Board see TRYSNS1 Is the harness conductive Book 1 Harness General Troubleshooting 3 87 Staple Cartridge Is Empty The Stapler Self Prime Sensor in the Staple Cartridge indicates no staples remain Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Stapler Self Prime Sensor m Finisher Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board Step Actions and Questions Yes No 1 T
50. any Go to Step 2 damage damaged parts m Paddle Assembly m Alignment Motors Is there any damage 2 Test the Alignment Plate Sensors Replace the Paddle Replace the Run the Service Diagnostics Front and Assembly sensor Rear Alignment Plate Sensor tests page 5 43 Do the sensors function correctly General Troubleshooting 3 57 Finisher Lift Motor Failure The Paper Surface Upper Limit or Lift Motor Clock Sensor detected a Lift Motor error Applicable Status Code Code F115 Lift Motor Failure Initial Actions m Check the Tray lift mechanism for obstructions or damage m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Upper Tray Lift Motor m Finisher Control Board m Inverter Power Supply Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board m Options Finisher Controller to Switches Step Actions and Questions Yes No 1 Test each of these sensors Go to Step 2 Replace the m Paper Surface Sensor Sensor If the error m Tray Upper Limit Sensor persists go to Shift Motor Clock Sensor Step 2 Run the appropriate Service Diagnostics sensor test Do all sensors function correctly 2 Check the tray lift mechanism Go to Step 5 Repair the lift Does the mechanism move freely mechanism 3 Test the Lift Motor Go to Step
51. evidence of fault or Replace any Go to Step 2 damage damaged parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Are there any defects or misalignment 2 Test the Bind Tray Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the at the Finisher Control Board Finisher Control harness Actuate the sensor Does the voltage across CN15 3 lt gt ground change when the sensor is actuated Board page 5 46 General Troubleshooting 3 25 Jam at Finisher Door G Jam detected in the saddle stitch path Applicable Status Code Code FNB8 Jam at Finisher Door G Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 7 Finisher Sensor Locator 1 2 m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 m Options Finisher Controller to Sensors 2 3 Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to St
52. evidence of fault or Replace any Go to Step 2 damage damaged parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Are there any defects or misalignment 2 Test the Processing Tray Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the at the Finisher Control Board Finisher Control harness Actuate the sensor Board page 5 46 Does the voltage across CN5 3 lt gt ground change when the sensor is actuated 3 24 Phaser 7400 Color Printer Options Service Manual Jam at Finisher Stapler Media remains in the Compiler Tray This error represents a jam in the Finisher staple path Applicable Status Code Code FN7 Jam at Finisher Stapler Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Compiler Tray m Options Map 7 Finisher Sensor Locator 1 2 m Front and Rear Alignment Guides m Transport Rollers m Stapler m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 Step Actions and Questions Yes No 1 Check the following for
53. procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Stapler m Options Map 1 Finisher Controller Board m Options Finisher Controller to Printer Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Replace the Stapler page 5 29 Replace the Engine Complete Cycle printer power Control Board Does the error persist NVRAM If the error persists replace the Engine Control Board see Book 1 General Troubleshooting 3 69 Finisher Interface Error Applicable Status Code Code F186 Finisher serial communications error Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Finisher Control Board mw Finisher Interconnect Cable m Engine Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Print Engine Motor Driver Board 6 6 see Book 1 m Options Map 1 Finisher Controller Board m Options Finisher Controller to Printer Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Finisher Interconnect Cable m Finisher connections Is there any damage 2 Check all the pins of the Finisher Go to Step 3 Replace the cable Interconnect Cable for continuity Is the cable conductive 3 Check all the pin
54. section provides procedures for the adjustment of print engine components Section 7 Cleaning and Maintenance This section provides periodic cleaning procedures for the printer Section 8 FRU Disassembly This section contains removal procedures for parts listed in the print engine s Field Replaceable Units FRUs Parts List A replacement procedure is included when necessary Section 9 Parts Lists This section contains exploded views of the print engine FRUs as well as part numbers for items available as FRUs Part numbers for printer options and accessories are also included Section 10 Wiring Diagrams This section contains the plug jack locations and the wiring diagrams for the print engine Appendix A Menu Maps This section provides an illustration of the front panel menu as well as a listing of the Service Diagnostics tests available xii Phaser 7400 Color Printer Options Service Manual Contents Service CUMS i crier ents reiteriai pasa a bean tetas bonwn dese lil Symbols Marked on the Product 0 0 0 0 cece eee eee iV Power Safety Precautions 0 0 c ccc cece ees V Electrostatic Discharge ESD Precautions 000 vi Service Safety SUMMAary 1 ee ees vii Regulatory Specifications 0 0 0 cc eee eee Ix Manual Organization 0 0 0 0 ccc eee eee XI 1 General Information Printer Introduction and Overview 0 0 0 c cee eee eee 1 2 Printer Configur
55. standards and other normative documents Low Voltage Directive 73 23 EEC as amended EN 60950 2000 EN 60825 1 1994 A1 2001 A2 2002 Electromagnetic Compatibility Directive 89 336 EEC as amended EN 55022 1998 A1 2000 A2 2003 EN 55024 1998 A1 2000 A2 2003 EN 61000 3 2 2000 EN 61000 3 3 1995 A1 2001 Radio amp Telecommunications Terminal Equipment Directive 1999 5 EC as amended EN 300 330 2 V1 1 1 EN 300 440 2 V1 1 1 EN 300 489 3 V1 3 1 This product if used properly in accordance with the user s instructions is neither dangerous for the consumer nor for the environment A signed copy of the Declaration of Conformity for this product can be obtained from Xerox x Phaser 7400 Color Printer Options Service Manual Manual Organization The Xerox Phaser 7400 Color Printer Service Manual is the primary document used for repairing maintaining and troubleshooting the printer The manual is organized into two books This volume Book 2 Phaser 7400 Options includes an overview of option theory option FRU replacement procedures parts lists and wiring diagrams Use this volume after you ve isolated a problem internal to a specific option or when a problem arises at the engine option interface Use Book 1 for diagnostic and troubleshooting procedures for the printer and all its options Use Book 2 as a reference when servicing printer options Book 2 includes information important for the repair o
56. steps through 4 the following illustration shows the top view of the Punch Slide Unit in the Finisher Paper Horizontal Registration Sensor 1 LED1 PT1 Used To Detect The Edge Of Sheets Of A3 A4 LTR 279X432 11 x17 Horizontal Registration Sensor 2 LED2 PT2 Used To Detect The Edge Of Sheets Of B4 B5 LTRR LGL Used To Detect The Edge Of Sheets Of AAR Horizontal Registration Sensor 4 LED4 PT4 Used To Detect The Edge Of Sheets Of BOR 7400 155 Theory of Operation 2 17 Folding Finisher paper fold rollers and a paper pushing plate are the main assemblies for the paper folding process when creating a booklet Concurrent with the start of the stack feed roller rotation the paper pushing plate pushes the middle of the paper stack into the gap between the paper fold rollers When the paper stack is fed about 10 mm into the rotating paper fold rollers the paper pushing plate returns to the home position The paper stack is then delivered to the Bind Tray using the paper fold rollers and bind delivery rollers Because of the large area size of the rollers the paper stack is fed without paper creases The large size of the area also allows the paper stack to fold while being fed Paper Stack a Inlet Paper push plate Outlet SN Folds Feeds a Paper Stack Feeds a Paper Stack 7400 150 2 18 Phaser 7400 Color Printer Options Service Manual Stacking There are two types of st
57. table see Book r Step Actions and Questions Yes No 1 Check the paper in the affected tray Go to Step 2 Reload the Is paper loaded in the tray properly paper 2 Check the tray paper guides Go to Step 3 Reset the Are the paper guides set correctly guides 3 Check the Paper Size Switch for the affected Go to Step 4 Correct the tray installation Is the switch installed correctly 4 Test the Paper Size Switch for the affected tray Go to Step 7 Go to Step 5 Run the Service Diagnostics Size Sensor test for the affected tray Does the sensor state change each time the loaded tray is moved in or out 5 Check the Paper Size Switch connection Go to Step 6 Connect the Is the switch connected at either end switch 6 Check continuity between the affected Paper Go to Step 7 Repair the Size Switch and the Option Control Board wiring Is the harness conductive 7 Check for 5 V to the Paper Size Switch Replace the Replace the Is there 5 V across each switch lt gt ground Paper Size Switch Option Control when the switch is actuated for the affected Board tray page 7 30 3 42 Phaser 7400 Color Printer Options Service Manual Wrong Paper Type Load Tray 3 4 5 6 with size type The Media Thickness Sensor has detected a change in the media type thickness in the same tray or reports a thickness value exceeding the reference Initial Actions m Ensure the tray is free of ob
58. the Duplex Unit Controller Board 3 Lift the fan free from the plastic molding Caution Be careful not to lose any of the retainer springs s7400 600 Service Parts Disassembly 5 131 Interconnect Connector The Duplex Unit Connector transfers signals between the printer and the Duplex Controller Board To remove the connector 1 Remove the Front Door and Front Cover Assembly page 5 122 Disconnect the Duplex Connector plug from the controller MAIN1 2 3 Free the cable harness from the chassis 4 Remove two screws metal 4 mm from the connector and lift the connector and cable from the chassis Duplexer Connector 7400 508 5 132 Phaser 7400 Color Printer Options Service Manual Paper Tray Disassembly The printer includes one 550 sheet tray Below the single tray on the printer the options tray includes one single tray 550 sheets and 3 additional stacked trays 1650 sheets Each tray is basically identical except for some interconnecting hardware The following subsections describe how to remove elements of an optional 550 sheet tray Options Connector On top of each optional tray is an options connector for cascading each of the trays as they rest on top of each other To replace 1 Remove the two screws metal flange 6 mm that fasten the connector to the top of the tray 2 Lift the connector up to reveal the two connector plugs on the underside of the connector 3 Disconnect the t
59. the chassis side carefully free the paper guide from the swing plate Remove two screws metal flange 6 mm from the solenoid casing oN OQ 0 To remove the solenoid unit remove two small brass screws metal 4 mm from the solenoid casing and lift the relay from the casing LDN ine X VO 5 70 Phaser 7400 Color Printer Options Service Manual Inverter Lower Roller Solenoid Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Rear Covers page 5 19 Remove the Top Cover page 5 23 Aa O N a Disconnect the cable from the Inverter Controller Board Be sure you free the cable harness from the cable guide Remove the Inverter Controller Board page 5 55 Remove the Power Supply Board page 5 56 Remove the tension spring from the solenoid and swing plate From the chassis side carefully free the paper guide from the swing plate Remove two screws metal flange 6 mm from the solenoid casing O O ON OO Ol To remove the solenoid unit remove two small brass screws metal 4 mm from the solenoid casing and lift the relay from the casing O a AO AO ji lt ne LE o Lower Roller ay Solenoid Casing 7400 493 Service Parts Disassembly 5 71 Finisher Sensors and Switches The topics in this section describe the disassembly for each sensor in the Finisher See page 5 99 for details of the Inverter sensors withi
60. the connector on the Finisher Controller Board Remove the Front Door page 5 8 and slide out the Stapler Unit to the front Remove the Rear Cover page 5 11 Remove the screw metal flange 6 mm and detach the Interface Retainer Free the seven harness retainers and disconnect the cable to connector CN18 oF O N Free the harness from the harness retainer and the Edge Saddle disconnect the two remaining cables to connector CN11 and CN7 and unroute from the harness O O Harness Retainers Harness Retainers s7400 226 amp Interface Retainer 5 30 Phaser 7400 Color Printer Options Service Manual 6 Disconnect the cable connector to CN10 behind the Punch Unit 7 Slide the Finisher away from the Inverter and then free the harness 8 Free the harness from the Edge Saddle and disconnect the two connectors to CN18 a S M pAn C EN BEA w S s7400 227 9 Remove the two screws metal flange 6 mm free the tab of the harness guide and remove all connectors to clear the harness guide Ni ey O N D2 Harness Guide Hook HOK gt RAIAR Service Parts Disassembly 5 31 10 Disconnect the connector to CN8 and the connector to CN6 and free the harness from the Edge Saddle Edge Saddle s7400 229 Staple Fold Motor Staple Fold Clock Sensor 5 32 Phaser 7400 Color Printer Options Service Manual 11 Remove the five screws metal 10 mm lift to free two hooks one on
61. the half of the periphery where gears with a smaller face width are arranged Saddle Cam Drive Gear Relay Gear Paper Folding Roller Drive Gear s7400 214 3 With the mark on the saddle cam drive gear aligned with the mark on the relay gear align the other mark on the relay gear with the rib of the paper folding roller drive gear Adjustments and Calibrations 4 19 4 20 Phaser 7400 Color Printer Options Service Manual service Parts Disassembly In this chapter General Notes on Disassembly Overview Finisher Disassembly Inverter Disassembly Duplex Unit Disassembly Optional Paper Tray Disassembly Section Overview This section contains the removal and replacement procedures for selected parts of the printer options package according to the Field Replaceable Units FRUs Parts List Not all replacement procedures are included in this Service Manual In most cases to reinstall a part simply reverse the removal procedure shown In some instances replacement notes are included providing special steps For specific assemblies and parts see the Parts List on page 6 1 General Notes on Disassembly Preparation Before you begin any Removal and Replacement Procedure 1 Switch Off the printer power as well as power to the Finisher and options 2 Wear an electrostatic discharge wrist strap to help prevent damage to the sensitive electronics of the printer circuit boards Note Names of parts
62. when the Upper Cover Door H is open or removed Shift Upper Limit Sensor Detects the upper limit of the delivery tray stack Shift Lower Limit Sensor Detects the lower limit of the delivery tray stack Lift Motor Clock Sensor Detects clock pulses for the stacking operation Full Stack Sensor Detects overstacking of media in the delivery tray Processing Tray Sensor Detects the processing stack within the delivery path Aligning Plate Front Home Position Sensor Aligns one side of the selected paper with the entrance into the paper path Aligning Plate Rear Home Position Sensor Aligns one side of the selected paper with the entrance into the paper path Stack Feed Roller Home Position Sensor Detects the initial home position of the stack feed rollers Waster Full Sensor Detects the full condition of the punch waste unit Swing Guide Home Position Sensor Detects the home position for the Swing Guide Delivery Belt Home Position Sensor Detects the end location of the delivery rollers Paddle Home Position Sensor Detects when it is necessary to drive the paddle and feed the next sheet of paper Stapler Safety Interlock Switch Protects current overloads in case of a staple jam Staple Fold Cock Sensor Counts timing pulses during staple and fold operations 2 28 Phaser 7400 Color Printer Options Service Manual Sensor Function
63. 0 0 ccc ee eee ee 5 87 Swing Guide Home Position Sensor 0005 5 89 Delivery Belt Home Position Sensor 006 9 90 Paddle Home Position Sensor 000 000 e 5 91 Stapler Safety Interlock Switch 0 0 0 0 cee 5 92 Table of Contents xvii XVIII otaple Fold Clock Sensor 2 2 0 cee eee 9 93 Folding Home Position Sensor 0 00 00 eee ee 5 94 Folding Position Sensor 0 0 0 cece ee eee 5 96 Bind Tray OGNSOM aioe oneetan eek A 5 98 Inverter Sensors and Switches 0 0 ccc cee eee eee 9 99 Inverter Docking Sensor 0 0 0 cee ee eee 9 100 Inverter Door Door F Open Interlock Switch 5 101 Inverter Upper Paper Present Sensor 5 102 Inverter Lower Paper Present Sensor 5 104 Inverter Paper in Sensor 0 0 0 000 cee ee eee 9 106 GUIDES and ROIG saseea crated 2 aed oh ad eared aa ha ana ac 9 107 Sde GU Cts a cai ce rare cee as Sy thas anti heated tyne Sbr Na aa 9 107 he e i ee 9 109 Upper Stack Delivery Roller 0008 5 112 PACUIC Kot uot bind nap ate sare awe eae ee 9 115 Lower Stack Delivery Roller Belt 5 117 Duplex Unit Disassembly 0 0 0 0 c eee eee 9 122 Front Cover Assembly 0 0 00 cc cee eee eee 5 122 Bottom Cover Plate 0 0 cc eee 9 124 DICE dS cra a5 a Sed Sasa ade Sees Sa nda ieee eget bral 9 126 Paper
64. 0 Color Printer Options Service Manual Jam Detection Chart Inverter Eject Jam Inverter Feed Jam Inverter Front Stack moe z Inverter Route Jam ee ees aai l_ Inverter Reverse Stack Area Jam Jam 07 Jam 05 Jam 08 Jam 09 57400 563 General Troubleshooting 3 5 Error Message Summary The Error Message Summary table below lists possible errors along with the corresponding code and page reference for the corrective procedure for the finisher Duplex Unit and paper trays The Error column lists the error code for fatal or jam errors that appears in the Help text displayed by pressing the Help button listed on the printer s Status page or logged by the Service Usage Profile The Control Panel Message column shows the message as is appears on the printer s display when the error occurs during normal operation The Page column provides the page reference to the corrective procedure Use this table to identify the proper procedure to clear the reported error Note When Printer error Contact service report fault nnn is displayed nnn is replaced by a code These codes along with a brief description appear in this table under Fatal Errors Appendix A includes a complete list of codes arranged in alphanumeric order Error Control Panel Message Page Jam Errors D1 Jam at Door D Open Door D to Clear 3 16 D2 Jam in Duplex Unit Pull out Duplex Unit to Clear 3 17 TC3 Jam at Duplex Entrance Open Top Co
65. 00 dots per inch dpi 32 level grayscale print is applicable at 600x600 dpi The base configuration Phaser 7400N features USB 2 0 and 10 100baseT Ethernet Ports 256 MB of memory a 250 sheet multi purpose Tray 1 MPT a 550 sheet input tray Tray 2 a 500 sheet face down Top Output Tray and a 250 sheet face up Side Output Tray Phaser 7400 printer options add memory paper capacity and functionality For configurations not originally equipped an internal Hard Drive is available for font storage storing print files job collation proof personal and secure print support A selection of RAM memory upgrades are available to raise the installed quantity to the 1 GB maximum A 1650 Sheet High Capacity Feeder HCF is available with three 550 sheet universal trays A 550 Sheet Feeder Tray 3 Lower Tray Assembly LTA is also available On the output side a 1000 Sheet Finisher provides punching stapling saddle stitching and offset stacking which raises the output total to 1750 sheets A Duplex Unit is available to add automatic 2 sided printing for supported paper sizes from all trays 1 2 Phaser 7400 Color Printer Options Service Manual Printer Configurations The Phaser 7400 Color Printer is available in five configurations The main differences are standard memory optional high capacity feeders duplexing 2 sided printing capabilities networking Finisher capabilities and internal Hard Drive The following table lists the avai
66. 03 and P J2004 connected harness 2 Cycle printer power Replace the Punch Complete Does the error persist Control Board page 5 50 General Troubleshooting 3 61 Finisher Punch Communications Failure An communications error occurred with the Punch Unit Applicable Status Code Code F132 Punch Unit communications failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Finisher Control Board m Print Engine Motor Driver Board 6 6 see Book 1 m Punch Control Board m Options Map 2 Punch Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the connection between the Finisher Go to Step 2 Connect the and Punch Controller Boards harness Are CN12 and CN14 on the Finisher Control Board connected Are P J2003 and P J2004 on the Punch Control Board connected 2 Check all the pins of the harness for Go to Step 3 Replace the continuity harness Is the cable conductive 3 Check for 24 V at the Finisher Control Replace the Punch Replace the Board Control Board Finisher Control Is there 24 V at CN14 5 lt gt CN14 3 page 5 50 Board page 5 46 3 62 Phaser 7400 Color Printer Options Service Manual Finisher Punch Unit Transfer Motor Failure An error was detected in the Punch Transfer Moto
67. 13 Aa N Open the Front Door and turn the knob on the stapler slide in the direction of the arrow to slide the stapler to the front most position Remove the Stapler Unit page 5 108 Oo Oo Place the Stapler Unit as shown below 7 Remove the two screws metal flange 6 mm and detach the metal guide ey 7400 251 Service Parts Disassembly 5 47 8 Turn the knob on the stapler side in the direction of the arrow so that the fixing screw metal 10 mm of the Slide Home Position Board is in view through the round hole Fixing Screw 7400 252 9 Remove the fixing screw metal 10mm 5 48 Phaser 7400 Color Printer Options Service Manual 10 Disconnect the connector 11 Remove the flexible cable retainer 12 Free the lock of the connector in the direction of the arrow and then detach the flexible cable LD SS Connector Lock Connector Se T AS Flexible Cable on O Slide Home Position PCB O N Flexible Cable Retainer ooN Dbm s7400 253 13 Detach the board Service Parts Disassembly 5 49 Punch Control Board 1 Remove the Rear Cover page 5 11 2 Remove the Front Door page 5 8 3 Remove the Upper Cover page 5 13 4 Remove the two screws metal flange 6 mm 5 Disconnect the five connectors to remove the Punch Control Board Punch Controller Board 7400 262 5 50 Phaser 7400 Color Printer Options Service Manual Photo Sensor Board Remove
68. 2 Test the Finisher Entrance Sensor Replace the Engine Replace the Run the Service Diagnostics Finisher Control Board see sensor If the error Entrance Sensor test Book 1 persists go to Does the sensor function correctly Step 3 3 Check the Entrance Sensor signal at the Replace the Replace the Finisher Control Board Finisher Control harness Actuate the Entrance Sensor Board page 5 46 Does the voltage across CN16 12 lt gt ground change when the sensor is actuated 3 20 Phaser 7400 Color Printer Options Service Manual Jam at Finisher Door H Media reached the Finisher Entrance Sensor but did not clear the Inverter on time This error represents a jam in the Finisher Inverter Applicable Status Code Code FN2 Jam at Finisher Door H Initial Actions m Check for obstructions or debris in the paper path E Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter m Options Map 7 Finisher Sensor Locator 1 2 m Finisher Entrance Sensor m Options Map 8 Finisher Sensor Locator 2 2 m Finisher Inverter Rollers m Options Map 9 Inverter Sensor Locator m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Inverter m Inv
69. 24 V Initial Actions m Reset the Option connector at the base of the printer m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Motor Driver Board m Print Engine Motor Driver Board 6 6 see Book 1 m LVPS m Options Paper Tray Motors and Interconnect Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check for 24 V at OPTRY24 Replace the Go to Step 3 1 Close the Interlock Switches affected Option 2 Disconnect OPTRY24 Conto Board Is there 24 V at OPTRY24 1 and 2 lt gt ground 3 Check all pins on the OPTRY24 Harness Go to Step 4 Replace the for continuity OPTRY24 Disconnect the OPTRY24 Harness Harness Is the OPTRY24 Harness conductive 4 Check for 24 V from the LVPS Replace the Motor Go to Step 5 Disconnect POW24 Driver Board see Is there 24 V at POW24 1 lt gt ground Book 1 5 Check the LVPS 24 V output Replace the Engine Replace the LVPS 1 Close the Interlock Switches Control Board see see Book 1 2 Disconnect CN2 BOOK A Is there 24 V at CN2 1 and lt gt ground General Troubleshooting 3 83 Duplex Unit Clock Frequency Error The clock frequency for the Duplex Unit Control Board CPU is inac
70. 400 Color Printer Options Service Manual Paper Tray Controller Board Plug Jack Designator P J Map Coord Remarks FFSNS 5 __ F 837__ Connects to TRYSNS1 and TRYSNS2 signals from the feeder board CL1 5 F 836 Connects to the registration clutch CL2 5 C 836 No connection GDDC 5 D 836 Connects to the Lift Motor MOTOR A 5 C 837 Connects to the Feed Motor MOTOR B 5 A 837 Connects to the Registration Motor MAIN 1 5 J 837 Connects to connector supplying Feeder Board signals MAIN2 5 E 839 Connects to power supply from the Finisher FLASH 5 H 836 Connect to external equipment for FLASH memory POWER 5 A 836 No connection Paper Tray Feeder Board Plug Jack Designator P J Map Coord Remarks TRYSNS1 6 G 836 Connects signals from the Paper Tray Controller Board TRYSNS2 6 E 839 Connects to the Door C detect Sensor the Feed Out Sensor and the Registration Sensor PAPEND 6 D 838 Connects to the No Paper Sensor Finisher Sensor Designators P J Map Coord Remarks MS2 7 D 839 Connects to the Joint Switch MS1 7 H 839 Connects to the Front Door Switch CN25 7 D 839 Connects to the Front Door Sensor CN44 8 G 836 Connects to the Inlet Sensor CN32 8 D 837 Connects to the Tray Paper Sensor CN35 8 E 837 Connects to the Paper Surface Sensor CN24 7 D 838 Connects to the Upper Cover Door H Sensor CN50 8 F 836 Connects to the Shift Upper Limit Sensor CN49 7 F 837 Connects to
71. 5 R Executive Offset function Provided output paper size except for A5R 5 5 x 8 5 Recommended paper Normal paper 60 12g m 16 34 Ibs and weight Index paper 176 g m 47 Ibs Cover paper 9 200 205 g m 54 55 Ib Staple supply Staple cartridge replacement Staple detection Staple empty provided detection Cartridge empty provided detection Staple jam detection provided Stapling type Center stapling center fold Stapling position 1200 mm pitch from the paper center Paper size for saddle stitch A3 A4R B4 11x 17 8 5x11R Weight of paper for saddle stitch 64 80 g m Cover 64 128 g m Book tray stacking type Fixed Quantity of paper to be stapled General Information 10 sets 6 10 pages 20 sets 1 5 pages 1 9 Finisher Environmental Specifications Characteristic Specification Temperature Operating 10 to 32 C 50 to 89 6 F Storage O to 4 C 32 to 109 4 F Transport 10 to 43 C 14 to 109 4 F Humidity RH Relative Humidity 50 70 to assure the best print quality Operating 20 80 Storage 10 95 Transport 10 95 Altitude Operating O to 2500 meters 8 000 ft at 25 C Non operating O to 6000 meters 20 000 ft 1 10 Phaser 7400 Color Printer Options Service Manual Theory of Operation In this chapter Operational Overview Finisher Overview Printer Options Finishing Proce
72. 790 Fold Assembly Parts List 6 33 Inverter Parts Diagram 1 of 3 7400 625 6 34 Phaser 7400 Color Printer Options Service Manual Inverter Parts Diagram 2 of 3 6 35 Parts List Inverter Parts Diagram 3 of 3 7400 627 6 36 Phaser 7400 Color Printer Options Service Manual Parts List 1 13 Inverter Parts List Inverter Parts List ID Part Number Name Description 0 112K00720 Inverter and Base 6 031E11260 Guide Sheet L Assy XOBG 60 110E20010 PWR unit ACDC Switch 61 960K32850 On Board Assy V72 3 62 117E29240 CONN Cord Wire AMP3P SW 67 106E00920 Photo Interrupter 71 059E05480 Roller Register 72 059E05490 Roller Exit 73 059E05500 Roller Main 116 055K37080 Plate Guide C Assy 129 121E20450 Solenoid 151 127E15500 Motor Inverter 169 059E05510 Roller Invert Parts List 6 37 s7400 649 SS ea cat a a es te Duplex Unit Parts Duplex Unit Parts Diagram Phaser 7400 Color Printer Options Service Manual 6 38 Parts List 1 14 Duplex Unit Parts List Duplex Unit Parts List ID Part Number Name Description 0 084K35440 Duplex Unit Parts List 6 39 Optional Paper Tray Parts 6 40 Phaser 7400 Color Printer Options Service Manual Optional Tray Parts Diagram 1 of 2
73. 8 Replace the motor 1 Close the Interlock Switches for test If the error 2 Run the Service Diagnostics Shift Motor persists 0010 t Step 6 est Does the motor operate 4 Check for 24 V to the Lift Motor Replace the Lift Replace the Disconnect CN70 Motor page 5 59 Finisher Control Is there 24 V across CN70 1 and 2 lt gt Board page 5 46 ground when the test is executed If the error persists go to Step 5 3 58 Phaser 7400 Color Printer Options Service Manual Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 5 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Power Supply Disconnect CN1 and CN2 from the Finisher page 5 56 Control Board and the opposite end from the Inverter Is the cable conductive General Troubleshooting 3 59 Finisher Exit Failure The Delivery Belt Home Position Sensor detected a Delivery Motor error Applicable Status Code Code F116 Delivery Motor Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Finisher Delivery Motor m Options Map 1 Finisher Controller Board m Finisher Control Board m Options Finisher Controller to Motors Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Test the Exit Motor Comple
74. 9 Finisher Internal Parts Diagram 2 of 2 See B6 30 s7400 631 6 10 Phaser 7400 Color Printer Options Service Manual Parts List 1 3 Finisher Internal Parts List Finisher Internal Parts List ID Part Number Name Description 7 137E16140 IC TLP1241 Photo Interrupter Parts List Stack Lift Motor Drive Assembly Parts Diagram 7400 632 6 12 Phaser 7400 Color Printer Options Service Manual Parts List 1 4 Stack Lift Motor Drive Assembly Parts List Stack Lift Motor Drive Assembly Parts List ID Part Number Name Description 0 005K12430 Stack Motor Drive Assembly Lift Motor Parts List 6 13 Staple Fold Drive Assembly Parts Diagram N Ty 7 CNSNS B AN x WN XO w ap X w s7400 633 Phaser 7400 Color Printer Options Service Manual 6 14 Parts List 1 5 Staple Fold Drive Assembly Parts List Staple Fold Drive Assembly Parts List ID Part Number Name Description 0 005K12440 Drive Assembly Staple Fold Parts List 6 15 Bundle Support Cover Assembly Parts Diagram 7400 634 6 16 Phaser 7400 Color Printer Options Service Manual Parts List 1 6 Bundle Support Cover Parts List Bundle Support Cover Assembly Paper Detection Parts List ID Part Number Name Description 0
75. 96 Inlet Sensor 5 75 Inverter Docking Sensor 5 100 Inverter Lower Paper Present Sensor 5 104 Inverter Paper in Sensor 5 106 Inverter Upper Paper Present Sensor 5 102 Lift Motor Clock Sensor 5 80 Paddle Home Position Sensor 5 91 Paper Registration Sensor 2 5 143 Paper Surface Sensor 5 77 Paper Tray Feed Out Sensor 5 146 Paper Tray No Paper Sensor 5 142 Processing Tray Sensor 5 82 Shift Limit Sensors 5 79 Stack Feed Roller Home Position Sensor 5 85 Stack Full Sensor 5 81 Staple Fold Clock Sensor 5 93 Swing Guide Home Position Sensor 5 89 Tray Paper Sensor 5 76 Waste full Sensor 5 88 sensor type 2 25 microswitch 2 26 photo receptive 2 25 photo reflective 2 25 service bulletins 1 2 Service Diagnostics 3 2 Shift Lower Limit Sensor 2 24 Shift Upper Limit Sensor 2 24 Side Cover Paper Detection Bundle parts diagram 6 16 Side Cover Paper Detection Bundle parts list 6 17 Slide Motor theory 2 23 solenoid removal Diverter Solenoid 5 129 Inverter Lower Roller Solenoid 5 71 Index Inverter Upper Roller Solenoid 5 69 5 70 Specifications 1 7 electrical 1 7 environmental 1 10 functional 1 8 stacking process 2 19 standard orientation 5 4 Staple Empty Sensor 2 23 Staple Top Position Sensor 2 23 Staple Unit clincher cam 4 13 driver gear 4 11 process 2 23 Safety Interlock Switch removal 5 92 staple position check gear 4 10 4 15 theory 2 6 Staple Unit parts diagram 6 27 Staple Uni
76. Check the motor harness continuity Replace the motor Replace the Is the harness conductive If the error persists harness Go to Step 10 8 Test the Registration Clutch Go to step 11 Go to step 9 Run the Service Diagnostics Clutch test Does the clutch function correctly 9 Check the CL1 harness continuity Replace the clutch Replace the Is the harness conductive If the error persists harness go to Step 10 10 Check for 24 V at the Motor Driver Replace the Go to Step 11 Board s OPTRY24 connector affected Option 1 Close the Interlock Switches Control Board 2 Disconnect OPTRY24 Is there 24 V at OPTRY24 1 and 2 lt gt ground 3 14 Phaser 7400 Color Printer Options Service Manual Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 11 Check OPTRY24 Harness continuity Go to Step 13 Replace the Disconnect the OPTRY24 Harness OPTRY24 Is the OPTRY24 Harness conductive Harness 12 Check the Registration Assembly Replace the Go to Step 13 Is there a gap between the rollers Registration Assembly page 8 84 13 Check the DRV1 harness continuity Replace the Motor Replace the Is the harness conductive Driver Board harness page 8 141 If the error persists replace the Engine Control Board page 8 112 General Troubleshooting 3 15 Jam at Door D Open Door D to Clear Media reached Duplex Reverse Sensor but did not leave the Duplex
77. Check the sensor connection Go to Step 3 Reconnect the Is CN39 connected sensor 3 Replace the sensor Go to Step 4 Complete Does the error persist 4 Check all pins on the harness for continuity Replace the Replace the Is the harness conductive Finisher Control harness Board page 5 46 3 52 Phaser 7400 Color Printer Options Service Manual Finisher Paddle Failure An error was detected in the Finisher Paddle Motor Applicable Status Code Code F103 Paddle Motor failure Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Finisher Paddle Motor m Finisher Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board m Options Finisher Controller to Motors Step Actions and Questions Yes No 1 Test these sensors Go to Step 2 Replace the Swing Guide Home Position sensor If the error Sensor persists go to m Paddle Home Position Sensor Step 2 Run the appropriate Service Diagnostics sensor test Do the sensors operate 2 Test the Paddle Motor Replace the Go to Step 4 1 Close the Interlock Switches for test Finisher Control 2 Run the Service Diagnostics Paddle aly page Onno Motoriest the error persists go to Step 4 Does the motor operate 3 Check for 24 V to the Paddle Motor Replace the Replace the Disconne
78. Continued Sensor Function Folding Home Position Detects the positions of the paper fold rollers and the paper Sensor pushing plate Bind Tray Sensor Detects when paper is present in the Saddle Unit s bind tray Folding Position Sensor Detects the leading edge of the paper stack Note The punch assembly includes up to five light receiving transistors photosensor board mounted over the inlet paper path of the Punch Unit The same number of LEDs are mounted under the path as well The front most sensor LEDS PT5 detects the trailing edge of each sheet The remaining four LEDs LED1 through LED4 PT1 through PT4 are horizontal registration sensors which detect the rear position of sheets when punching holes Theory of Operation 2 29 Inverter Sensors The following illustration shows the general location of the Inverter sensors The topics in this section describe the disassembly for each sensor Inverter Paper in Sensor Inverter Upper Paper present Sensor Inverter Door Open Interlock Switch Sh N Inverter Docking Sensor Inverter Lower Paper present Sensor Q i i L s7400 611 Sensor Function Sensor Function Inverter Docking Sensor Detects when the Inverter interconnects with the Printer Inverter Door Open Detects when the Inverter Door F is open Interlock Switch 2 30 Phaser 7400 Color Printer Options Service Manual Sensor Function Continued Sensor Function
79. Fe Folding Home Pa Ne AS Position Sensor Cam A Q Paper Pushing Plate Paper Stack 8 6 SS Saddle Unit Components Component Function Stack feed rollers Rotates to feed the stacking mechanism Paper pushing plate Pushes the center of the paper stack toward the feed rollers Stapling mechanism Performs stitching term for center punching Swing guide Places the paper stack between the delivery rollers Theory of Operation 2 9 Inverter Unit The Inverter Unit receives paper from the printer and physically inverts the paper for stacking or folding The Inverter is a self enclosed unit which connects on a common base with the Finisher itself The entire Finisher Inverter can then physically connect to the printer and tray units with a sliding mount The Inverter receives instructions from the printer and or Finisher Controller Board Through various sensors switches solenoids and motors it moves the selected media through the paper path to invert and position the paper for stacking or folding s 400 710 Inverter Unit Components Component Function Inverter controller board Receives commands from the printer and controls all elements of Inverter operation Sensors and switches Detects the position of the paper through all phases of the inversion process Solenoids and clutch Receives commands from the Inverter controller board to determine the paper path invert or not Deliv
80. From the left side view disconnect the sensor connector Connector sensor Support DAN 5 26 Phaser 7400 Color Printer Options Service Manual s7400 258 10 Remove one screw metal flange 6 mm and washer 11 Disconnect the connector from the underside of the unit and then the assembly Remove the two screws self tapping plastic 10 mm to detach the base cover Base Cover 7400 259 Service Parts Disassembly 5 27 12 Remove the three screws metal flange 6 mm to remove the Upper Transmission Sensor Unit and the Lower Transmission Sensor Upper Transmission Sensor Unit an ii ce i a eg eae a amp Lower Transmission Sensor S s7400 260 13 Remove the Punch Unit from the Finisher Punch Transfer Motor assembly Finisher Punch Transfer Motor Assembly Punch Unit s7400 261 5 28 Phaser 7400 Color Printer Options Service Manual Staple Unit 1 Open the Front Door to gain access to the Staple Unit 2 Slide out the Staple Unit while pressing the stopper Note Do not remove the Stapler Frame Shaft If removed the position where the staple driver lower unit of the stapler inserts the staple through the paper will shift from the position where the staple clincher upper unit of the stapler clinches staples Front Door W AS S FZ aS r JE Syl Stapler Unit s7400 200 Service Parts Disassembly 5 29 Staple Fold Drive Unit Note The references indicate
81. Inverter Binding and i Saddle Stitch Tray pomaeet May Saddle Unit OD s7400 709 Theory of Operation 2 3 Punch Unit The Punch Unit punches holes in sheets coming from the printer It provides for 2 hole 3 hole and 4 hole punching The unit installs into the pickup assembly of the finisher Since the punch unit is not equipped with a paper feeding mechanism the sheets from the printer move through the punch unit and feed system of the finisher If the punch feature has been selected when the trailing edge of a sheet from the printer reaches the punch unit the sheet stops while the punch shaft rotates to punch a hole along the trailing edge This operation is controlled through various commands from the Finisher Controller Board and the Punch Controller Board Horizontal Registration Drive System Punch Controller PCB 400 151 2 4 Phaser 7400 Color Printer Options Service Manual The Punch Unit consists of a die and hole punch punch blade which is driven by aa DC motor The unit attaches to the eccentric cam of the punch shaft A punch home position sensor detects the home position of the punch shaft to ensure that the punch motor stops exactly at its home position the punch motor stops in relation to the count of clock pulses from the Punch Motor Clock Sensor When the punch shaft rotates 180 degrees from its home position it initiates a single punch operation Punch Unit Components Component
82. Is the connector damaged 2 Check for 24 V at DUPLEX on the Motor Replace the Duplex Go to Step 3 Driver Board Control Board 1 Close the Interlock Switches page 5 139 2 Disconnect DUPLEX Is there 24 V at DUPLEX 6 and 13 lt gt ground 3 Check all pins on the DUPLEX Harness for Go to Step 4 Replace the continuity DUPLEX Harness Disconnect the DUPLEX Harness Is the DUPLEX Harness conductive 4 Check for 24 V from the LVPS Replace the Motor Go to Step 5 Disconnect POW24 on the Motor Driver Driver Board see Board Book 1 Is there 24 V at POW24 1 lt gt ground General Troubleshooting 3 81 Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 5 Check the LVPS 24 V output Go to Step 6 Replace the LVPS 1 Close the Interlock Switches see book 1 2 Disconnect CN2 Is there 24 V at CN2 1 and lt gt ground 6 Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive 3 82 Phaser 7400 Color Printer Options Service Manual 24 V Not Available to Tray 3 4 5 6 Voltage detection indicates that 24 V is not available to the indicated option tray Applicable Status Codes Code 924 Tray 3 not receiving 24 V Code 925 Tray 4 not receiving 24 V Code 926 Tray 5 not receiving 24 V Code 927 Tray 6 not receiving
83. Jack References m Options Map 3 Inverter Controller Board m Options Map 9 Inverter Sensor Locator m Options Inverter Sensors Diagram Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Sensor Actuator m Paper Guides m Transport Rollers Are there any defects or misalignment 2 Test the affected sensor Replace the Engine Go to Step 3 Run the Service Diagnostics test for the Control Board see reporting sensor Book 1 Does the sensor function correctly 3 Test the sensor signal Replace the Either the sensor Does the signal voltage change on the SNSCNO connector of the Inverter Control Board Inverter Control Board page 5 46 or the wiring is defective Check the resistance of the wires and if no problem is found replace the sensor General Troubleshooting 3 29 Jam at Finisher Entrance Media remains in the Inverter Entrance Sensor This error represents a jam in the Printer Finisher interface Applicable Status Codes Code IN5 Media did not reach the Inverter Entrance Sensor following an Eject command from the printer Code IN8 Media remains in the Inverter Entrance Sensor Initial Actions m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Entrance S
84. NE 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 l ii Phaser 7400 Color Printer Options Service Manual Service Terms Manual Terms Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action Be aware of all symbols and terms when they are used and always read NOTE CAUTION and WARNING statements Common Acronyms The following list defines the acronyms that may be found in this manual ADC Automatic Density Control MCU Engine Control Board BTR Bias Transfer Roller NCS Non Contact Sensor CRUM Customer Replaceable Unit PHD Imaging Unit Monitor CTD Toner Density Control PL Corresponds to the FRU Parts List ESD Electrostatic Discharge ROS Laser Scanning Unit IDT Intermediate Transfer Unit RTC Charge Roller Note A note indicates an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A note can 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 results in damage to or destru
85. Phaser 7400 XEROX ec eee color printer Service Manual Book 2 Options Phaser 7400 Color Printer service Manual Book 2 Options 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 the operating instructions unless you are qualified to do so First Printing August 2005 07 1 0876 00 Copyright 2005 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 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 XEROX The Document Company the digital xo 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 Acrobat Adobe Reader Adobe Type Manager ATM Illustrator PageMaker Photoshop PostScript Adobe Brilliant Screens Adobe Garamond Adobe J enson Birch Carta IntelliSelect
86. Sensor but did not leave the Duplex Unit on time This error represents a misfeed jam inside the Duplex Unit Applicable Status Code Code D2 Jam in Duplex Unit Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Duplex Unit m Options Map 4 Duplex Unit Controller Board m Options Duplex Unit Sensors and Interconnect Wiring Troubleshooting Procedure Table Wiring and Plug Jack References Step Actions and Questions Yes No 1 Ensure the correct weight and type of Go to Step 2 Run several test paper is loaded in the tray prints Does the media meet specifications Ifa jam persists go to Step 2 2 Check for and remove any dirt debris or Complete Go to Step 3 obstructions in the paper path around the Duplex Unit Did this correct the problem 3 Clean and check the Duplex Unit rollers Go to Step 4 Replace the Duplex Do the rollers move freely and are free of Unit page 5 122 dirt or debris 4 Test the Duplex Entrance Reverse Front Go to Step 5 Replace the Duplex and Rear actuators and sensors using Unit page 5 122 Service Diagnostics Do the sensors function correctly 5 Test the Duplex Motors Go to Step 6 Replace the Duplex Do the motors function correctly Unit page 5 122 6 Inspect the DUPLEX harness If defective Replace the Motor Replace the Duplex replace the wiring ha
87. Test the Door F Interlock Switch Replace the Engine Go to Step 3 NOTE Door sensor tests are located under Control Board see the Interlock Switches sub menu Book 1 Run the Service Diagnostics Front Door Switch test Does the switch function correctly 3 Check the switch connection Go to Step 4 Connect the Is CN68 connected switch 4 Check all pins on the harness for continuity Go to Step 5 Replace the Disconnect the Switch harness from CN8 harness Is the harness conductive 5 Replace the Door F Interlock Switch Replace the Complete Does the error persist Finisher Control Board page 5 46 General Troubleshooting 3 35 Close Finisher Door H The Upper Cover Door H Sensor indicates that Door H is open Initial Actions Ensure that the door is free of obstructions and fully closed Verify that the actuator is not broken Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Upper Cover Sensor Wiring and Plug Jack References m Options Map 7 Finisher Sensor Locator 1 2 m Options Finisher Controller to Sensors 1 8 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace the parts Go to Step 2 damage concerned m Door H Actuator m Door H Switch 2 Test the Door H Switch Replace the Engine Go to Step 3
88. Unit on time This error represents a misfeed jam inside the Duplex Unit Applicable Status Code Code D1 Jam at Door D Initial Actions E Ensure that the Duplex Unit is free of obstructions and fully seated m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Duplex Unit m Options Map 4 Duplex Unit Controller Board m Options Duplex Unit Sensors and Interconnect Wiring Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Duplex Unit Entrance Roller m Duplex Unit Connector m Duplex Unit Is there any damage or debris 2 Test the Duplex Entrance Reverse Front Go to Step 3 Replace the and Rear actuators and sensors using Duplex Unit Service Diagnostics page 5 122 Do the sensors and actuators function correctly 3 Test the Duplex Motors using Service Go to Step 4 Replace the Diagnostics Duplex Unit Do the motors function correctly page 5 122 4 Inspect the DUPLEX harness If defective Replace the Motor Replace the replace the wiring harness Driver Board see Duplex Unit Is the harness properly seated and free Book 1 page 5 122 from defects 3 16 Phaser 7400 Color Printer Options Service Manual Jam in Duplex Unit Media reached Duplex Reverse
89. 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 printer You must also disconnect the power cord from the printer s AC inlet Disconnect the power cord by pulling the plug not the cord Disconnect the power cord in the following cases m if the power cord or plug is frayed or otherwise damaged m if any liquid or foreign material is spilled into the product m if the printer is exposed to any excess moisture m if the printer is dropped or damaged m if you suspect that the product needs servicing or repair m whenever you clean the product Phaser 7400 Color Printer Options Service Manual V Electrostatic Discharge ESD 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 p
90. able to the Duplex Unit 3 81 Printer error Contact service report fault nnn Continued Where nnn is one of the codes described below 924 24 V not available to Tray 3 3 83 925 24 V not available to Tray 4 3 83 926 24 V not available to Tray 5 3 83 927 24 V not available to Tray 6 3 83 931 The Duplex Unit CPU clock frequency is inaccurate 3 84 932 The Inverter CPU clock frequency is inaccurate 3 85 933 The Tray 3 Feeder Board clock frequency is inaccurate 3 86 934 The Tray 4 Feeder Board clock frequency is inaccurate 3 86 935 The Tray 5 Feeder Board clock frequency is inaccurate 3 86 936 The Tray 6 Feeder Board clock frequency is inaccurate 3 86 Warning Messages No Paper in Tray 3 4 5 6 3 87 General Troubleshooting 3 9 Error Control Panel Message Page Staple Cartridge Is Empty 3 88 _ Finisher Away From Base o 888 3 10 Phaser 7400 Color Printer Options Service Manual Using the Troubleshooting Procedures 1 2 Applicable Status Code s lists the error message s addressed by each troubleshooting procedure Applicable Parts and Wiring and Plug Jack References assist you in locating information available for a particular part or procedure Follow each Step in a troubleshooting procedure sequentially in the order given until the problem is fixed or resolved The Actions and Questions box instructs you to perform a certain action or procedure Also
91. abs with needle nose pliers and then pull the sensor free Service Parts Disassembly 5 93 Folding Home Position Sensor The Folding Home Position Sensor detects the positions of the paper fold rollers and the paper pushing plate To remove and replace the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 Remove the metal cover plate to expose the sensor O oo Ff Q N 7 LLU G ALLJ s7400 661 5 94 Phaser 7400 Color Printer Options Service Manual 7 Locate the sensor see illustration Swing Guide Home Position Sensor _ Stack Feed Roller VIS Home Position Sensor TS Bes BS Folding Home Position Sensor Folding Position Sensor 7400 659 8 To remove the sensor disconnect CN40 from the sensor remove one screw metal 4 mm and then pull the sensor free Service Parts Disassembly 5 95 Folding Position Sensor The Folding Position Sensor detects the leading edge of the paper stack To remove and replace the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 oa OF O N Remove the metal cover plate to expose the sensor A y 5 96 Phaser 7400 Color Printer Options Service Manual 6 Locate the sensor see il
92. acking presented to the delivery tray m Simple Stacking The unit pulls in the sheet to the processing tray and then delivers it to the delivery tray 7400 122 Theory of Operation 2 19 m Job offset The machine places the sheet into the processing tray It then moves the sheet to the front or the rear using the aligning plate When it has deposited a specific number of sheets it delivers them as a stacked set Direction Of Delivery 7400 123 2 20 Phaser 7400 Color Printer Options Service Manual When the number of sheets stacked on the processing tray reaches a specified value the sheets are delivered in stack form Even if the unit never reaches a specified value stacked sheets are temporarily delivered when 25 sheets of large size paper 300 mm or longer or 50 sheets of small size paper 299 mm or shorter have been stacked The finisher also uses a Tray Paper Sensor to detect the presence or absence of paper in the stack tray It also includes a Full Stack Sensor to detect overstacking we S Pa P a ra C pi k S ae ae n N T Shift Upper gt Limit Sensor 6 All Z ry Shift Lower oW Limit Sensor AMn hift Motor 57400 140 Stacking in Booklet Mode In the Booklet stitching format the stack feed system feeds up to 50 sheets of stitched paper stack to the folding position When stitching is complete the Feed Motor rotates until the up
93. ad 2 18 SEKIN 0m ded rahe se On heed a ace Shaw ode wa ot 2 19 AD Sncunehuteveee oh ben acdnd scores eben ewes ens 2 23 DOVO ooa a herd exichcboip ate E oy aes eb a a a ao ie 2 24 Table of Contents xiii Xiv SensSorS aaua a a oe Ae MS eee oe 2 25 Finisher Paper Path Sensors 0 0 00 c eee eee 2 21 Inverter Sensors 0 ce ee ee eee 2 30 Duplex Sensors 0 04 kind ot tud ei tan Since he deedetexaws 2 31 Optional Tray Sensors n on naana aaa 2 32 Motors Rollers Solenoids and Clutches 2 33 Finisher Motors 6 dee sn te aca erie at ead ealh we dokats eden eae eae 2 33 Inverter Solenoids and Motors 000 00 eee 2 39 Duplex Solenoids Rollers and Motors 2 36 Optional Tray Motors Rollers and Clutches 2 3 Detecting JAMS oicrirririccisere rinis he mew Sommaire aean oats 2 40 Finisher Punch Power Supply 0 0 00 e cece eee eae 2 41 Finisher Power Supply Protection 08 2 42 Punch Unit Power Supply Protection 2 42 3 General Troubleshooting MMMPOGUGHONG EE E ones bes eee ne ba td ae EEN 3 2 Using Service DiagnoSticS 0 c eee eee ee 3 2 Servicing Instructions 0 0 ccc ee eee 3 3 Jam Locator 2 eee eee 3 4 Jam Detection Chart 0 0 0 0 ccc eee 3 5 Error Message SummMary 0 00 cece eee 3 6 Using the Troubleshooting Procedures 3 11 Measurement Tec
94. ap 3 page 10 6 m Feeder Assembly m Print Engine Map 5 page 10 8 m Option Control Board m Print Engine Map 11 page 10 14 m Feeder Board m Print Engine Motor Driver Board 6 6 page 10 36 m Options Map 5 Paper Tray Controller Board m Options Paper Tray Sensors and Interconnect Wiring General Troubleshooting 3 13 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Clean or replace Go to Step 2 dirt debris or damage the appropriate DoorC parts m Feed Rollers m Registration Rollers m Transport Rollers m Sensor Actuators Is there any damage or debris 2 Check the Option connection Reconnect or Go to Step 3 Is the Option connection to the Printer replace the cable damaged or disconnected 3 Check the Option Harness continuity Go to Step 4 Replace the Option Disconnect OPTIF from the Engine Control harness Board and the Option connector Is the harness conductive 4 Test the tray sensors Go to Step 6 Go to Step 5 Run the Service Diagnostics Tray Switches test for the appropriate tray Do the sensors function correctly 5 Check the sensor harness continuity Replace the Replace the Is the harness conductive sensor If the error harness persists replace the Feeder Board 6 Test the Feeder Motors Go to step 8 Go to Step 7 Run the Service Diagnostics Motor tests Do the motors function correctly T
95. ard Does the sensor state change when the sensor is actuated 2 Check the sensor harness connections Go to Step 4 Connect and go to Is the sensor connected Step 3 3 Print a test print Go to Step 4 Problem solved Does the error still occur 4 Check sensor harness continuity Go to Step 5 Replace the Is the harness conductive Sensor Harness 5 Check for 5 V to the Upper Tray Stack Full Go to Step 6 Replace the Sensor Finisher Control Is there 5 V on the Finisher Control Board Board 6 Check the Finisher Control Board signal Replace the Replace the Upper Does the voltage across on the Finisher Control Board change when the sensor is actuated Finisher Control Board page 5 46 Tray Full Stack Sensor General Troubleshooting 3 4 Wrong Paper Size Load Tray 3 4 5 6 with size type Tray 3 4 5 6 paper size mismatch error The Paper Size Switch indicates that the media loaded in the source tray does not match the size specified by the print job Initial Actions Inspect the tray to ensure that it is free of obstructions is loaded with the expected media and the guides are adjusted correctly Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Paper Size Switch m Paper Tray m SIZE Harness Troubleshooting Procedure Table Wiring and Plug Jack References m Paper Size Switch Signal Definitions
96. ars belts and the door solenoid To remove the belts remove only the left side rail using the following steps 1 Remove the Front Cover assembly page 5 122 2 Slide the mounting slides to the rear of the side rail 3 Remove three screws metal flange 6 mm fastening the side rail to the chassis and lift the rail free from the chassis Left Side Rail 7400 503 5 126 Phaser 7400 Color Printer Options Service Manual Paper Guides 1 Remove Front Door and Cover assembly page 5 122 2 To remove either the Top Paper Guide or the Lower Paper Guide lift the paper guide to the open position loosen one end of the plastic insert and lift away from the chassis Caution Removing any of the guides will expose paper sensors Top Paper Guide 7400 504 Service Parts Disassembly 5 127 Duplex Motor Assembly Motor A and Motor B are assembled in one unit Use the following steps to remove and replace the motor assembly 1 Remove the Front Door and Front Cover Assembly page 5 122 2 Remove the right side rail page 5 126 3 Lift the rubber belt free from the motor gears 4 Disconnect Motor A and Motor B connectors Motor_A and Motor_B from the Duplex Unit Controller board 5 Remove two screws metal flange 6 mm from the motor assembly see illustration 6 Lift the motor assembly two motors and associated gears from the chassis SO A x lt Duplex Unit Motor Assembly Pi z gt D
97. assembly 5 59 Staple Fold Motor Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Staple Fold Drive Unit page 5 30 Disconnect connector CN71 from the motor oa Aa O N Face the drive unit toward you and remove two screws metal 6 mm holding the motor to the Staple Fold Drive Unit Note You will need to rotate the sensor wheel to access the screws 7400 229 Staple Fold Motor Staple Fold Clock Sensor 5 60 Phaser 7400 Color Printer Options Service Manual Slide Motor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Remove the Staple Unit page 5 29 4 With the Staple Unit facing you disconnect connector CN72 from the motor 5 Slide the belt off of the motor gear 6 Remove two screws metal 4 mm holding the motor to the Staple Unit Stapler Light Shielding Plate Slide Home Position Sensor Slide Motor 57400 132 Service Parts Disassembly 5 61 Feed Motor Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Punch Unit page 5 50 Open the harness retainer and disconnect the cable from connector CN56 oF O N Remove two small screws metal flange 6 mm and detach the Feed Motor Unit e oe ON ans KY 5 62 Phaser 7400 Color Printer Options Service Manual SEE Wa s7400 231 Paddle Motor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear
98. ations 0 0 ccc cece ee eee ees 1 3 Parts of the Finisher and Paper TrayS 005 1 4 Printer ODVONS gacdtiastehesd oedea eh einenewsenand gumn emer oe 1 5 Ae i 8c e E x eta a as ane tecaw Ber ash aa hae a 1 5 DUDIEX UNI y s mses een inei Ped been ene naan ee 3 1 6 550 Sheet Feeder 0 ccc eee eee eee 1 6 1650 Sheet Feeder a na ce ee ees 1 7 SCC MICAVONG cscs creers enia Hay tebe wile E A AENA oe heh 1 7 Consumable Life Specifications 00004 1 7 Finisher Electrical Specifications 00008 1 7 Physical Dimensions and Clearances 000 1 8 Finisher Functional Specifications 0008 1 8 Finisher Environmental Specifications 1 10 2 Theory of Operation Options Operational Overview 0 0 ccc ce eee 2 2 Finisher OvervieW 0 0 ccc teeta 2 3 PUNCH NU sory cre tn ners roe oie atta oak west Gea acetal i 2 4 Staple Unit aana cece eee eee eens 2 6 Saddle Unit a na 2 8 inverter 0 9 eae ee 2 10 Printer OPHONS sa aeina radad 2 Gh hae sd wt doe dew ia added WE wes 2 11 DUDEX UDI sase tak Sanne srin baa we od hha eae cola 2 11 550 Sheet Feeder 0 eee ee eee eee 2 11 1650 Sheet Feeder 0 cee eee 2 12 Finishing Process SUMMAaIy 0 00 ee eee 2 13 MVO 3 4 8 Gave toe eee cee ERREEN EEEE EERUN 2 14 PURGING few paare piisaa E Sadek eee ee a 2 14 POIQING uot ereer EEEE ee cherie acme ner ee dan e
99. bleshooting 3 63 Finisher Punch Motor Failure An error was detected in the Punch Motor Applicable Status Code Code F134 Punch Motor Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Punch Motor m Punch Control Board m Inverter Power Supply Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 2 Punch Controller Board m Options Punch Controller to Sensor and Motors Step Actions and Questions Yes No 1 Test the Punch Motor 1 Close the Interlock Switches for test 2 Run the Service Diagnostics Punch Motor test Does the motor operate Complete Go to Step 2 2 Check for 24 V to the Punch Motor Disconnect P J2002 Is the 24 V across J2002 1 lt gt ground Replace the Punch Motor page 5 50 Go to Step 3 3 Check Punch Control Board for 24 V 1 Disconnect P J1002 on the Punch Control Board Is the 24 V across P1002 pins 1 and 2 Replace the Punch Motor Harness Replace the Punch Control Board page 5 50 If the error persists go to Step 4 4 Check all pins of the Inverter Interface Cable for continuity Disconnect CN1 and CN2 from the Finisher Control Board and the opposite end from the Inverter Is the cable conductive Replace the Inverter Power Supply page 5 56 If the error persists rep
100. bly 5 99 Inverter Docking Sensor The Inverter Docking Sensor detects when the Inverter interconnects with the Printer To remove the sensor 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Rear Covers page 5 19 3 Disconnect the 3 wire cable from the connector SNSCN1 at the Inverter Controller Board 4 Free the cable from the cable harness 5 Remove single screw self tapping plastic 10 mm and open Door I to expose the sensor 6 Pinch the plastic hooks on the interlock switch to remove the switch from the chassis Inverter Docking Interlock Actuator Inverter Docking Interlock Sensor s7400 614 5 100 Phaser 7400 Color Printer Options Service Manual Inverter Door Door F Open Interlock Switch The Inverter Door Open Interlock Switch detects when the Inverter Door F is open To remove the switch 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Rear Covers page 5 19 3 Remove the Top Cover page 5 23 4 Disconnect the 2 wire cable from the connector SNSCN2 at the Inverter Controller Board O1 Free the cable from the cable harness 6 Remove a single small metal screw metal 4 mm and remove the switch Q ana Door Open ae z5 Interlock Switch s7400 496 Service Parts Disassembly 5 101 Inverter Upper Paper Present Sensor The Inverter Upper Paper Present Sensor detects the leading edge o
101. cation error has occurred in the Finisher Inverter Applicable Status Code Code U51 Inverter Unit Interface Failure Initial Actions E Reseat the Finisher connections m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Control Board m Print Engine Map 3 see Book 1 m Engine Control Board m Print Engine Motor Driver Board 6 6 see Book 1 m Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Inverter Interface Cable m Inverter connections Is there any damage 2 Check the Inverter connection Go to Step 3 Connect the Is the Inverter interface cable securely Inverter to the connected at both ends Finisher 3 Check all pins on the OPTIF Harness for Replace the Inverter Replace the continuity Control Board Ifthe OPTIF Harness Disconnect OPTIF from the Engine Control error persists Board and Option connector replace the Engine Is the harness conductive Control Board see Book 1 General Troubleshooting 3 47 Unsupported Duplex Unit ROM The installed Duplex Unit does not contain the correct firmware Applicable Status Code Code U34 Unsupported Duplex Unit ROM Initial Actions m Reseat the Dup
102. ch SSS Circuit Breaker CB1 Finisher Host Controller PCB Machine is Regulator IC IC1 A Logic System Punch Controller PCB Puncher Unit Finisher Controller PCB Punch Controller PCB Sensors je eee ee ee ee ee ee ee ee Ke eK HK HK Logic System 3 7400 157 7 16 Phaser 7400 Color Printer Options Service Manual Finisher Controller to Printer Wiring Finisher Controller Board To Printer ap ap pe oO FGND 1 row eNe ee Ww ep s7400 271 Wiring Diagrams 7 17 Finisher Controller to Sensors 1 of 3 Finisher Controller 5voc Board FJHPS Aligning Plate Home Position Sensor Front TCS Upper Cover Sensor FDS Front Door Sensor AS Processing Tray Sensor Somes i ADJ_TRAY_S C 3 ml Ug Ug Ud DC 5V OBHPS Delivery Belt Home Position Sensor 2 sa a Amaria l 5 _E BES 8 2 C Tray Paper Sensor CN34 CN35 SLS C Paper Surface Sensor RJHPS co Aligning Plate Home Position Sensor Rear iain ani 7400 272 7 18 Phaser 7400 Color Printer Options Service Manual Finisher Controller to Sensors 2 of 3 Finisher Controller 5VvDC Board CN38 CN39 k oo FPS Folding Position Sensor H tina BnL f Po N ml ml Ug Ud CN38 CN40 A oo FHPS Folding Home Position Sensor Sz MN nnn CN16 CN37 CN38 CN41 t FRHPS Stack Fe
103. ck gear so that the blue mark on the staple position check gear is aligned with the round hole in the frame Reinstall the E ring on the gear Caution It is necessary to mount the gear at the correct position The position where the blue mark aligns with the round hole is the home position for stapling If you move the staple jam cancel dial the home position deviates making it impossible to remove the stapler cartridge If this happens you can return the gear to the home position by checking the blue mark position with the cover installed Hole in Frame Blue Mark agi 5 p Sy Staple Position en Gear aN s7400 211 15 Remove the pins securing the gear and the cam Adjustments and Calibrations 4 15 16 Assemble the spring spacer staple jam releasing gear timing belt and relay gear Secure them with the E ring Relay Gear E Ring staple Jam Releasing Gear 7400 212 17 Replace the front cover and two knobs and reinstall the Stapler Unit 4 16 Phaser 7400 Color Printer Options Service Manual Saddle Unit Adjustments Adjusting the Folding Position If you replace the Finisher Controller Board you must match the folding position to the stapling position Perform the following steps 1 Locate DIP switch SW1 on the Finisher Controller Board LED3 LED2 LED1 O o mm PSW3 PSW2 PSW1 2 Set SW1 on the Finisher Controller Board as follows eet 400 532 3 To adjust the folding po
104. ct CN57 Delivery Motor harness If the Is there 24 V across CN57 1 and 2 lt gt page 5 64 error persists go ground to Step 5 4 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Disconnect CN1 and CN2 from the Finisher Control Board and the opposite end from the Inverter Is the cable conductive Power Supply page 5 56 General Troubleshooting 3 53 Finisher Stapler Swing Motor Failure The Stapler Swing Home Position Sensor detected a Stapler Swing Motor error Applicable Status Code Code F106 Swing Motor Failure Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Stapler Swing Motor m Finisher Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board m Options Finisher Controller to Switches Step Actions and Questions Yes No 1 Test the Stapler Swing Home Position Go to Step 2 Replace the Sensor sensor If the error Run the Service Diagnostics Stapler Slide persists go to Home Position Sensor test Step 2 Do the sensors operate 2 Test the Swing Motor Replace the Go to Step 4 1 Close the Interlock Switches for test Finisher Control 2 Run the Service Diagnostics Sliding aay page 5 46 Motor test If the error persists go t
105. ct the connector JOO2 on the Punch Motor a Aa OO N Remove the two metal screws metal flange 6 mm securing the motor to the chassis 6 Lift out and remove the Punch Motor Unit e Punch Motor s7400 254 Service Parts Disassembly 5 57 Finisher Punch Transfer Motor Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Disconnect connector to the motor Remove the harness from the harness guide oOo ao fF QO N To remove the Finisher Punch Transfer Motor from the Punch Unit remove the two metal screws metal flange 6 mm securing the motor to the chassis and lift out Finisher Punch Transfer Motor TA APN Harness Guide s7400 255 5 58 Phaser 7400 Color Printer Options Service Manual Lift Motor Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 Remove three screws metal 6 mm from the Lift Motor cover box oOo ao fF O N Disconnect connector CN 70 from the cover box and motor then lift the cover box which includes motor and gear assembly free from the chassis 7 Slide the belt off of the motor Lift Motor Lift Motor Cover Box ge Lift Motor Clock Sensor s7400 667 8 To remove the motor remove the two small screws metal 4 mm holding the motor to the cover box Service Parts Dis
106. ction of equipment Warning A warning indicates an operating or maintenance procedure practice or condition that if not strictly observed results in injury or loss of life Product Terms 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 7400 Color Printer Options Service Manual lil Symbols Marked on the Product DANGER high voltage Protective ground earth symbol Hot surface on or in the printer Use caution to avoid personal injury The surface is hot while the printer is running After turning off the power wait 30 minutes Avoid pinching fingers in the printer Use caution to avoid personal injury Use caution or draws attention to a particular component Refer to the manual s for information S A A Q al A iv Phaser 7400 Color Printer Options Service Manual Power Safety Precautions 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
107. curate Applicable Status Code Code 931 The Duplex Unit s CPU clock frequency is inaccurate Initial Actions m Reseat the Duplex Unit m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References Motor Driver Board m Duplex Unit Print Engine Map 3 see Book 1 Print Engine Map 5 see Book 1 Print Engine Motor Driver Board 6 6 See Book 1 Options Map 4 Duplex Unit Controller Board Troubleshooting Procedure Table E E m Print Engine Motor Driver Board 5 6 see Book 1 E E Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check all pins on the DUPLEX Harness for Replace the Duplex Replace the continuity Unit page 5 122 If DUPLEX Harness Disconnect the DUPLEX Harness the error persists Is the DUPLEX Harness conductive go to Step 3 3 Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive 3 84 Phaser 7400 Color Printer Options Service Manual Finisher Inverter Clock Frequency Error The clock frequency for the Inverter Control Board CPU is inaccurate Applicable Status Code Code 932 The Inverter s CPU clock frequency is inaccurate
108. de 222 Software error in Tray 4 Flash Memory Code 223 Software error in Tray 5 Flash Memory Code 224 Software error in Tray 6 Flash Memory Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Option Tray Control Board m Engine Control Board m Print Engine Map 5 see Book 1 m Print Engine Motor Driver Board 6 6 see Book 1 Wiring and Plug Jack References m Options Map 5 Paper Tray Controller Board m Options Paper Tray Sensors and Interconnect Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check all pins on the OPTIF Harness for Replace the Option Replace the continuity Disconnect OPTIF from the Engine Control Board and Option connector Is the harness conductive Control Board If the error persists replace the Engine Control Board see Book 1 OPTIF Harness 3 72 Phaser 7400 Color Printer Options Service Manual Duplex Unit Firmware Error Applicable Status Code Code 225 A firmware error with the Duplex Unit Initial Actions m Reseat the Duplex Unit m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Duplex Un
109. e belt tensioner from its mounting post also remove the spring staple Jam Releasing Gear Belt Tensioner 7400 204 7 Remove the timing belt Adjustments and Calibrations 4 9 8 Remove the E ring to remove the staple position check gear 4 10 Staple Position Check Gear Timing Belt 7400 205 Phaser 7400 Color Printer Options Service Manual 9 Turn the gear to align the round hole in the staple driver gear with the round hole at the back Staple Clincher Staple Driver a Gear Hole 4 O LTA Staple Driver s7400 206 Adjustments and Calibrations 4 11 4 12 10 Insert a pin with a diameter of approximately 2 mm use recommended diameter size in the round hole to secure the gear VENN K eX K s7400 207 Phaser 7400 Color Printer Options Service Manual 11 Turn the gear to align the round hole in the staple clincher cam with the round hole at the back Vi A O NN SZ aS FOE QO VS Staple Clincher Sa 57400 208 Staple Clincher Cam Hole Adjustments and Calibrations 4 13 12 Insert a pin with a diameter of approximately 2 mm use of a 2 mm Allen wrench as recommended in the round hole to secure the gear 7400 209 13 With the gears and cam fixed install the timing belt on the gears Timing Belt Gear 7400 210 4 14 Phaser 7400 Color Printer Options Service Manual 14 Mount the staple position che
110. e plastic tabs with needle nose pliers and then pull the sensor free Service Parts Disassembly 5 89 Delivery Belt Home Position Sensor The Delivery Belt Home Position Sensor detects the end location of the delivery rollers sensor is off To remove and replace the Delivery Belt Home Position Sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Side Guide page 5 107 To locate the sensor manually rotate the delivery roller belts You will see the activator which is attached to the belt trip the sensor 2 3 4 Remove the Upper Cover page 5 13 5 6 Tray Paper Sensor Delivery Belt Home Position Sensor s7400 708 7 To remove the sensor first remove the 4 wire connector CN31 from the sensor Using small needle nose pliers pinch the plastic tabs to pull one side of the sensor free 5 90 Phaser 7400 Color Printer Options Service Manual Paddle Home Position Sensor The Paddle Home Position Sensor detects when it is necessary to drive the paddle and feed the next sheet of paper To remove the sensor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Locate the sensor see illustration and disconnect connector CN39 Paddle Home Position Sensor CN39 7400 665 4 To remove the sensor pinch the plastic tabs with needle nose pliers and then pull the sensor free Service Parts Disasse
111. e sensor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Remove the Upper Cover page 5 13 4 Remove the Side Guide page 5 107 Eas Ow i SOS ES SS Stack Full Sensor ia 7400 673 5 Remove two screws metal flange 6 mm holding the sensor to the sensor bracket and activator Hold the belt to one side to free the bracket and sensor 6 To remove the sensor first remove the 3 wire connector CN44 from the sensor Using small needle nose pliers pinch the plastic tabs to pull the sensor free Service Parts Disassembly 5 81 Processing Tray Sensor The Processing Tray Sensor detects the processing stack within the delivery path To remove and replace the Processing Tray Sensor Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 Refer to the illustration to locate the sensor O ao fF OO N Tray Paper Sensor Delivery Belt Home Position Sensor Paper Surface Sensor Processing Tray Sensor s7400 705 7 To remove the sensor first remove the 4 wire connector CN29 from the sensor Pinch the plastic tabs to pull one side of the sensor free 5 82 Phaser 7400 Color Printer Options Service Manual Aligning Plate Home Position Sensors The Aligning Plate Home Position Sensors front and back ensure that the size of the se
112. each side and remove the unit 7400 230 Service Parts Disassembly 5 33 Saddle Unit Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Aa N a Open the Jam Removal Cover Door I and remove two screws metal 10mm and the right stay 5 Turn the Fold Jam Releasing Dial Assembly to move the Paper Retaining Plate Assembly to the inside Paper Retaining Plate Assembly SLO O h ra Stay 0 le l 5 Q D OS tare ooo Nin a ee wi W ES X ee Jam Removal Cover VE Fold Jam Releasing Dial Assembly s7400 215 6 Remove the Punch Unit Assembly page 5 24 5 34 Phaser 7400 Color Printer Options Service Manual 7 Remove the Stop Ring and detach the Timing Belt stop Ring p Timing Belt J Y Connectors A 8 Disconnect the two connectors Service Parts Disassembly 5 35 9 Remove the three screws metal 10mm and slide out the Stapler Unit slightly to the front and remove the Saddle Unit stapler Unit Saddle Unit 7400 217 5 36 Phaser 7400 Color Printer Options Service Manual Assemblies Upper Right Cover Assembly 1 Remove the Front Door page 5 8 2 Remove the Rear Cover page 5 11 3 Remove two screws metal 6 mm at the front and two screws at the rear of the assembly 4 Detach the assembly and lift up to remove Sw S Service Parts Disassembly Processing Tray Assembly Aa
113. ed Roller Upper Home Position Sensor oo Po nnan CN42 CN43 ES Inlet Sensor FES CJ Bind Tray Sensor LE Shift Motor Clock Sensor LLLS Shift Lower Limit Sensor I ULS Shift Upper Limit Sensor L m a l Ul s7400 273 Wiring Diagrams 7 19 Finisher Controller to Sensors 3 of 3 Finisher Controller 5voc Board Paddle Home Position Sensor i C C ii ae Staple Fold E L Clock i Sensor in CN9 DC 5V CN53 CN54 CN55 Swing Guide L Home Position Sensor Full Stack C Sensor TEE MEE iol lol Ui 7400 274 7 20 Phaser 7400 Color Printer Options Service Manual Finisher Controller to Motors Finisher Controller Board 12VDC Some H Sore Le ep Ws gt C 24VDC m oe m e oan m o ourn a b 0 om 1 CO aa E L R E 24VDC 5 Lee a Cee nma pe Ce ema N SS A me a Ws gt CE 24VDC CN3 DC 24V CN62 1 SS oma H Si i rone H CERE LCE CN3 De424v CN64 SS ma H T f noou H St oome A Lee C Wiring Diagrams s7400 275 7 21 Finisher Controller to Switches Finisher Controller Board i E STAPLE_SAFE_SW FDOOR_SW no S FDOOR_SW JOINT_SW 24VDC CN8 JOINT_SW 5 gt DC 24VP 6 CNE siii CN70 CN70 CN70 CN70 l IFTMTR Oo 2 gt 1 CNS BINDMTR_1 ir BINDMTR_0 4 gt 1 24VDC CN18 aay ta s B_CLU j s7400 276 7 22 Phaser 7400 Color Pri
114. ed position m Feed Motor This motor drives the Feed Rollers to pick paper from the tray and position it at the Registration Roller Theory of Operation 2 39 Detecting Jams The microprocessor CPU on the Finisher Controller Board checks for jams in the Finisher and other optional units The CPU identifies a jam in reference to the presence or absence of paper at a specific sensor In general the Jam will be generated because of sensors from one or more of the following door locations see illustration below 7400 696 When a jam is detected the Finisher Controller Board communicates the nature of the jam to the printer in the form of a jam code from one or more specific locations The jam code descriptions are found when viewing the service mode of the Phaser 7400 printer Refer to Section 3 for troubleshooting information 2 40 Phaser 7400 Color Printer Options Service Manual Finisher Punch Power Supply When the printer is powered ON and connected to the finisher it supplies the Finisher Controller Board with two channels of 24 VDC one for the motors and clutches and the other for conversion into 5 VDC in the regulator IC IC1 of the Finisher Controller Board The 5 VDC supplies power to sensors and ICs on the printed circuit boards If the system configuration includes a punch unit option power is also supplied to the Punch Controller Board Front Door Switch Stapler Safety Joint Switch JS FDSW Switch SSS
115. ensor V s7400 676 Theory of Operation 2 31 Duplex sensors include m Duplex Entrance Sensor Detects the leading edge of the media and signals the Duplex Motor to begin rotation in the forward direction m Duplex Reverse Sensor Detects media in the lower portion of the Duplex Unit and signals the Duplex Motor to reverse rotation Duplex Front and Rear Sensors Monitor media transport through the upper portion of the Duplex Unit Optional Tray Sensors The paper supply and path for the optional trays involve these sensors see page 5 133 for detailed illustrations and sensor location m Door C Detect Sensor Detects presence of media in the tray based on the position of the Actuator m Registration Sensor This sensor detects media as it arrives at the Registration Rollers m Feed Out Sensor This sensor detects the media as it leaves the Tray 3 Feed Rollers m No Paper Sensor The actuator lowers as print media is used in the tray When the actuator lowers to a pre determined position it blocks the sensor to trigger a low paper status 2 32 Phaser 7400 Color Printer Options Service Manual Motors Rollers Solenoids and Clutches Finisher Motors Paddle Motor ae Feed Motor 44 Delivery Motor Motor Rear Alignment xX Front Alignment ae SR R Shift M oto r s7400 543 Theory of Operation 2 33 Punch Unit Solenoids and Motors ya Motor Clock Sensor Punching Home Sensor wg gt
116. ensor m Options Map 3 Inverter Controller Board m Options Map 9 Inverter Sensor Locator m Options Inverter Sensors Diagram Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Sensor Actuator m Paper Guides m Transport Rollers Are there any defects or misalignment 2 Test the Inverter Entrance Sensor Replace the Engine Go to Step 3 Run the Service Diagnostics Inverter Input Control Board see Sensor test Book 1 Does the sensor function correctly 3 Test the sensor signal Replace the Either the sensor Does the voltage change on SNSCNO 5 Inverter Control or the wiring is connector of the Inverter Control Board Board page 5 55 defective Check when the sensor is actuated the resistance of the wires and if no problem is found replace the sensor 3 30 Phaser 7400 Color Printer Options Service Manual Finisher Output Tray Jammed This error represents a failure of or an obstruction in the Finisher Upper Output Tray s up or down motion Applicable Status Code Code FT Finisher Output Tray Jammed Initial Actions m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Finisher Lift Motor m Options Map 7 Finisher Sensor Locator 1 2 m Lif
117. ep 2 damage damaged parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Are there any defects or misalignment 2 Test the Bind Tray Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the at the Finisher Control Board Finisher Control harness Actuate the sensor Board page 5 46 Does the voltage across CN15 3 lt gt ground change when the sensor is actuated 3 26 Phaser 7400 Color Printer Options Service Manual Jam at Finisher Saddle Stapler This error represents a jam in the Finisher staple path Applicable Status Code Code FN9 Jam at Finisher Saddle Stapler Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Compiler Tray m Options Map 7 Finisher Sensor Locator 1 2 m Front and Rear Alignment Guides m Transport Rollers m Stapler m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts
118. er Parts List 6 3 Finisher Unit Assembly Diagram Bi s7400 628 6 4 Phaser 7400 Color Printer Options Service Manual Parts List 1 1 Finisher Unit Assembly Parts List Finisher Unit Parts List ID Part Number Name Description 0 097803363 Finisher 3 hole 097803364 Finisher 2 4 hole B 1 050E23450 Base Unit B 5 005K12430 Stack Motor Drive Assembly Lift Motor and sensors B 6 005K12440 Drive Assembly Delivery Motor Assembly B 7 848K00040 Bundle Support Cover Paper Detector B 8 054K37780 Dispose assembly ProcessingTray B 9 059K52480 Paper Feeder Assembly Paddle Assembly B 10 054K37790 Fold Assembly B 11 029K04400 Staple Assembly Staple Unit Parts List 6 5 Finisher External Parts Diagram 502 N 28 24 501 Qll 29 7400 629 6 6 Phaser 7400 Color Printer Options Service Manual Parts List 1 2 Finisher External Parts List Finisher External Parts List ID Part Number Name Description 0 848K00040 Bundle Support Cover Assembly Paper Detector Parts List 6 7 6 8 Phaser 7400 Color Printer Options Service Manual Finisher Internal Parts Diagram 1 of 2 4 oa AY oe AG N of 38 37 ee cae Z lo ro v A Tla A Y 26 iN a 16 ToB2 99 K a 28 29 SF 7400 630 Parts List 6
119. er Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 oa OF O N Refer to the illustration below to locate either sensor shift Limit Sensor Upper Shift Lower Limit Sensor Bind Tray Sensor s7400 704 6 To remove either sensor first remove the 4 wire connector CN49 Lower and CN50 Upper from the sensor Pinch the plastic tabs to pull the sensor free Service Parts Disassembly 5 79 Lift Motor Clock Sensor The Lift Motor Clock Sensor detects clock pulses for the stacking operation To remove and replace the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 oa OF O N Remove 4 screws metal flange 6 mm holding the metal cover box to the chassis and one screw metal flange 6 mm attaching the large harness to the metal cover box 6 Turn the box so that you can view the sensor Lift Motor Lift Motor Cover Box QP WY Lift Motor Clock Sensor G s7400 667 7 To remove the sensor first remove the 4 wire connector CN48 from the sensor Using small needle nose pliers pinch the plastic tabs to pull the sensor free 5 80 Phaser 7400 Color Printer Options Service Manual Stack Full Sensor The Stack Full Sensor detects over stacking of media in the delivery tray To remove and replace th
120. er base 5 39 Processing Tray Assembly 5 45 Upper Cover 5 38 Processing Tray parts diagram 6 18 Processing Tray parts list 6 19 proof print 1 2 Punch Controller Board function 2 5 plug jack locator diagram 7 8 registering punch holes 4 2 removal 5 50 wiring to sensors and motors 7 25 4 Punch LED Board removal 5 53 Punch Unit parts list 6 23 6 25 punch assembly photosensors 2 29 punch blade 2 5 Punch Home Position Sensor 2 15 Punch Motor Clock Sensor 2 5 Punch Motor function 2 14 punch process 2 14 Punch Slide Unit 2 14 Punch Transfer Motor 2 14 Punch Transfer Motor function 2 16 theory 2 4 waste box missing error 3 89 R Registering 4 2 registering punch holes 4 2 Registration Clutch removal 5 140 Registration Roller 2 31 Registration Sensor 2 32 relay gear 4 19 release latch 5 8 resolution 1 8 roller disassembly Finisher Feed Roller 5 109 Lower Stack Delivery Roller 5 120 Paper Tray Feed Roller 5 150 Upper Stack Delivery Roller 5 112 S saddle cam 4 19 screw types 5 3 secure print 1 2 self tapping screws 5 3 sensor locator Duplex Unit 2 31 Finisher 2 27 Inverter 2 30 Paper Trays 2 32 sensor removal Aligning Plate Home Position Sensors 5 83 Bind Tray Sensor 5 98 Delivery Belt Home Position Sensor 5 90 Door C Detect Sensor 5 141 Finisher Front Door Sensor 5 74 Finisher Upper Cover Sensor 5 78 Folding Home Position Sensor 5 94 Folding Position Sensor 5
121. erter Rollers m Finisher Transport Rollers Are there any defects or misalignment 2 Test the Finisher Entrance Sensor Replace the Engine Replace the Run the Service Diagnostics Finisher Control Board see sensor If the error Entrance Sensor test Book 1 persists go to Does the sensor function correctly Step 3 3 Check the Entrance Sensor signal at the Replace the Replace the Finisher Control Board Finisher Control harness Actuate the Entrance Sensor Board page 5 46 Does the voltage across CN16 12 lt gt ground change when the sensor is actuated General Troubleshooting 3 2 Jam at Finisher Upper Output Tray Media remains in the upper output path This error represents a jam in the Finisher Applicable Status Code Code FN4 Jam at Finisher Upper Output Tray Initial Actions m Check for obstructions or debris in the paper path m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Compiler Tray m Options Map 8 Finisher Sensor Locator 2 2 m Front and Rear Alignment Guides m Options Finisher Controller to Sensors 1 3 m Transport Rollers Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Compiler Tray m Front and Rear Alignment Guides m Transport R
122. ery motors Physically moves the media through the designated paper path 2 10 Phaser 7400 Color Printer Options Service Manual Printer Options Duplex Unit The Duplex Unit adds two sided printing The Duplex Unit attaches to the left side above Tray using two twist locks Installation of the Duplex Unit requires that the Exit 2 Module also be added to provide reverse drive Electrical connection to the printer is made by an interface cable 7400 305 550 Sheet Feeder The 550 Sheet Feeder increases the input capacity of the printer The feeder attaches below Tray 2 with four screws When used in combination with the 1650 Sheet Feeder the 550 Sheet Feeder is installed between the printer and 1650 Sheet Feeder Up to four optional 550 Sheet Feeders per printer can be installed totaling six universal trays Trays 2 6 However when the 1650 Sheet Feeder HCF is installed only one additional 550 Sheet Feeder is allowed between the HCF and the printer Electrical connection to the printer is made by a single interface connector 400 001 Theory of Operation 2 11 1650 Sheet Feeder The 1650 Sheet Feeder combines three 550 sheet trays Control signals reach the 1650 sheet feeder through a single connection The sheet feeder is secured to the print engine or 550 Sheet Feeder with four screws located under the front and rear edges of the tray 2 12 Phaser 7400 Color Printer Options Service Manual Finishing Process S
123. es m Lift Motor m Print Engine Map 3 see Book 1 m Option Control Board m Print Engine Map 5 see Book 1 m Engine Control Board m Print Engine Motor Driver Board 6 6 see Book 1 m LVPS m Print Engine LVPS see Book 1 m Options Map 5 Paper Tray Controller Board m Options Paper Tray Motors and Clutches Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Test the appropriate Lift Motor Go to Step 3 Replace the motor page 5 139 If the error 1 Close the Interlock Switches for test persists go to 2 Run the Service Diagnostics Lift Motor Step 4 test Does the motor operate 3 Check all pins on the OPTIF Harness for Replace the Option Replace the continuity Control Board Ifthe OPTIF Harness Disconnect OPTIF from the Engine Control error persists Board and Option connector replace the Engine Is the harness conductive Control Board see Book 1 3 78 Phaser 7400 Color Printer Options Service Manual Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 4 Check for 24 V at OPTRY24 Replace the Go to Step 5 1 Close the Interlock Switches affected Option 2 Disconnect OPTRY24 sonto Bodia Is there 24 V at OPTRY24 1 and 2 lt gt ground 5 Check all pins on the OPTRY24 Harness Go to Step 6 Replace the for continuit
124. est the Stapler Self Prime Sensor Run the Service Diagnostics Stapler Self Prime Sensor test Does the sensor state change when the Staple Cartridge is removed or replaced Go to Step 9 Go to Step 2 2 Check the Staple Cartridge for faulty parts or debris Are there damaged parts or debris Replace faulty parts or clean as needed Go to Step 3 3 Check the Staple Harness connections Go to Step 5 Connect the Is the Staple Harness connected harness If the error persists go to Step 4 4 Check Staple Harness continuity Go to Step 6 Replace the Is the Staple Harness conductive Staple Harness 5 Check for 5 V to the Stapler Self Prime Go to Step 7 Replace the Sensor Finisher Control Is there 5 V on the Finisher Control Board Board page 5 46 6 Check the Stapler Self Prime signal Go to Step 8 Replace the Does the voltage on the Finisher Control Finisher Control Board change when the Staple Cartridge is Board removed or replaced page 5 46 7 Replace the Stapler Assembly page 5 29 Goto Step 9 Complete Does the error still occur 8 Replace the Finisher Control Board Replace Engine Complete page 5 46 Control Board Does the error still occur 3 88 see Book 1 Phaser 7400 Color Printer Options Service Manual Punch Waste Box is Full or Missing The Punch Box Sensor indicates the Punch Box is full or not installed in the Finisher Initial Actions m Cycle the printer s po
125. f the selected paper size To remove the sensor 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Front Covers page 5 17 3 Remove the Inverter Rear Covers page 5 19 4 Remove the Top Cover page 5 23 5 Open Door F to expose the screws metal flange 6 mm to the top paper guide and the Upper Paper Present Actuator 6 Disconnect the 3 wire cable from the actuator Note The other end of this cable connects to connector SNSCNO on the Inverter Controller Board 7 Free the cable from the cable harness near the paper guide 8 Remove two screws metal flange 6 mm holding the top paper guide to the lower paper guide and then remove the top paper guide 9 To remove the actuator from the top paper guide pinch the plastic release tab to free the actuator 10 To remove the Upper Paper Present Sensor pull the connector off the sensor pinch the plastic hooks together and push the sensor free from the chassis Paper Guide s7400 608 5 102 Phaser 7400 Color Printer Options Service Manual 11 To remove the Upper Paper Present Sensor pull the connector off the sensor pinch the plastic hooks together and push the sensor free from the chassis Inverter Upper Paper Present Sensor 7400 615 Service Parts Disassembly 5 103 Inverter Lower Paper Present Sensor The Inverter Lower Paper Present Sensor detects the trailing edge of the selected paper size To remove the sensor
126. f this 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 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 m Increase the separation between the equipment and receiver m 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 complies with Canadian ICES 003 Cet appareil num rique de la classe A est conforme a la norme NMB 003 du Canada Phaser 7400 Color Printer Options Service Manual iX European Union Warning 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 Xerox Corporation declares under our sole responsibility that the product to which this declaration relates is in conformity with the following
127. form the following steps to identify the type of punch unit and associated number of punch holes The Punch Controller Board uses this switching information to identify and register the finisher type whenever you replace the board To register the punch holes 1 Locate DIP switches SW1001 SW1002 and SW1003 and LEDs LED1001 LED1002 and LED1003 on the Punch Controller Board SW1001 O sw1002 Osw1003 LED1001 LED1002 LED1003 7400 270 2 Set bits 1 through 4 on the switch SW1001 on the Punch Controller Board as follows 7400 536 4 2 Phaser 7400 Color Printer Options Service Manual 3 Press Switch SW1002 on the Punch Controller Board to select the appropriate number of punch holes Each press on SW1002 moves the selection through the following repeatedly from top to bottom Number of punch holes LED1001 LED1002 LED1003 2 holes punch Unit J1 ON OFF OFF 2 3 holes punch Unit K1 ON ON OFF 4 holes punch Unit G1 OFF OFF OFF 4 holes punch Unit H1 OFF OFF ON 4 Press switch SW1003 on the Punch Controller Board twice The presses will store the selected number of punch holes on the Punch Controller Board m A single press on SW1003 will cause the LED indication to flash m Another press on SW1003 will cause the indication to remain ON to indicate the end of registration 5 Shift all bits of DIPSW1001 to OFF this action ensures that the LEDs will remain unaffected and the switch setting will have n
128. function correctly error persists go to Step 3 3 Check all pins on the DUPLEX Harness for Replace the Motor Replace the continuity Driver Board see DUPLEX Harness Disconnect the DUPLEX Harness Book 1 If the error Is the DUPLEX Harness conductive persists go to Step 4 4 Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive 3 80 Phaser 7400 Color Printer Options Service Manual 24V Not Available to the Duplex Unit Abnormal current indicates that 24 V is not being supplied to the Duplex Unit Applicable Status Code Code 225 Duplex Unit is not receiving 24 V Initial al Actions Reseat the Duplex Unit Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Motor Driver Board m LVPS m Duplex Unit Troubleshooting Procedure Table Print Engine Map 5 see Book 1 Print Engine Map 6 see Book 1 Print Engine Motor Driver Board 1 6 see Book 1 Print Engine Motor Driver Board 5 6 see Book 1 Print Engine LVPS see Book 1 Options Map 4 Duplex Unit Controller Board Options Duplex Unit Motors and Solenoid Wiring and Plug Jack References Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Go to Step 2 damage connector
129. g I m J m J m m I I J J J J _ a os kk BWP O 7400 715 Wiring Diagrams 7 31 7 32 Phaser 7400 Color Printer Options Service Manual index Numerics 1650 Sheet Feeder dimensions 1 8 overview 1 7 5 VDC Power Supply 2 41 550 Sheet Feeder dimensions 1 8 overview 1 6 A AC power consumption 1 7 input specifications 1 7 addressability 1 8 adjustments 4 2 gear phase 4 18 registering punch holes 4 2 sensor output 4 4 stapler phase 4 7 stapling position 4 6 aligning plates 5 43 assembly removal Duplex Motor Assembly 5 128 Front Cover Assembly 5 122 Paddle Assembly 5 43 Processing Tray Assembly 5 38 Upper Right Cover Assembly 5 37 B Bind Clutch 2 21 Bind Tray 2 24 Bind Tray Sensor 2 24 Binding Clutch removal 5 66 board removal Duplex Unit Controller Board 5 122 Finisher Controller Board 5 46 Home Position Board 5 48 Il 1 Inverter Controller Board 5 55 Inverter Power Supply Board 5 56 Paper Tray Feeder Board 5 149 Photosensor Board 5 52 Punch LED Board 5 53 Waste Full LED Board 5 54 booklet 2 21 booklet mode 4 7 C circuit breaker 2 42 clearances minimum 1 8 Clock Lift Motor Clock Sensor 2 24 2 28 7 5 Punch Motor Clock Sensor 2 5 connector designators 7 2 representation 3 12 Control Panel error messages 3 6 cover removal Finisher Rear Cover 5 12 Finisher Upper Cover 5 13 Inverter Front Cover 5 17 Inverter Rear Co
130. g position in the direction press switch PSW2 m Pressing the PSW1 and PSW2 at the same time clears the adjustment value 4 After adjusting the stapling position set all bits of switch SW1 on the Finisher Controller Board to OFF this action ensures that the LEDs will remain unaffected and the switch setting will have no further effect 5 Enter the booklet mode of the printer and check whether the stapling position is adjusted properly If necessary adjust repeat the above steps to adjust the stapling position again Adjusting the Stapler Phase When you remove or replace the gears or timing belt at the front of the stapler the staple insertion timing of the staple unit may be faulty Use the following steps to adjust the timing for the Finisher stapler phase Gear Timing Belt __s7 Gear 57400 202 1 Remove the two knobs from the front of the Staple Unit 2 Remove 3 screws and remove the Staple Unit Cover 3 Detach the gear cover from the staple driver Adjustments and Calibrations 4 7 4 Remove the E ring to detach the side cover of the staple clincher Staple Clincher Staple Driver KLE SS Bees Gear Cover K sided 6 s7400 203 5 Remove the two E rings to remove the staple jam releasing gear timing belt and relay gear 1 Remove the spacer and spring at the back of the staple jam releasing gear 4 6 Phaser 7400 Color Printer Options Service Manual 6 Remove the screw to remove th
131. ge drop occurs during component actuation Gating signals may be nothing more than a pulse resulting in a momentary drop in voltage that may be difficult or impossible to read on the average multi meter When a troubleshooting procedure instructs you to replace a non spared component and that component is part of a parent assembly you should replace the entire parent assembly Ensure that you are using a supported media size and type Power and signal grounds are connected to the frame ground All circuit troubleshooting can be performed using the metal frame chassis as the grounding point 3 12 Phaser 7400 Color Printer Options Service Manual Troubleshooting the Finisher Jam at Door C for Tray 3 4 5 6 Media reached the Feed Out Sensor but did not arrive at the Transfer Unit Entrance Sensor on time This error represents a misfeed jam for media fed from an optional tray Applicable Status Codes Code C3 Jam at Door C for Tray 3 Code C4 Jam at Door C for Tray 4 Code C5 Jam at Door C for Tray 5 Code C6 Jam at Door C for Tray 6 Initial Actions Try picking paper from a different tray Ensure the tray is installed properly and the paper guides are set correctly Remove any obstructions or debris in the paper path Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Feed Rollers m Print Engine M
132. gh the Registration Clutch 2 is activated to move the sheet through the Registration Roller 2 to the Registration Roller 1 As the sheet reaches the Registration Roller 1 it is detected by the Registration Sensor 1 When the Registration Sensor 1 goes High the Registration Clutch 1 is activated to move the sheet through the Registration Roller 1 to the Transfer Unit The sheet is detected by the Transfer Unit Entrance Sensor and the Transfer Unit Motor rotates to drive the sheet under the Imaging Units Theory of Operation 2 37 a Registration Roller 2 Registration Clutch 2 4 CS ae Tt cog OKI N N 8 i i 8 nn 8 5 5 5 ss en Registration Roller 3 Registration Clutch 3 ec PA Tray 3 Sensor 3 lt Registration ITN S Sensor 3 o o Feed Roller Pick Roller Retard Roller Registration Motor 7400 027 The paper supply and path for the optional trays involve these motors rollers and clutches 2 38 Phaser 7400 Color Printer Options Service Manual Registration Motor This motor drives the Registration Rollers to pull media from the tray into the paper path m Registration Clutch This clutch transfers Registration Motor drive to the Registration Roller E Registration Roller This roller aligns the leading edge of the sheet to correct any skew m Lift Motor This motor lifts the tray s base plate raising the media to the pre fe
133. he Delivery Tray to lower to the home position The Lift Motor Clock Sensor detects when the tray reaches the home lowest position The Shift Upper Limit Sensor detects the upper limit of the Delivery Tray In an upper limit condition the Finisher Controller Board stops sending commands that lift the Lift Motor Conversely the Shift Lower Limit Sensor detects the lower limit of the Delivery Tray In a lower limit condition the controller board stops the Lift Motor Delivery after Stapling When stapling completes the Finisher Controller Board drives the Delivery Motor in the forward direction to feed the paper stack When the Delivery Belt Home Position Sensor reaches the OFF position the delivery stack is full The Slide Motor is then driven to return the Stapler Unit back to the standby position which initiates the Delivery Motor drive Then the paper stack is delivered to the tray Paper Stack swing Guide Delivery Tray Stapler Delivery Belt vod Stack Delivery WA C 447400135 2 24 Phaser 7400 Color Printer Options Service Manual Sensors The Finisher Inverter Duplex Unit and paper trays contain sensors of various types that perform a variety of functions One group of sensors track the progress of the paper along the paper path and detects if a paper jam occurs Other sensors stop printer activity if a door is open interlock detect the presence and size of media in the trays a
134. he Rear Cover page 5 11 Remove the Staple Fold Drive Unit page 5 30 Aa O N With Staple Fold unit out of the way you can now disconnect connector CN72 from the clutch Ol Remove the k clips from the gear assembly of the clutch Slide the belt off of the clutch gear 7 Remove three screws metal 6 mm holding the clutch to the chassis Binding Clutch s7400 694 5 66 Phaser 7400 Color Printer Options Service Manual Inverter Upper Roller Motor 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Rear Covers page 5 19 3 Disconnect the 4 wire cable from the Inverter Controller Board connector labeled Motor_B Be sure to lift the cable harness out of the cable guides 4 Remove one screw metal flange 6 mm from the upper right and its anti vibration spring and one screw from the lower left of the motor 5 Pull the motor and its associated gear free from the gear assembly a Z SU Upper Roller Motor s7400 492 Service Parts Disassembly 5 67 Inverter Lower Roller Motor 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Rear Covers page 5 19 3 Disconnect the 4 wire cable from the inverter controller board connector labeled Motor_A Be sure to lift the cable harness out of the cable guides 4 Remove the Inverter Controller Board page 5 55 5 Remove the Power Supply Board page 5 56
135. here 24 V across POW24 1 lt gt POW24 2 11 Check for 24 V at the LVPS Replace the Replace the LVPS 1 Disconnect CN2 on the LVPS POW24 Harness See Book 1 Is there 24 V across pins 1 and 2 12 Check the DRVO and DRV1 ribbon cables Replace the Engine Replace the DRVO that connect the Motor Driver Board to the Engine Control Board Are these cables connected and undamaged Control Board See Book 1 and DRV1 Harnesses General Troubleshooting 3 19 Jam at Finisher Punch Unit Media did not clear the Finisher Entrance Sensor on time This error represents a jam at the Finisher entrance Applicable Status Code Code FN1 Jam at Finisher Punch Initial Actions m Check for obstructions or debris in the paper path m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Punch Unit m Options Map 2 Punch Unit Controller Board m Finisher Entrance Sensor m Options Map 8 Finisher Sensor Locator 2 2 m Finisher Transport Rollers m Options Punch Unit Sensors and Motors m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Punch Unit m Transport Rollers m Exit Rollers Are there any defects or misalignment
136. hniques 0 0000 cee eae 3 12 Troubleshooting the Finisher 0 0 0c cee eee ee eee 3 13 Jam at Door C for Tray 3 4 5 6 0 2 3 13 Jam at Door D Open Door D to Clear 0 3 16 Jam in Duplex Unit 0 ee 3 17 Jam at Duplex Entrance 0 00 c cee eee eee 3 18 Jam at Finisher Punch Unit 0 000 000 ee 3 20 Jam at Finisher Door H 2 1 es 3 21 Jam at Finisher Upper Output Tray 0 06 3 22 Jam at Finisher Saddle Stapler 0000005 3 23 Jam at Finisher Upper Output Tray 0 06 3 24 Jam at Finisher Stapler 0 0 0 0 cc eee 3 25 Jam at Finisher Door G 0 0 ccc eee 3 26 Jam at Finisher Saddle Stapler 0 00004 3 2 Jam at Finisher Upper Output Tray 0006 3 28 Jam Inside Finisher 0 0 cece eee ees 3 29 Jam at Finisher Entrance 0 02 cece eee eee 3 30 Finisher Output Tray Jammed 0 0 00 eee eee 3 31 Close Right Door C for Tray 8 4 5 6 8 3 33 Close Left Door D 0 ce eee 3 34 Close Finisher Door F 2 0 0 cece eee 3 35 Close Finisher Door H 0 0 0 cece eee 3 36 Close Finisher DoorJ 2 es 3 37 Phaser 7400 Color Printer Options Service Manual Clear Tray 2 3 4 5 6 Riser Plate 0 Out of Paper Load Tray 2 3 4 5 6 with size type Finisher Lower Out
137. hrough the paper path otapler Safety Interlock Switch Shift Lower Limit Sensor Shift Clock Sensor Upper Cover Sensor Joint Switch ve Full Stack Sensor Front Alignment Plate Home Position X A Bind Tray Sensor h Staple Fold Wwe YE a Clock N SY s we Door Switch otaple ow Sensor Vos AA Front Door Switch and Sensor Staple Slide Home Sensor Shift Upper Limit Sensor Stacking Roller Home Position Sensor Position Sensor Rear Alignment Plate as Home Sensor ov Mi Sensor iA p i Full Sensor vy Stack Feed Home m E A Roller Home Sensor Position Sensor Tray Paper wT Ha E Clutch a a Home Position sensor Paper Surface Sensor Processing Tray Sensor Paddle Home Delivery Belt 7400 542 Theory of Operation 2 27 Sensor Function Sensor Function Joint Switch Prevents the power supply from placing hazardous voltages in accessible areas when the Finisher is undocks from the Printer Front Door Switch Prevents the power supply from placing hazardous voltages in accessible areas when the Front Door Door J is removed Front Door Sensor Detects when the Front Door is open or removed Inlet Sensor Detects the presence of media in the finisher paper path Tray Paper Sensor Detects when the paper tray is removed from the Finisher Paper Surface Sensor Detects media in the home position of the delivery tray Upper Cover Door H Sensor Detects
138. iagram 7 7 removal 5 46 wiring to motors 7 21 wiring to printer 7 17 wiring to Punch Controller Board 7 24 wiring to stapler sensors and motors 7 23 wiring to switches 7 22 fold jam release knob 5 8 5 10 5 21 5 22 fold jam releasing dial 5 34 Fold Unit parts diagram 6 30 Fold Unit parts list 6 33 folding position 4 17 folding process 2 18 fonts 1 2 3 Front Door Interlock Switch removal 5 74 Full Stack Sensor 2 21 G guide removal Paddle Guide 5 116 Paper Guide 5 127 Side Guide 5 107 H Home Position Board removal 5 47 Inverter clock frequency error 3 85 Door Open Interlock Switch removal 5 101 Feeder Clutch removal 5 69 firmware error 3 74 flash memory failure error 3 77 interface failure error 3 47 sensor locator 5 99 theory 2 14 unsupported ROM error 3 50 Inverter Controller Board plug jack locator diagram 7 9 wiring to sensors and switches 7 26 wiring to solenoids and clutch 7 27 Inverter Controller Board removal 5 55 Inverter parts diagram 6 34 Inverter parts list 6 37 Inverter Power Supply Board removal 5 56 J jam detection jam code 2 40 jam location map 3 4 jam errors 3 6 job collation 1 2 Joint Switch removal 5 73 Index L Lift Motor Clock Sensor 2 24 Drive Assembly parts diagram 6 12 Drive Assembly parts list 6 13 Paper Tray theory 2 37 theory 2 24 LVPS troubleshooting 3 4 M measurement techniques 3 12 media errors 3 7 m
139. ight Side Door on the Inverter The illustration below identifies the location of the Right Side Door Door I Inverter Right Side Door Door 1 we Upper Rear Cover s7400 490 5 22 Phaser 7400 Color Printer Options Service Manual Inverter Top Cover Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Front Covers page 5 17 Remove the Inverter Rear Covers page 5 19 Remove two black screws self tapping 6 mm on each side of the cover 0 Aa O N Lift the cover up and away from the chassis s7400 491 Service Parts Disassembly 5 23 Units Punch Unit The steps in this procedure show you how to remove the Punch Unit Boss Hole Boss Hole Loea Punch Module Screw With Rosette Supplied With This Module 57400 103 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Waste Case Box 0 A O N Remove the two screws metal 6 mm securing the top cover of the punch unit 5 24 Phaser 7400 Color Printer Options Service Manual 6 Remove the screw self tapping plastic 10 mm to detach the Jam Processing Cover Jam Processing Cover 7400 256 Service Parts Disassembly 5 25 7 Disconnect the connector and remove the harness from the harness guide Harness Guide 400 257 8 Remove the screw metal flange 6 mm and Sensor Support Plate 9
140. included are precautions and or additional procedures you must follow to isolate the problem When a procedure instructs you to test a component using Service Diagnostics see Fault Isolation on page 4 6 for the detailed steps and functions for testing parts assemblies or subsystems of the printer Some actions are followed by a question If your response to the question is Yes then follow the instructions for a Yes reply If your response to the question is No then follow the instructions for a No reply Note that two types of photo sensors are used photo reflective and photo receptive Photo reflective sensors use light reflected back from an object to detect its presence or absence Photo receptive sensors use an actuator or the object itself to block the light path to detect an object or condition Troubleshooting procedures frequently ask you to take voltage readings or test for continuity or resistance at certain test points The Wiring and Plug Jack References table provides pointers to the diagrams that provide this information Troubleshooting procedures often ask you to replace a printer component When instructed to replace a non spared component and that component is part of a parent assembly replace the entire parent assembly General Troubleshooting 3 1 Measurement Techniques 1 Unless indicated otherwise the instruction switch On printer power means for you to switch On printer power a
141. inisher Control Board sensor connected 4 Check the Door J signal Replace the Replace the Does the voltage change on CN4 9 of the Finisher Control harness Finisher Control Board when the switch is activated Board page 5 46 General Troubleshooting 3 37 Clear Tray 2 3 4 5 6 Riser Plate The Lift Motor failed to raise the media to the pre feed position For a Remove Paper error the Level Sensor indicates Pre Feed position or higher before a lift is executed Initial Actions Remove the tray and inspect the tray cavity to ensure that it is free of obstructions or debris Reinstall the tray and cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Level Sensor Lift Motor Universal Tray Option Control Board Option Feeder Board Troubleshooting Procedure Table Wiring and Plug Jack References Print Engine Map 5 see Book 1 Print Engine Map 12 see Book 1 Print Engine Feeder Board see Book 1 Options Map 5 Paper Tray Controller Board Options Map 6 Paper Tray Feeder Board Options Paper Tray Motors and Clutches Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Level Sensor Actuator m Lift Plate and gearing m Lift Motor Is there any damage 2 Test the Level Sensor Go to Step 3 Replace the R
142. inisher Punch Transfer Home Position Sensor detects the home position of the punch slide unit The punch slide unit detects the trailing edge of sheets with the trailing edge sensor LEDS PT5 and the horizontal registration sensors LED1 through 4 SREGI through 4 This action moves the unit to the desired position matching the trailing edge of each sheet in relation to the size of the sheet The horizontal registration operation takes place as follows 1 When the trailing edge sensor LEDS PTS detects the leading edge of a sheet from the printer the Finisher Punch Transfer Motor begins to move the punch slide unit toward the front 2 When the horizontal registration sensor LED1 through 4 for the appropriate the paper size from the printer detects the leading edge of the sheet the Finisher Punch Transfer Motor moves to the specified position then stops the slide unit 3 When the trailing edge sensor LED5 PT5 detects the trailing edge of the sheet the drive of the Feed Motor stops also stopping the sheet Then the Finisher Punch Motor energizes to punch holes in the sheet 2 16 Phaser 7400 Color Printer Options Service Manual 4 When the punching operation ends the Feed Motor moves the paper through the rest of the paper path The Finisher Punch Transfer Motor then rotates in reverse to return the slide unit to home 5 For each sheet that arrives in succession the Punch Slide Unit returns to its home position and repeat
143. inuity Go to Step 4 Replace the Is the DUPLEX Harness conductive DUPLEX Harness 4 Print a test print in Duplex mode Go to Step 6 Replace the Duplex Does the sheet reverse in the printer Unit If the error persists go to Step 5 3 18 Phaser 7400 Color Printer Options Service Manual Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 5 Check for 24 V to the Duplex Motors Go to Step 6 Go to Step 10 Disconnect DUPLEX on the Motor Driver Board Is there 24 V at DUPLEX 6 lt gt ground 6 Test the Fuser Motor Go to Step 8 Go to Step 7 Run the Service Diagnostics Fuser Motor test Does the Fuser Motor function correctly 7 Check for 24 V to the Fuser Motor Replace the Fuser Go to Step 10 Disconnect DCHEAT on the Motor Driver Motor see Book 1 Board Is there 24 V at DOHEAT 3 lt gt ground 8 Test the Exit Gate Solenoid Replace the Exit Go to Step 9 Run the Service Diagnostics Exit Gate Assembly see Solenoid test Book 1 Does the solenoid function correctly 9 Check for 24 V to the solenoid Replace the Replace the Rear 1 Actuate the interlock switches solenoid Sensor Board See 2 Disconnect SOLENOID from the Rear page 5 129 Book 1 Sensor Board Is there 24 V across SOLENOID 1 lt gt ground 10 Check Motor Driver Board POW24 Replace the Motor Go to Step 11 connector for 24 V Driver Board see 1 Disconnect POW24 Book 1 Is t
144. ions Service Manual Inverter Controller Board 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Remove the Inverter Rear Covers page 5 19 3 Disconnect all cables Replacement Note It is a good idea to label all connectors to make sure that you replace each one in its proper plug during reassembly 4 Remove the two top screws metal flange 6 mm securing the board to the chassis It is not necessary to remove the lower left screw 5 Lift the board up to free it from the slots before you pull it out of the chassis Inverter Controller Board 7400 499 Service Parts Disassembly 5 55 Inverter Power Supply Board Remove the Inverter and base unit from the Finisher page 5 5 Remove the Inverter Rear Covers page 5 19 Remove the Inverter Controller Board page 5 55 Aa O N a Disconnect all cables Replacement Note It is a good idea to label all connectors to make sure that you replace each one in its proper plug during reassembly 5 Remove three screws metal flange 6 mm securing the board to the chassis 6 Pull the board out of the chassis slots to remove the board C amp A O O 0 Uy N e MACA K4 s7400 500 5 56 Phaser 7400 Color Printer Options Service Manual Motors Clutches and Solenoids Punch Motor Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Disconne
145. it m Print Engine Map 5 see Book 1 Motor Driver Board m Print Engine Motor Driver Board 5 6 see Book 1 m Options Duplex Unit Sensors and Interconnect Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Replace the damage connector Duplex Unit Is the connector damaged page 5 122 Ifthe error persists go to Step 2 2 Check all pins on the DUPLEX Harness for Replace the Motor Replace the continuity Driver Board see DUPLEX Harness Disconnect the DUPLEX Harness Book 1 If the error Is the DUPLEX Harness conductive persists go to Step 3 3 Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive General Troubleshooting Finisher Inverter Firmware Error Applicable Status Code Code 227 A software error with the Inverter s Flash Memory Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Control Board m Print Engine Map 3 see Book 1 m Print Engine Motor Driver Board 6 6 see Book 1 m Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence
146. itch indicates that the Finisher is detached from the Inverter Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Joint Switch mw Finisher Control Board m Options Map 7 Finisher Sensor Locator m Options Finisher Controller to Switches Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Joint Switch and actuator m Finisher Base Are there any defects or misalignment 2 Test the Joint Switch Replace the Engine Go to Step 3 NOTE Door sensor tests are located under Control Board see the Covers Doors and Interlocks Book 1 sub menu Run the Service Diagnostics Joint Switch test Does the switch function correctly 3 Check the switch signal Replace the Go to Step 4 Disconnect CN8 from the Finisher Control Finisher Control Board Board page 5 46 Is there 24 V at CN8 5 when the switch is activated 4 Check the switch signal Replace the Joint Replace the Disconnect CN8 from the Finisher Control Switch page 5 73 Finisher Control Board If the error persists Board page 5 46 Is there 24 V at CN8 6 when the switch is replace the wiring activated 3 90 Phaser 7400 Color Printer Options Service Manual
147. ix universal trays Trays 2 6 is allowed However when the 1650 Sheet Feeder HCF is installed only one additional 550 Sheet Feeder is allowed between the HCF and the printer Electrical connection to the printer is made by a single interface connector s7400 001 1 6 Phaser 7400 Color Printer Options Service Manual 1650 Sheet Feeder The 1650 Sheet Feeder adds three 550 sheet trays Control signals reach the sheet feeder by a single connection The sheet feeder is secured both to the print engine and the 550 Sheet Feeder Specifications Consumable Life Specifications Maintenance Items Size Product name Staple Cartridge 5000 staples x3 AR SC2 Finisher Electrical Specifications Characteristic Specification Primary line 110 127 V Printer 12 amp circuit voltages 220 240 V Printer 6 amp circuit Primary line 100 120 V Printer 50 60 Hz 2 Hz voltage 220 240 V Printer 50 60 Hz 2 Hz frequency range Power 60 watts 12 Watts consumption finishing standby General Information l 7 Physical Dimensions and Clearances Finisher including stand Value Height 1016 mm 40 0 in Width 813 mm 82 in Depth 595 mm 23 6in Weight Approximately 55 kg 122 Ib Finisher only 1650 Sheet Feeder Value Height 401 mm 15 8 in Optional Paper Tray Assembly Width 597 mm 23 5 in Depth 599 mm 23 6 in Weight Approximately 53 6 kg
148. l Information 1 3 Parts of the Finisher and Paper Trays Front View Rear View 7400 533 1 4 Phaser 7400 Color Printer Options Service Manual Printer Options Phaser 7400 Color Printer options include m 1 000 Sheet Finisher with hole punch staple saddle stitch and inverter m 550 Sheet Feeder LTA m 1650 Sheet Feeder HCF m Duplex Unit Finisher The Finisher increases the output capacity of the printer by 1 000 sheets Printer output is directed to the Finisher by way of the side exit Depending on the job specifications as paper enters the Finisher it is punched stapled offset and stacked The Finisher has two cables one to hook up to the printer and another to connect to the Inverter The Finisher also includes its own power supply The Finisher includes a separate Inverter unit to position paper from the printer before the paper reaches the finisher unit for final stacking Finisher Inverter 7400 306 General Information 1 5 Duplex Unit The Duplex Unit adds two sided printing The Duplex Unit attaches into the left side above Tray 2 using two latches 7400 305 550 Sheet Feeder The 550 Sheet Feeder increases the input capacity of the printer The feeder attaches below Tray 2 with four screws When used in combination with the 1650 Sheet Feeder the 550 Sheet Feeder is installed between the printer and 1650 Sheet Feeder Up to four optional 550 Sheet Feeders per printer totaling s
149. lable configurations Printer Configuration Features 7400N 7400DN 7400DT 7400DX 7400DXF Max Print Speed ppm 36 40 36 40 36 40 36 40 36 40 color monochrome Hard Drive for Secure Optional Optional Yes Yes Yes Proof Personal and Saved Print Jobs Standard Memory 256 MB 256 MB 512 MB 512 MB 512 MB USB Port Yes Yes Yes Yes Yes 10 100 Ethernet Port Yes Yes Yes Yes Yes RAM Collation Yes Yes Yes Yes Yes Duplex Unit Optional Yes Yes Yes Yes PostScript PCL Fonts Yes Yes Yes Yes Yes Resolutions dpi Standard 600x600x1 600x600x1 600x600x1 600x600x1 600x600x1 Enhanced 1200x600x1 200x600x1 1200x600x1 1200x600x1 1200x600x1 Photo 600x600x5 600x600x5 600x600x5 600x600x5 600x600x5 Tray 1 MPT Yes Yes Yes Yes Yes Optional Trays Optional Optional 1 x 550 3 x 550 4 x 550 550 Sheet Feeder Optional Optional Yes Optional Yes 1650 Sheet Feeder Optional Optional Optional Yes Yes 1000 Sheet Finisher Optional Optional Optional Optional Yes All configurations have two memory slots supporting 256 MB and 512 MB cards up to a maximum of 1 GB Trays 1 and 2 are standard on all configurations All configurations support additional paper trays in the following combinations One 550 Sheet Feeder Tray 3 One 1650 Sheet Feeder Trays 3 4 and 5 or 4 5 and 6 One 550 Sheet Feeder Tray 3 and one 1650 Sheet Feeder Trays 4 5 and 6 Requires a total of 4 optional trays for fitment Genera
150. lace the Finisher Control Board page 5 46 Replace the cable 3 64 Phaser 7400 Color Printer Options Service Manual Finisher Backup RAM Failure An error was detected in the Finisher s backup RAM Applicable Status Code Code F137 Finisher s backup RAM Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Finisher Control Board m Print Engine Motor Driver Board 6 6 see Book 1 m Finisher Interconnect Cable m Options Map 1 Finisher Controller Board m Engine Control Board m Options Finisher Controller to Printer Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Finisher Interconnect Cable m Finisher connections Is there any damage 2 Check all the pins of the Finisher Go to Step 3 Replace the cable Interconnect Cable for continuity Is the cable conductive 3 Check all the pins of the OPTIF Harness Go to Step 4 Replace the for continuity OPTIF harness Is the harness conductive 4 Replace the Finisher Control Board Replace the Engine Complete Does the error persists Control Board see Book 1 General Troubleshooting 3 65 Finisher Punch Dust Sensor Failure An error was detected in the Punch Waste Senso
151. lected paper aligns properly with the entrance into the paper path To remove and replace either Sensor 1 Remove the Front Door page 5 8 oOo oo Ff OQ N Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Locate the sliding position activators see illustration Locate the front sensor ois Front Aligning Plate Home Position Sensor 7400 706 Service Parts Disassembly 5 83 7 Locate the rear sensor Rear Alignment Plate Home Sensor shift Limit Sensor Upper Shift Limit Sensor Lower Bind Tray Sensor s7400 707 8 To remove the Front or Rear Aligning Plate Home Position Sensor first remove the 4 wire connector CN23 for the front or CN36 for the rear and then pinch the plastic tabs to pull the sensor free 5 84 Phaser 7400 Color Printer Options Service Manual Stack Feed Roller Home Position Sensor The Stack Feed Roller Home Position Sensor detects the initial home position of the stack feed To remove and replace the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 oF OQ N Remove the metal cover plate to expose the sensor and connector CN41 7 N Service Parts Disassembly 5 85 6 To remove the sensor disconnect CN41 from the sensor remove one screw metal 4 mm and then pull the sensor free
152. lex Unit m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Duplex Unit m Engine Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 4 Duplex Unit Controller Board Step Actions and Questions Yes No 1 Check the following for evidence of fault or damage m Duplex Connector Is there any damage Replace any damaged parts Go to Step 2 2 Check that the Duplex Unit is correctly Go to Step 3 installed and fully seated Reseat the Duplex Unit page 5 122 Replace Engine Control Board see Book 1 if the error persists replace the DUPLEX harness 3 Check the Duplex Unit version using the Service Diagnostics General Status menu Is the version current Replace the Duplex Unit page 5 122 3 48 Phaser 7400 Color Printer Options Service Manual Unsupported Tray 3 4 5 6 ROM The printer has detected an incompatible LTA or HCF assembly Applicable Status Codes Code U35 Unsupported Tray 3 ROM Code U36 Unsupported Tray 4 ROM Code U37 Unsupported Tray 5 ROM Code U38 Unsupported Tray 6 ROM Initial Actions m Reseat the Option Tray connector m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Option Control Board m
153. lly to avoid bending pins m Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards vi Phaser 7400 Color Printer Options Service Manual service Safety Summary 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 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 Phaser 7400 Color Printer O
154. lustration Swing Guide Home Position Sensor Stack Feed Roller VR Home Position Sensor LAOS S JINN NQS a aN wri TEDAR Folding Home A LE Sem NCA iding y N Position Sensor s7400 65 7 To remove the sensor disconnect CN40 from the sensor remove one screw metal 4 mm and then pull the sensor free Service Parts Disassembly 5 97 Bind Tray Sensor The Bind Tray Sensor detects when paper is present in the Saddle Unit s bind tray To remove and replace the sensor 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 Remove the Bind Tray Sensor Cover see illustration O a fF O N Bind Tray Sensor Bind Tray Sensor Cover Plate q s7400 7 To remove the Bind Tray Sensor first remove the 4 wire connector CN47 from the sensor and then pinch the plastic tabs to pull the sensor free 5 98 Phaser 7400 Color Printer Options Service Manual Inverter Sensors and Switches The following illustration shows the general location of the Inverter sensors The topics in this section describe the disassembly for each sensor Inverter Paper in Sensor Inverter Upper Paper present Sensor A i Inverter Door Open Ve S Y Interlock Switch lt S Paper present Sensor Inverter Docking l Inverter Lower Sensor s7400 611 Service Parts Disassem
155. m Finisher 1 Release the hook attaching the Finisher to the Base Unit 2 Remove the two screws metal 6 mm securing the Base Unit to the Finisher 3 Lift the Finisher from the four slots on the Base Unit Caution Use two people to lift the Finisher from the Base Unit Service Parts Disassembly 5 5 Undocking Inverter from Printer 1 Slide out the bar on the bottom of the Finisher Base Unit 2 Remove two screws metal 6 mm holding the Inverter to the printer 3 Remove guide pins 4 Slide Inverter away from the printer 7400 528 5 6 Phaser 7400 Color Printer Options Service Manual Trays and Covers Paper Exit Tray 1 Remove four screws metal 6 mm and detach the Paper Exit Tray Paper Tray W VAAL Ye O s7400 527 5 7 Service Parts Disassembly Front Door Door J 1 Open the Front Door 2 Remove two screws metal 6 mm 3 While squeezing the plastic hooks remove the fold jam release knob Hooks Fold Jam Releasing Dial s7400 160 4 Press the release latch and slide the finisher away from the Finisher Base Unit 5 8 Phaser 7400 Color Printer Options Service Manual 5 To detach the Front Door remove four screws metal 6 mm pull the right side of the cover away from the Finisher and then slide the cover to the left moving the guide tab out of the slot on the cover Front Door NN 7400 161 Service Parts Disassembly 5 9 Right Side Door Door G
156. m Front and Rear Alignment Guides m Transport Rollers Are there any defects or misalignment 2 Test the Tray Paper Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the at the Finisher Control Board Finisher Control harness Actuate the sensor Board page 5 46 Does the voltage across CN5 9 lt gt ground change when the sensor is actuated 3 28 Phaser 7400 Color Printer Options Service Manual Jam Inside Finisher Media remains in the Inverter These errors represent a jam in the Inverter path Applicable Status Codes Code Code Code Code Code Code IN1 Media remains in the Inverter Lower Sensor IN2 Media remains in the Inverter Exit Sensor IN3 Media reached the Inverter Entrance Sensor but did not reach the Inverter Exit Sensor on time IN4 Media reached the Inverter Entrance Sensor but did not clear on time IN6 Media reached the Inverter Exit Sensor but did not clear on time IN7 Media remains in the Inverter Lower Sensor Initial Actions Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Inverter Lower Sensor m Inverter Entrance Sensor m Inverter Exit Sensor Troubleshooting Procedure Table Wiring and Plug
157. make sure that side guide is mounted securely 5 108 Phaser 7400 Color Printer Options Service Manual Feed Roller Remove the Upper Cover page 5 13 Remove the Upper Right Cover Assembly page 5 37 Remove the Feed Motor Unit page 5 62 Remove the screw metal flange 6 mm oF O N Remove the stop ring and detach the bushing pushing lt 7 7Y K Clip 7400 232 Service Parts Disassembly 5 109 6 Remove the two screws metal flange 6 mm 7 Remove the gear and detach the gear while releasing the latch 8 Remove the stop ring and detach the bushing KN 7400 233 5 110 Phaser 7400 Color Printer Options Service Manual 9 Remove the Lower Paper Guide Bushing K 7400 234 7400 235 Service Parts Disassembly 5 111 Upper Stack Delivery Roller 1 Remove the Paddle Assembly page 5 46 2 Place the assembly as shown 3 Push up the Upper Stack Delivery Roller from below to free it from the shaft 7400 236 5 112 Phaser 7400 Color Printer Options Service Manual 4 Shift the roller upwards and then push down to detach Upper Stack Delivery Roller j s7400 237 Service Parts Disassembly 5 113 5 In a similar manner remove the Upper Stack Delivery Roller at the front Note Be careful not to lose the gear pin in the roller Upper Stack 2 Delivery Rollers 7400 238 5 114 Phaser 7400 Color Printer Options Service Manual Paddle 1
158. mbly 5 9 Stapler Safety Interlock Switch The Stapler Safety Interlock Switch protects current overloads in case of a staple jam This switch will open to remove voltage from the stapler unit To remove and replace the switch 1 Remove the Front Door page 5 8 oF O N Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Locate the Paddle Motor and Staple Safety Switch see illustration Staple Safety x Interlock Switch s7400 675 Slide the small belt from the Paddle Motor 7 Remove two screws metal 6 mm and washers from the motor casing and pull the motor away from the chassis so that you have access to the switch Lift connector CN66 off of the two connector pins You may need to free the two wires from the cable harness Remove the single screw metal 6 mm holding the switch to the chassis To remove the switch release the three plastic hooks securing the switch to the plastic 5 92 Phaser 7400 Color Printer Options Service Manual Staple Fold Clock Sensor The Staple Fold Clock Sensor counts timing pulses during staple and fold operations To remove the sensor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Rear Cover page 5 11 3 Locate the sensor see illustration and disconnect connector CN52 7400 229 staple Fold Motor Staple Fold Clock Sensor 4 To remove the sensor pinch the plastic t
159. n the Finisher Stapler Safety Interlock Switch Shift Lower Limit Sensor Shift Clock Sensor Upper Cover Sensor ae Joint Switch XN Front Alignment Plate y lt a Pa Full Stack Sensor Home Position Sensor ia P A Pas Staple Fold lt i D LQ ij Bind Tray Sensor Clock Sensor 2 SE ne Front Door Switch Staple aN a g A Front Door Switch and Sensor Staple Slide Home Sensor Stacking Roller Shift Upper Limit Sensor Home Position Sensor Paddle Home INL Position Sensor Rear Alignment Plate Home Sensor ag apa Inlet Sensor __ Waste Full Sensor vi Delivery Belt v Stack Feed Home e A Roller Home Sensor Ha Position Sensor Tray Paper S AN Binding Clutch in Home Position Sensor Paper Surface Sensor Processing Tray Sensor 57400 542 5 72 Phaser 7400 Color Printer Options Service Manual Joint Switch The Joint Switch is activated when the Finisher Unit connects to the printer This switch opens to prevent the power supply from placing hazardous voltages in accessible areas when the Finisher is undocked from the printer To replace 1 Remove the Paper Exit Tray page 5 7 Remove the Front Door page 5 8 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 oF O N Locate the Joint Switch and plastic harness protector see illustration Joint Switch CN 69 SEE Actuator s7400 664 6 Lift connector CN69 off of the two connecto
160. nd let the printer proceed through Power On Self Test POST to a Ready condition Conventions used in this manual to represent connectors Jack Plug K ml s 400 314 When instructed to take voltage continuity or resistance readings on wiring harness proceed as follows Check P J 232 1 to P J 210 5 by placing the red probe of your meter on pin 1 of P J 232 and place the black probe of your meter on pin 5 of P J 210 When you are instructed to take resistance readings between P J 232 lt gt P J 210 without specified pin numbers check all pins When you are instructed to run a test run the Service Diagnostics test associated with the component being examined When you are instructed to take a voltage reading the black probe is generally connected to a pin that is either RTN Return or SG Signal Ground You can substitute any RTN pin or test point in the printer and you can use FG frame ground in place of any SG pin or test point Before measuring voltages make sure the printer is switched On the Imaging Unit and the paper trays are in place and the interlock switch is actuated unless a troubleshooting procedure instructs otherwise All voltage values given in the troubleshooting procedures are approximate values The main purpose of voltage readings is to determine whether or not a component is receiving the correct voltage value from the power supply and if gating a volta
161. nd monitor the fusing temperature Photo Sensors Two types of photo sensors are used photo reflective and photo receptive Photo reflective sensors use light reflected back from an object to detect its presence Photo receptive sensors use an actuator or the object itself to block the light path to detect an object or condition Photo reflective sensors have the light emitter and light receiver aligned on a single surface Output of the photo receptor is High gt 4 5 V when light is being reflected back and Low lt 3 V when it isn t Photo receptive sensors consist of a LED in one arm of a U shaped holder and a photo transistor in the other arm When the sensing area is vacant nothing is between the arms of the sensor light falls on the photo receptor sending the signal High If the light is interrupted the photo transistor goes Low Hooks 7400 310 Theory of Operation 2 25 Microswitches Microswitches are used primarily as paper size sensors and cover interlocks They are in a normally open state and close when actuated A bank of microswitches detect paper size in the universal trays Microswitches also employ hooks or catches for retention in the bracket or frame 400 311 2 26 Phaser 7400 Color Printer Options Service Manual Finisher Paper Path Sensors The following illustration identifies the various sensors located in the Finisher Error reporting is dependent on these sensors as the paper moves t
162. ng for evidence of fault or damage m No Paper Sensor m No Paper Actuator Is there any damage Replace any damaged parts Go to Step 2 2 Test the No Paper Sensor for the affected tray test Run the Service Diagnostics Tray Switches Does the sensor function correctly Replace the Engine Control Board see Book 1 Replace the sensor If the error persists go to Step 3 3 Check for 5 V to the No Paper Sensor Go to Step 4 Replace the Feeder Is there 5 V across PAPEND 1 lt gt Board ground 4 Check all pins on the Main Harnesses for Replace the Option Replace the Main continuity Is the harness conductive Control Board Harness 5 Test the OPTIF Harness continuity Is the OPTIF Harness conductive Replace the Engine Control Board see Book 1 Replace the harness General Troubleshooting 3 39 Finisher Lower Output Tray is Full Unload Paper Initial Actions m Ensure that the output tray is empty and the actuator is in the correct position m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Saddle Stitch Bind Tray m Bind Tray Sensor Flag m Stapler Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 7 Finisher Sensor Locator 1 2 m Options Finisher Controller to Sensors 2 3 Step Actions and
163. nter Options Service Manual Finisher Controller to Stapler Sensors and Motors Finisher Controller Board 5VDC Stapler Unit STPL_CNCT 24VDC 7400 277 Wiring Diagrams 7 23 Finisher Controller to Punch Controller Punch Controller Board CN12 J1003 Finisher Controller Board ok NO RAO0OONO CN14 7400 278 7 24 Phaser 7400 Color Printer Options Service Manual Punch Controller to Sensors and Motors Punch Controller Board J2011 Photosensor PCB J2010 1 J LED PCB 2 EB 3 4 _ a 6 J2006 Waste Full Photosensor PCB 2 J2005 i E Waste Full LED PCB 2 E J2009 9 1 Punch Motor 8 2 Clock Sensor 7 3 J2008 6 1 Punch Home 5 2 Position Sensor 4 3 Horizontal Registration Home Position Sensor Horizontal Registration s7400 279 Wiring Diagrams 7 25 Inverter Sensors Wiring Diagram Inverter Controller ener Board SNSCN1 SNS P J13 Docking Sensor 5 8 gt ral Co Door Open Interlock Switch SNSCNO P Ji2 Lower Paper Present Sensor 1 3 CJ 2 SNSCNO P14 SNS1_N Paper In Sensor 2 oS lt 3 DC 5V Upper Paper Present Sensor 3 C s7400 616 7 26 Phaser 7400 Color Printer Options Service Manual Inverter Motors Solenoids and Clutch Wiring Diagram Inverter Controller Board 24VDC Inverter Power Supply Board 7400 617 Wiring Diagrams 7 27 Duplex Unit Wiring Diagrams Duplex Unit Sensors and I
164. nterconnect Wiring Duplex Unit Interconnect Controller APTP Connector Board 5V OPTCNT 5V OVL OVP From Printer SNSCNO P J81 Paper End Sensor S a JE 3 Cj 2 SNSCNO SNS1 N P J82 Duplex Front Sensor on Ki E Duplex Rear Sensor inl Duplex Entrance Sensor m Duplex Reverse Sensor m s7400 712 7 28 Phaser 7400 Color Printer Options Service Manual Duplex Unit Motors and Solenoids Duplexer Controller Board 24VDC 24VDC 7400 713 Wiring Diagrams 7 29 Optional Tray Wiring Diagrams Paper Tray Sensors and Interconnect Wiring Feeder Board TRYSNS2 Feed Out Sensor 3 Registration Sensor 3 COVOPN P Door C Detect 5VDC PAPEREND No Paper Sensor Paper Tray Controller Board TRYSNS1 FFSNS IN4 HOP ra PAPEREND GND 5VDC LIFT cover pS 3 a E gt N C va Oo o noo Aa UO N Oo onoo Aa UO N oO i Option Tray Paper Size Switch PSIZE P J145 o Aa N s7400 714 7 30 Phaser 7400 Color Printer Options Service Manual Paper Tray Motors Clutches and Interconnect Wiring Paper Tray Controller Board 24VDC MAIN1 OPTSIN N P J60 gt e NN 3 SL OPDP O 4 S OPTSDRN S 5 S v O 6 7 8 9 Interconnect Connector 24VDC 5VDC OPTCNT2_N 5VDC lt L 11 724VDC 12 o ER 8 lt L 14 Se Se OS O O ee O O O O i a Ce oe BwohPpP MAIN2 P J61 Interconnect Plu
165. o Step 4 Does the motor operate 3 Check for 24 V to the Swing Motor Replace the Slide Replace the Disconnect CN72 Motor page 5 61 harness If the Is there 24 V across CN72 8 and 9 lt gt error persists go ground to Step 5 4 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Power Supply Disconnect CN1 and CN2 from the Finisher page 5 56 Control Board and the opposite end from the Inverter Is the cable conductive 3 54 Phaser 7400 Color Printer Options Service Manual Finisher Stack Handling Motor Failure The Delivery Belt Home Position Sensor detected a Stack Handling error Applicable Status Code Code F111 Stack Handling Motor Failure Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Finisher Stack Handling Motor m Finisher Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board m Options Finisher Controller to Motors Step Actions and Questions Yes No 1 Check the delivery mechanism Go to Step 2 Repair the Does the Delivery Belt turn freely when mechanism operated manually 2 Test the Delivery Belt Home Position Go to Step 3 Replace the Sensor sensor If the error Run the Service Diagnostics Exit Belt persists go to Home Position Sensor test S
166. o further effect Adjustments and Calibrations 4 3 Adjusting Sensor Output After Sensor Replacement Perform the following steps whenever you replace the Punch Controller Board horizontal registration sensor photosensor board LED board or waste full sensor waste full photosensor board waste full LED board 1 Locate DIP switches SW1001 SW1002 and SW1003 and LEDs LED1001 LED1002 and LED1003 on the Punch Controller Board SW1001 O sw1002 O sw1003 LED1001 LED1002 LED1003 7400 270 2 For DIP switch SW1001 on the Punch Controller Board press shift bits 1 through 4 as follows 7400 535 3 Press switches SW1002 or SW1003 on the Punch Controller Board m Pressing either switch will adjust the sensor output m The adjustment is complete when all LEDs on the Punch Controller Board are ON for LEDS LED1001 LED1002 LED 1003 4 Shift all bits of DIPSW1001 to OFF this action ensures that the LEDs will remain unaffected and the switch setting will have no further effect 4 4 Phaser 7400 Color Printer Options Service Manual Adjusting Sensor Output After EE PROM Replacement To adjust the sensor output after replacing the EE PROM use the following steps 1 Turn off the Phaser 7400 Color Printer 2 Locate DIP switches SW1001 SW1002 and SW1003 and LEDs LED 1001 LED1002 and LED1003 on the Punch Controller Board SW1001 O sw1002 O sw 003 LED1001 LED1002 LED1003 400 270
167. oblems Troubleshooting procedures isolate a problem to a specific component or subassembly If you go through the procedures and are still unable to solve the problem re read the Theory of Operation section for the problem area to understand how that section of the option functions Using Service Diagnostics Service Diagnostics provides tests for most electro mechanical components Service Diagnostics also contains test procedures If confronted with an error that requires more than a cursory investigation to clear or when directed by a troubleshooting procedure use Service Diagnostics to exercise selected sub assemblies of parts in the vicinity of the reported error The system monitors sensors located throughout all attached options Sensor signals are used to monitor paper handling and mechanical activity along the entire paper path As a sheet travels along the paper path sensors change state temporarily to indicate the sheet s presence If the pattern of sensor state changes differs from the expected timing for a particular paper size and path the sensor where the timing difference occurs identifies the error to report However having the error message information doesn t necessarily pinpoint the problem Sensor signals locate where but often cannot identify why Motors belts gears solenoids and numerous other parts are involved in paper transport The Service Diagnostics suite of tests and utilities are the best tool
168. of fault or Replace any Go to Step 2 damage damaged parts m Inverter Interface Cable m Inverter connections Is there any damage 2 Check the Inverter connection Go to Step 3 Connect the Is the Inverter interface cable securely Inverter to the connected at both ends Finisher 3 Check the version of Inverter firmware Replace the Inverter Reload the Inverter Is the latest version installed Control Board firmware page 5 55 3 74 Phaser 7400 Color Printer Options Service Manual Tray 3 4 5 6 Flash Memory Failure Applicable Status Codes Code 242 Hardware error in Tray 3 Flash Memory Code 243 Hardware error in Tray 4 Flash Memory Code 244 Hardware error in Tray 5 Flash Memory Code 245 Hardware error in Tray 6 Flash Memory Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Option Tray Control Board m Engine Control Board m Print Engine Map 3 see Book 1 m Print Engine Motor Driver Board 6 6 see Book 1 Wiring and Plug Jack References m Options Map 5 Paper Tray Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check all pins on the OPTIF Harness for Replace the Option Replace the continuity Disconnect OPTIF fr
169. ollers Are there any defects or misalignment 2 Test the Processing Tray Sensor Replace the Engine Replace the Run the Service Diagnostics sensor test Control Board see sensor If the error Does the sensor function correctly Book 1 persists go to Step 3 3 Check the Processing Tray Sensor signal Replace the Replace the Actuate the sensor at the Finisher Control Finisher Control harness Board Board page 5 46 Does the voltage across CN5 9 lt gt ground change when the sensor is actuated 3 22 Phaser 7400 Color Printer Options Service Manual Jam at Finisher Saddle Stapler Media remains in the buffer area This error represents a jam in the Finisher Applicable Status Code Code FN5 Jam at Finisher Saddle Stapler Initial Actions m Check for obstructions or debris in the paper path m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Compiler Tray m Options Map 7 Finisher Sensor Locator 1 2 m Front and Rear Alignment Guides m Transport Rollers m Stapler m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged
170. om the Engine Control Board and Option connector Is the harness conductive Control Board If the error persists replace the Engine Control Board see Book 1 OPTIF Harness General Troubleshooting 3 75 Duplex Unit Flash Memory Failure Applicable Status Code Code 246 Hardware failure with Duplex Unit Flash Memory Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Duplex Unit Motor Driver Board m Print Engine Map 5 see Book 1 m Print Engine Motor Driver Board 5 6 see Book 1 m Options Map 4 Duplex Unit Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Replace the damage connector Duplex Unit Is the connector damaged page 5 122 Ifthe error persists go to Step 2 2 Check all pins on the DUPLEX Harness for Replace the Motor Replace the continuity Driver Board see DUPLEX Harness Disconnect the DUPLEX Harness Book 1 If the error Is the DUPLEX Harness conductive persists go to Step 3 3 Check all pins of the DRV1 harness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive 3 76 Phaser 7400 Color Printer Options Service Manual Fini
171. om the actuator cover metal plate oOo o Ff Q N Disconnect the 3 wire connector at the actuator location Note The other end of this cable connects to connector SNSCNO on the Inverter Controller Board 7 Pinch the plastic hooks together to free the actuator from the metal support case then pinch the plastic tab to pull the actuator free from the chassis Connector ee mt Oe ON W Paper In Sensor O O O s7400 497 5 106 Phaser 7400 Color Printer Options Service Manual Guides and Rollers Side Guide 1 Remove the Paper Exit Tray page 5 7 2 Remove the Front Door page 5 8 3 Remove the Rear Cover page 5 11 4 While gently holding the Rear Delivery Tray Support Plate and track to the side remove three screws metal 10 mm and one specialty screw metal 16 mm from the Side Guide 5 Pull the Side Guide slightly away from the Finisher side Guide Rear Delivery Tray Support Plate Front Delivery Tray Support Plate Metal 16 mm 7400 168 Service Parts Disassembly 5 107 6 Twist the guide slightly clockwise free the engagement of the paper surface detecting lever rear and then remove the guide Paper Surface Detecting Lever Rear Paper Surface Detecting Lever Middle A 7400 280 Replacement Note Be sure to insert the paper detecting lever in the groove of the paper surface After completion of mounting activate the paper detecting lever several times to
172. oor C Detect Sensor Replace the Engine Go to Step 3 Run the Service Diagnostics Door C test Control Board for the appropriate tray page 8 112 NOTE Door sensor tests are located under the Interlock Switches sub menu Does the switch function correctly 3 Replace the Door C Detect Sensor Go to Step 4 Complete Does the error persist 4 Check for 0V on the OPTIF connection Replace the Engine The Door C sensor Is there 0 V at OPTIF 7 when the dooris Control Board see is signaling an closed Book 1 open condition go to Step 5 5 Check for 0V on the FFSNS connector of Replace the Option If the wiring from the Option Control Board Is there 0 V at FFSNS 8 when the door is closed Control Board the Option Control Board to the sensor is OK replace the sensor General Troubleshooting 3 33 Close Left Door D The Door D Detect Sensor on the Duplex Unit indicates that Door D is open Initial Actions Ensure that the door is free of obstructions and fully closed Verify that the Detect Sensor Actuator is not broken Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Door D Detect Sensor m Print Engine Map 3 see Book 1 Wiring and Plug Jack References m Options Map 4 Duplex Unit Controller Board m Options Duplex Unit Sensors and Interconnect Wiring Troubleshooting Procedure Table
173. otor disassembly Alignment Motors 5 65 Delivery Motor 5 64 Feed Motor 5 62 Finisher Punch Transfer Motor 5 58 Inverter Lower Roller Motor 5 68 Inverter Upper Roller Motor 5 67 Lift Motor 5 59 Paddle Motor 5 63 Paper Tray Feed Motor 5 138 Paper Tray Lift Motor 5 139 Paper Tray Registration Motor 5 137 Punch Motor 5 57 Slide Motor 5 61 Staple Fold Motor 5 60 O Optional Trays parts diagram 6 41 6 42 parts list 6 43 options 1 5 P Paddle Assembly 5 45 Paper Feeder Assembly parts diagram 6 20 Paper Feeder Assembly parts list 6 21 paper path paper detecting lever 5 108 Index paper fold rollers 4 19 paper folding drive gear 4 19 paper pushing plate 2 18 paper retaining plate 5 34 sensing 2 27 Paper Tray Feeder removal 5 136 Options Connector removal 5 133 Registration Clutch 2 39 Registration Motor 2 39 Registration Roller 2 39 Paper Tray Controller Board plug jack locator diagram 7 11 wiring to motors and clutches 7 31 wiring to sensors and interconnect connector 7 30 Paper Tray Feeder Board plug jack locator diagram 7 12 parts list using 6 2 personal print 1 2 Photosensor Board removal 5 52 power requirements 1 7 power saver mode 1 9 power supplys 2 42 Printer 1 2 configurations 1 3 dimensions 1 8 operational characteristics 1 8 options 1 5 power consumption 1 7 power requirements 1 7 required minimum clearances 1 8 printing process 2 13 processing stopp
174. ower is off to the chassis or circuit board and observe all other safety precautions m 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 m 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 E Do not use freon propelled chemicals These can generate electrical charges sufficient to damage some devices m Do not remove a replacement component or electrical sub assembly from its protective package until you are ready to install it E 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 m 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 m Handle IC s and EPROM s carefu
175. parts m Compiler Tray m Front and Rear Alignment Guides m Transport Rollers m Stapler Are there any defects or misalignment 2 Test the Folding Position Sensor Replace the Engine Replace the Run the Service Diagnostics Folding Control Board see sensor If the error Position Sensor test Book 1 persists go to Do the sensor function correctly Step 3 3 Check the Folding Position Sensor signal at Replace the Replace the the Finisher Control Board Finisher Control harness Actuate the sensor Does the voltage across CN16 2 lt gt ground change when the sensor is actuated Board page 5 46 General Troubleshooting 3 23 Jam at Finisher Upper Output Tray Media remains in the Finisher offset rollers This error represents a jam in the Finisher upper output path Applicable Status Code Code FN6 Jam at Finisher Upper Output Tray Initial Actions m Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Compiler Tray m Options Map 7 Finisher Sensor Locator 1 2 m Front and Rear Alignment Guides m Transport Rollers m Stapler m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table m Options Map 8 Finisher Sensor Locator 2 2 m Options Finisher Controller to Sensors 1 3 Step Actions and Questions Yes No 1 Check the following for
176. path m Duplex Motors One motor drives the Duplex Entrance Roller the other drives the Transport Rollers using a series of belts Duplex Solenoid s7400 678 2 36 Phaser 7400 Color Printer Options Service Manual Optional Tray Motors Rollers and Clutches The following describes the paper path as it is fed from the optional Tray 3 Trays 4 through 6 function in the same manner Media moves along the paper path as follows 1 2 10 11 12 Paper loaded in the tray is detected by the Paper Size Switches The tray s Lift Motor rotates lifting the sheet to the pre feed position detected by the Level Sensor The Feed Motor turns CCW driving the Feed and Pick rollers to feed the sheet from the tray into the Registration Roller The Feed Out Sensor 3 detects the media as it leaves the Feed Rollers As the trailing edge of each sheet passes the Feed Out Sensor 3 the Lift Motor lifts the next sheet to pre feed position The Feed Motor rotates until the leading edge is against the Registration Roller 3 inducing a deskew buckle Registration Sensor 3 goes High to indicate the sheet s position The sheet moves towards the Transfer Unit when the Registration Clutch 3 is engaged driving the Registration Roller 3 and Transport Rollers As the sheet reaches the Registration Roller 2 it is again aligned and detected by the Registration Sensor 2 When the Registration Sensor 2 goes Hi
177. patible Finisher Applicable Status Code Code U55 Unsupported Finisher Unit ROM Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Finisher Control Board m Options Map 1 Finisher Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Finisher firmware version using Replace the Engine Replace the the Service Diagnostics General Status Control Board see Finisher Control menu Book 1 Board page 5 46 General Troubleshooting 3 5 Finisher Fold Position Sensor Failure An error was detected with the Fold Position Sensor Applicable Status Code Code F131 Fold Position Sensor failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Fold Position Sensor m Options Map 1 Finisher Controller Board m Finisher Control Board m Options Map 8 Finisher Sensor Locator m Options Finisher Controller to Sensors 2 3 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Test the Folding Position Sensor Replace the Go to Step 2 Run the Service Diagnostics Bookbinding Finisher Control Position Sensor test Board Does the sensor function correctly 2
178. per stack feed roller begins to descend After the paper stack is inserted between the stack feed rollers the Bind Clutch activates and rotates the Feed Motor in the forward direction feeding the paper stack to the middle position for folding The feed amount is equivalent to the number of pulses necessary to drive the Feed Motor until the paper stack is ready for folding Theory of Operation 2 21 stack Feed Roller Upper Phaser 7400 Color Printer Options Service Manual Stapling After stacking and alignment of paper on the processing tray is complete the finisher controller board moves the stapler for stapling according to the specified stapling position When the controller specifies rear 1 point stapling the stapler does not move it staples while in the standby position If a different stapling option is selected the stapler moves forward and the processing tray stopper leans to the forward position The Finisher Slide Motor moves the stapler unit The Slide Home Position Sensor detects when the unit reaches its home position The stapler waits at the back end of the stack irrespective of the staple mode and paper size Paper Stack Swing Guide stack Delivery Roller Upper Processing Tray Stopper A a Delivery Tray Yf N A stack pele oy Roller Lower Q N TA J LX Ji S N S N Jf Ss S oA y N fff Poa N gt A NSL L ibs x
179. ptions Service Manual vii 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 Servicing Mechanical Components When servicing mechanical components within the printer manually rotate drive assemblies rollers and gears Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running viii Phaser 7400 Color Printer Options Service Manual 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 This equipment 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 when the equipment is operated in a commercial environment 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 o
180. put Tray is Full Unload Paper Finisher Upper Output Tray is Full Unload Paper Wrong Paper Size Load Tray 3 4 5 6 with size type Wrong Paper Type Load Tray 3 4 5 6 with size type Paper Not Available Load Tray 3 4 5 6 with size type Duplex Interface Failure 0 0 ccc eee eee Tray 3 4 5 6 Interface Failure 04 Inverter Unit Interface Failure 0 0 0 0 eee eee Unsupported Duplex Unit ROM 008 Unsupported Tray 3 4 5 6 ROM Unsupported Inverter UnitROM 0 Unsupported Finisher Unit ROM Finisher Fold Position Sensor Failure 006 Finisher Paddle Failure 0 0 cee ee Finisher Stapler Swing Motor Failure 06 Finisher Stack Handling Motor Failure Finisher Staple Motor Failure 0 00000 eee Finisher Jog Motor Failure 0 cee ee eee Finisher Lift Motor Failure 0 0 0 cee eee eee Finisher Exit Failure 0 0 ce ee ee eee es Finisher Punch Backup RAM Failure 0 Finisher Punch Communications Failure Finisher Punch Unit Transfer Motor Failure Finisher Punch Motor Failure 00 000 eee uae Finisher Backup RAM Failure 0 0000 e eee Finisher Punch Dust Sensor Failure
181. r Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Aa N Disconnect the top end of the cable from the connector and free the cable from the harness 5 Remove the single screw metal 6 mm holding the tray to the chassis Connector 7400 165 Service Parts Disassembly 5 15 6 While lifting the Processing Tray Upper Cover disconnect the other end of the cable from the connector underneath the tray Replacement Note When replacing or reconnecting the connector be sure the connection is firm and secure Otherwise you will receive a Paddle Motor error Processing Tray Upper Cover SA s E AN Connector 57400 166 5 16 Phaser 7400 Color Printer Options Service Manual Inverter Front Covers 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Press the release latch and slide the Finisher away from the printer 3 Remove two screws metal flange 10 mm holding the Lower Front Cover to the chassis 4 Remove the Lower Front Cover 4 Inverter LEA o L i Lower Front Cover 7400 487 Service Parts Disassembly 5 17 5 Remove two screws metal flange 10 mm from the left side and two screws from the right side of the Upper Front Cover 6 Remove one screw metal flange 10 mm from the bottom of the Upper Front Cover 7 Carefully move the Finisher release latch out of the slot and remove the Uppe
182. r Applicable Status Code Code F181 Punch Transfer Motor Failure Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Punch Transfer Motor m Punch Control Board m Inverter Power Supply Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 2 Punch Controller Board m Options Punch Controller to Sensor and Motors Step Actions and Questions Yes No 1 Test the Punch Transfer Motor Complete Go to Step 2 1 Close the Interlock Switches for test 2 Run the Service Diagnostics Transfer Motor test Does the motor operate 2 Check for 24 V to the Punch Transfer Replace the Punch Go to Step 3 Motor Transfer Motor Disconnect P J2001 Is the 24 V across J2001 1 lt gt ground 3 Check Punch Control Board for 24 V Replace the Punch Replace the Punch 1 Disconnect P J1001 on the Punch Transfer Motor Control Board Control Board Harness page 5 50 If the Is the 24 V across P1001 pins 1 and 2 enor percists Je to Step 4 4 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Disconnect CN1 and CN2 from the Finisher Control Board and the opposite end from the Inverter Is the cable conductive Power Supply page 5 56 If the error persists replace the Finisher Control Board page 5 46 General Trou
183. r Applicable Status Code Code F139 Punch Waste Sensor Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Punch Box Sensor Emitter Board m Punch Box Sensor Receiver Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 2 Punch Controller Board m Options Punch Controller to Sensor and Motors Step Actions and Questions Yes No 1 Test the Punch Box Sensor Go to Step 6 Go to Step 2 Run the Service Diagnostics Punch Box Set Sensor test Does the sensor state change when the emitter is blocked 2 Check the Punch Box Sensor Harness Go to Step 3 Connect the connection harness Is P J1005 connected to the Punch Control Board Are P J2005 and P J2006 connected to the Emitter and Receiver boards 3 Check the Punch Box Sensor Harness Go to Step 4 Replace the continuity harness Is the harness conductive 4 Check the Punch Box Sensor Emitter Go to Step 5 Replace the Board Punch Box Is the LED illuminated Emitter Board 5 Check for 5 V to the Punch Box Sensor Replace the Replace the Disconnect P J2006 Punch Box Sensor Punch Control Is there 5 V at J2006 1 lt gt J2006 2 Receiver Board Board see Book 1 page 5 50 3 66 Phaser 7400 Color Printer Options Service Manual Troubleshooting Procedure Table Continued Step
184. r Front Cover D Upper Front Cover s7400 488 5 18 Phaser 7400 Color Printer Options Service Manual Inverter Rear Covers 1 Remove the Inverter and base unit from the Finisher page 5 5 2 Press the release latch and slide the Finisher away from the printer 3 Remove two screws metal flange 10 mm holding the Lower Rear Cover to the chassis 4 Remove the Lower Rear Cover WHI LS 7400 489 5 Remove one screw metal flange 10 mm from the left side and one screw from the right side of the Upper Rear Cover 6 Remove two inset screws metal flange 10 mm near the bottom of the Upper Rear Cover 7 Remove one screw metal flange 10 mm from the bottom of the Upper Rear Cover Service Parts Disassembly 5 19 8 Release the cover from the four tabs holding the cover to the frame 9 Pull the cover away from the frame This will expose the boards motors and clutch units a Inverter Right Side Door Door ee Upper Rear Cover 7400 490 5 20 Phaser 7400 Color Printer Options Service Manual Inverter Left Side Door Door F For diagnostic purposes you may be instructed to open or close the Left Side Door on the Inverter The illustration below identifies the location of the Inverter Left Side Door Door F Inverter Left Side Door Door F Service Parts Disassembly 5 21 Inverter Right Side Door Door I For diagnostic purposes you may be instructed to open or close the R
185. r page 5 11 Remove the Upper Cover page 5 13 Remove the Side Guide page 5 107 To locate the sensor look through the top of the side area where you removed the Side Guide and press the paper surface activator a few times see illustration You will see the activator as it enters the sensor below oOo oo Ff Q N Paper Surface Sensor Processing Tray Sensor s 400 701 7 To remove the sensor first remove the 4 wire connector CN35 from the sensor and then using small neediness pliers pinch the plastic tabs to pull one side of the sensor free Service Parts Disassembly 5 77 Upper Cover Sensor The Upper Cover Sensor detects when the Upper Cover Door I is open or removed To remove and replace the Sensor 1 Remove the Paper Exit Tray page 5 7 2 Remove the Front Door page 5 8 3 Remove the Rear Cover page 5 11 4 Remove the Upper Cover page 5 13 5 Locate the Upper Cover Sensor see illustration Upper Cover Sensor Front Door Sensor gf PR ak Us a wees ZN RN Front Door Switch s7400 703 6 To remove the Upper Cover Sensor first remove the 4 wire connector CN24 from the sensor and then pinch the plastic hooks to pull the sensor free 5 78 Phaser 7400 Color Printer Options Service Manual Shift Limit Sensors The Shift Upper and Lower Limit Sensors detect the upper and lower limits of the delivery tray stack To remove and replace either of the sensors 1 Remove the Pap
186. r pins You may need to free the two wires from the cable harness 7 Carefully holding the large plastic harness protector to one side remove the single screw metal 6 mm holding the switch to the chassis 8 Release the three plastic hooks securing the switch to the plastic and remove Service Parts Disassembly 5 73 Front Door Switch and Sensor The Front Door Sensor detects when the Front Door Door J is open or removed The Front Door Interlock Switch will open to prevent the power supply from placing hazardous voltages in accessible areas when the Front Door is removed To remove and replace the switch and or the Sensor 1 Remove the Front Door page 5 8 oF O N Remove the Paper Exit Tray page 5 7 Remove the Rear Cover page 5 11 Remove the Upper Cover page 5 13 Locate the plastic mounting unit that houses the Front Door Switch and the Front Door Sensor see illustration Upper Cover Sensor Front Door Sensor 7400 699 Remove the single screw metal 6 mm holding the plastic mounting holder to the chassis To remove the Front Door Switch first lift connector CN68 off of the two connector pins and then release the two hooks securing the switch to the chassis To remove the Front Door Sensor first remove the 4 wire connector CN25 from the sensor and then pinch the plastic tabs to pull the sensor free 5 74 Phaser 7400 Color Printer Options Service Manual Inlet Sensor
187. r replacement of option components Use the troubleshooting procedures in Book 1 to diagnose and isolated the problem Book 2 contains these sections Introductory Safety and Regulatory Information This section contains important safety information regulatory requirements and information about this manual Section 1 General Information This section contains an overview of the options available configuration specifications and consumables Section 2 Theory of Operation This section contains functional information on each option Section 3 General Troubleshooting This section provides troubleshooting methods for situations where no error indicator is available Section 4 Adjustments and Calibrations This section provides procedures for the adjustment of print engine components Section 5 Service Parts Disassembly This section contains removal procedures for parts listed in the option s Field Replaceable Units FRUs Parts List A replacement procedure is included when necessary Section 6 Parts Lists This section contains exploded views of the option FRUs as well as FRU part numbers Section 7 Wiring Diagrams This section contains option plug jack locations and wiring diagrams Phaser 7400 Color Printer Options Service Manual xi Book 1 Print Engine Use Book 1 as your primary resource for understanding the operational characteristics of the print engine Book 1 describes printer specifications theo
188. ring 7 29 Motor Assembly 5 128 Motors 2 36 parts diagram 6 38 parts list 6 39 Reverse Sensor 2 31 sensor and interconnect wiring 7 28 sensor locator 2 31 5 130 Side Rails 5 126 Transport Rollers 2 36 unsupported ROM error 3 48 Duplex Unit Controller Board plug jack locator diagram 7 10 wiring to motors and solenoids 7 29 wiring to solenoids and interconnect connector 7 28 E edge saddle 5 30 error messages Control Panel 3 6 jam errors 3 6 list of errors 3 6 warnings 3 9 Ethernet Port 1 2 Exit Gate Solenoid 2 31 F fasteners precautions 5 2 screws 5 3 Feed Motor funtion 2 21 Feed Motor Paper Tray 2 37 Feeder Board clock frequency error 3 86 Feeder Board cover removal 5 143 Feeder Board removal 5 148 Paper Tray Feeder Board parts 7 5 Paper Tray Feeder diagram 7 12 Feeder Clutch Inverter 2 35 Feed Out Sensor Paper Tray 2 32 2 37 Field Replaceable Units 5 2 Finisher assembly diagram 6 4 cover parts list 6 7 entrance jam error 3 30 Feed Motor 2 16 internal parts diagram 6 9 internal parts list 6 11 inverter jam error 3 29 jam at punch error 3 20 locator diagram 7 2 lower tray full error 3 40 Power suppy wiring 7 16 punch box full warning 3 89 Slide Motor 2 6 stacker jam 3 31 staple empty warning 3 88 theory 1 5 unsupported ROM error 3 51 upper tray full error 3 41 Finisher Controller Board adjusting stapling position 4 6 plug jack locator d
189. rness Is the harness properly seated and free from defects Driver Board see Book 1 Unit page 5 122 General Troubleshooting 3 17 Jam at Duplex Entrance Media reached the Fuser Exit Sensor but did not reach the Duplex Entrance Sensor on time This error represents a jam at the Duplex entrance or in the Exit Assembly Applicable Status Code Code TC3 Jam at Duplex Entrance Initial Actions Check for obstructions or debris in the output paper path Reseat the Duplex Unit Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Duplex Unit m Print Engine Map 5 see Book 1 m Duplex Entrance Sensor m Options Map 4 Duplex Unit Controller Board m Exit Assembly see Book 1 m Options Duplex Unit Sensors and Interconnect m Fuser Motor see Book 1 Wiring m Motor Driver see Book 1 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Duplex Unit m Exit Gate m Exit Assembly m Duplex Gate Are there any defects 2 Test the Duplex Entrance Sensor Go to Step 4 Replace the Duplex Run the Service Diagnostics Duplex Entrance Sensor if Entrance IN1 Sensor test the error persists Does the sensor function correctly go to Step 3 3 Check DUPLEX Harness cont
190. rness for Replace the Engine Replace the DRV1 continuity Control Board see Harness Disconnect the DRV1 ribbon cable Book 1 Is the cable conductive General Troubleshooting 3 45 Tray 3 4 5 6 Interface Failure A communications failure has occurred in the option tray interface Applicable Status Codes Code U14 Tray 3 Interface Failure Code U13 Tray 4 Interface Failure Code U16 Tray 5 Interface Failure Code U17 Tray 6 Interface Failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Option Tray Control Board m Engine Control Board m Print Engine Map 3 see Book 1 m Print Engine Motor Driver Board 6 6 see Book 1 Wiring and Plug Jack References m Options Map 5 Paper Tray Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check all pins on the OPTIF Harness for Replace the Option Replace the continuity Board and Option connector Is the harness conductive Disconnect OPTIF from the Engine Control Control Board If the error persists replace the Engine Control Board see Book 1 OPTIF Harness 3 46 Phaser 7400 Color Printer Options Service Manual Inverter Unit Interface Failure A communi
191. roller Board Plug Jack Designator P J Map Coord Remarks SNSCNO 3 F 837 Connects to paper sensors SNSCN1 3 E 837 Connects to Inverter Docking Sensor SNSCN2 3 E 837 Connects to Door Open Interlock Switch Door F CL1 3 F 836 Connects to Lower Roller Solenoid CL2 3 C 836 Connects to Paper Diverter Solenoid FAN 3 D 836 Connects to diverter clutch MOTOR A 3 C 837 Connects to the Upper Feed Motor MOTOR B 3 A 837 Connects to the Lower Feed Motor MAIN1 3 J 837 Connects to connector supplying Finisher Controller Board signals MAIN2 3 E 839 Connects to power supply from the Finisher FLASH 3 H 836 Connect to external equipment for FLASH memory POWER 3 A 836 Connects to the Power Supply Board Duplex Unit Controller Board Plug Jack Designator P J Map Coord Remarks SNSCNO 4 F 837 Connects to the Front and Rear Paper Sensor SNSCN1 4 E 837 Connects to the Entrance Sensor and the Reverse Sensor SNSCN2 4 E 837 No connection CL1 4 F 836 Connects to the Paper Diverter Solenoid CL2 4 C 836 No connection FAN 4 D 836 Connects to the fan MOTOR A 4 C 837 Connects to the Roller Motor MOTOR B 4 A 837 Connects to the Reverse Roller Motor MAIN 1 4 J 837 Connects to connector supplying signals from the Finisher including power MAIN2 4 E 839 No connection FLASH 4 H 836 Connect to external equipment for FLASH memory POWER 4 A 836 No connection 7 4 Phaser 7
192. ry and includes information important to the diagnosis and repair of problems occurring in the print engine and attached options Book 1 also provides detailed print engine replacement procedures parts lists and wiring diagrams Book 1 contains these sections Introductory Safety and Regulatory Information This section contains important safety information regulatory requirements and information about this manual Section 1 General Information This section contains an overview of the printer s operation configuration specifications and consumables Section 2 Theory of Operation This section contains detailed functional information on print engine components Section 3 Error Codes and Messages This section describes the resident diagnostics available to assist the troubleshooting process These diagnostics include error codes and messages and Service Usage Profile data stored in the printer This section provides complete troubleshooting information for the print engine and all options Section 4 General Troubleshooting Troubleshooting discussions cover the operation of Power On Self Test POST Service Diagnostics In addition this section includes troubleshooting methods for situations where no error indicator is available Section 5 Print Quality Troubleshooting This section focuses on techniques to correct image quality problems associated with printer output Section 6 Adjustments and Calibrations This
193. s Diagram 1 of 3 0 0 0 0 cee eee 6 34 Inverter Parts Diagram 2 of 3 0 0 0 cee eee 6 35 Inverter Parts Diagram 3 of 3 nnna 00 cee eee 6 36 Parts List 1 13 Inverter Parts List 0 6 37 Duplex Unit Parts 0 eee 6 38 Duplex Unit Parts Diagram 0 eee 6 38 Parts List 1 14 Duplex Unit Parts List 6 39 Optional Paper Tray Parts 0 0 eee 6 40 Optional Tray Parts Diagram 1 of 2 006 6 41 Optional Tray Parts Diagram 2 of 2 006 6 42 Parts List 1 15 Optional Tray Parts List 6 43 Table of Contents XIX 7 Wiring Diagrams Plug Jack Locator Diagrams 0 0 0 cc ee eee 1 2 Print Options Plug Jack Designators 1 2 Finisher Wiring Diagrams 0 0 0 ccc eee 7 16 Finisher Punch Power Supply Wiring Diagram 7 16 Finisher Controller to Printer Wiring 0 1 17 Finisher Controller to Sensors 1 of 3 00 7 18 Finisher Controller to Sensors 2 of 3 0000 7 19 Finisher Controller to Sensors 3 of 3 00 7 20 Finisher Controller to Motors 0 0 0 e eee eee 1 21 Finisher Controller to Switches 00008 1 22 Finisher Controller to Stapler Sensors and Motors 1 23 Finisher Controller to Punch Controller 7 24 Punch Controller to Sensors and Motors
194. s available to pinpoint the root cause behind the reported error 3 2 Phaser 7400 Color Printer Options Service Manual Servicing Instructions The service checklist below is an overview of the path a service technician should take when servicing the printer and printer optional equipment Step 1 Identify the Problem 1 Verify the reported problem does exist Verify failure symptoms behavior noises with customer end user 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 Status page if the printer is able to print View the fault history under the Service Tools Menu Verify the AC input power supply is within proper specifications Step 2 Inspect and Clean the Printer 1 oF W PY 8 Switch Off printer power Disconnect the AC power cord from the wall outlet Verify the power cord is serviceable Remove the Imaging Unit and protect it from light Inspect the printer interior and remove any foreign matter dust or loose toner m Do not use solvents or chemical cleaners to clean the printer interior m Do not use any type of oil or lubricant on printer parts unless directed to do so m Donotuse canned air to clean spilled toner or d
195. s of the OPTIF Harness Go to Step 4 Replace the for continuity OPTIF harness Is the harness conductive 4 Replace the Finisher Control Board Replace the Engine Complete page 5 46 Control Board see Does the error persists Book 1 3 70 Phaser 7400 Color Printer Options Service Manual Inverter Power Supply Failure Applicable Status Code Code 197 Inverter hardware error Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Power Supply m Options Map 3 Inverter Controller Board m Options Inverter Motors Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Inverter Power Cord m Inverter Power Supply Is there any damage 2 Check AC Power Go to Step 3 Advise customer Is the AC voltage available at the outlet 3 Check the Inverter connection Go to Step 4 Connect the Is the Inverter interface cable securely Inverter to the connected at both ends Finisher 4 Replace the Inverter Power Supply Replace the Inverter Complete page 5 56 Control Board Does the error persist page 5 46 General Troubleshooting 3 71 Tray 3 4 5 6 Firmware Error Applicable Status Codes Code 221 Software error in Tray 3 Flash Memory Co
196. sembly to the rear then lift it to detach Caution Note the inset in the illustration below to find two screws on the chassis side holding the tray to the unit You must remove these screws before you can free the unit s7400 222 5 42 Phaser 7400 Color Printer Options Service Manual Paddle Assembly 1 Remove the Processing Tray Assembly page 5 38 2 Place the assembly as shown Caution Be sure to take care not to damage the aligning plates Paddle Assembly Aligning Plates 57400 223 Service Parts Disassembly 5 43 3 Detach the Timing Belt and remove the two screws metal flange 6 mm 7400 224 5 44 Phaser 7400 Color Printer Options Service Manual 4 Separate the Processing Tray Assembly and the Paddle Assembly as shown Ss 7400 225 Service Parts Disassembly 5 45 Boards Finisher Controller Board 1 Remove the Rear Cover page 5 11 2 Disconnect the 17 connectors and remove the screw metal flange 6 mm 3 Free the board retainer and detach the Finisher Controller Board oF CN8 bie ee Rea A CN1 SOS 4 i CN7 Board Retainer icn14 222 ona oof fe Moo CN5 D gt ie E CN19 H a FT u W CN9 LY EE r T Finisher Controller Board aj S s7400 250 5 46 Phaser 7400 Color Printer Options Service Manual Home Position Board Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5
197. sensor housing to the top of the feeder 7 Release the hooks that secure the sensor in the housing 8 Disconnect the sensor connector P J43 and then remove the sensor Replacement Note Use care when replacing the feeder top Make sure the Level and Low Paper Sensor flags operate properly before tightening the screws Service Parts Disassembly 5 147 Feeder Board 1 Remove the Tray Feeder page 5 136 2 Remove 3 metal 10 mm screws that secure the hand holds to the feeder 7400 687 5 148 Phaser 7400 Color Printer Options Service Manual 3 Remove 1 metal 6 mm screw that secures the Feeder Board Cover E al ye h_ Lf mA TE GA Feeder Board s7400 688 4 Remove 1 metal 6 mm screw that secures the Feeder Board to the Feeder Disconnect the connectors TRYSNS1 TRY SNS2 and PAPEND to remove the board Service Parts Disassembly 5 149 Tray Feed Rollers Note Feed Roller Pick Feed Retard removal is identical for all Universal Trays Since each roller is unique match each replacement roller to the roller being removed 1 Remove Tray 2 2 Open Door B 3 Release the hook that secures each roller to the shaft eee i ZZ 7 Feed Rollers s7400 689 5 150 Phaser 7400 Color Printer Options Service Manual Parts List In this chapter m Using the Parts List m Finisher Parts m Duplex Unit Parts m Tray Parts Section 6 Using the
198. shaft rotates 180 degrees and the Punch Home Position Sensor activates The punching operation for the second sheet ends when the punch shaft rotates 180 degrees in reverse and the Punch Home Position Sensor activates 2 age Punch Shaft At Rest z Punch Shaft CCW 4 Punch Shaft CCW H Posit Home Position Rotation By 90 Rotation By 180 Hole Made End Of Punching Operation Punch Shaft CCW Rotation By 180 End Of Punching Operation Punch Shaft At Rest Home Position Punch Shaft CCW Rotation By 90 Hole Made 7400 153 Theory of Operation 2 15 m 2 Hole 3 Hole Type To make two holes the punching operation for the first sheet ends when the punch shaft rotates 180 degrees half circumference and the Punch Home Position Sensor activates At this time the 3 hole punch rotates once on a half circumference of the punch shaft The punching operation for the second sheet ends when the punch shaft rotates 180 degrees counterclockwise and the Punch Home Position Sensor activates half circumference At this time the 3 hole punch then releases itself from the punch process on the other half circumference of the punch shaft Punch Shaft At Rest Punch Shaft CCW Punch Shaft CCW Home Position Rotation By 90 Rotation By 180 Punch At Upper Limit Punch Back To Initial Position s7400 154 Finisher Punch Transfer Operation The Finisher Punch Transfer Motor provides horizontal registration for the punch slide unit The F
199. sher Inverter Flash Memory Failure Applicable Status Code Code 225 Hardware failure with Inverter Flash Memory Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Inverter Control Board m Options Map 3 Inverter Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Inverter Control Board m Inverter Interface Cable m Inverter connections Is there any damage 2 Check the Inverter connection Go to Step 3 Connect the Is the Inverter interface cable securely Inverter to the connected at both ends Finisher 3 Check the connections at the Inverter Replace the Inverter Reconnect the Control Board Control Board connectors Are the connections secure page 5 55 General Troubleshooting 3 77 Tray 3 4 5 6 Lift Motor Failure Applicable Status Codes Code 911 The Tray 3 Lift Motor is not rotating Code 912 The Tray 4 Lift Motor is not rotating Code 913 The Tray 5 Lift Motor is not rotating Code 914 The Tray 6 Lift Motor is not rotating Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack Referenc
200. sition press the PSW1 or PSW2 switches on the Finisher Controller Board as necessary to move the folding position to the correct location Pressing the switch once moves the folding position about 0 16 mm mon m To move the folding position in the direction press PSW1 m To move the folding position in the direction press PSW2 m Pressing the PSW1 and PSW2 at the same time clears the adjustment value Adjustments and Calibrations 4 17 4 After adjusting the folding position set all bits of SW1 on the Finisher Controller Board to OFF this action will ensure that the switch will no longer affect the settings 5 Enter the booklet mode of the printer and check whether the folding position is adjusted properly If necessary repeat the procedure Adjusting the Phase of the Saddle Unit Gear If you replace or remove the gears at the front of the saddle unit or the paper fold rollers in the saddle unit adjust the gear phase using the following procedure 1 Position the paper fold rollers and saddle cam as shown below _ y a S A D Cam Paper Fold Rollers 400 213 4 18 Phaser 7400 Color Printer Options Service Manual 2 With the paper fold rollers and saddle cam positioned as shown in the proceeding figure mount gears as shown in the following figure Align the mark either one of the two marks on the saddle cam drive gear with the mark on the relay gear The relay gear is located on
201. ss Summary Sensors Motors Rollers Solenoids and Clutches Detecting Jams Power Supplies Section Options Operational Overview The Phaser 7400 Color Printer Options package consists of Finisher Punch Unit Provides various punch hole 2 3 and 4 hole options m Staple Unit Staples stacked paper for various media type and size m Saddle Unit Delivers and folds stacked paper m Inverter Physically inverts the paper for stacking or folding Print Options m 550 Sheet Feeder Represents one physical tray with 550 sheet output m 1650 Sheet Feeder Represents a 3 tray combined output of 1650 sheets Duplex Unit Provides printing for both sides of selected media 2 2 Phaser 7400 Color Printer Options Service Manual Finisher Overview The Finisher increases the output capacity of the printer by 1 000 sheets Printer output is directed to the Finisher by way of the side exit Depending on the job specifications as paper enters the Finisher it can be inverted punched stapled offset and stacked Power is supplied from the printer s AC Accessory Panel The Finisher consists of the following major assemblies m Punch Unit Provides various punch hole 2 3 and 4 hole options m Staple Unit Staples stacked paper for various media type and size m Saddle Unit Delivers and folds stacked paper m Inverter Physically inverts the paper for stacking or folding Paper Exit Tray Punch Unit
202. structions and loaded with the expected media m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Media Thickness Sensor m Print Engine Map 9 see Book 1 m Front Sensor Board m Print Engine Front Sensor Board 1 2 see Book 1 Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace the parts Go to Step 2 debris damage of misalignment concerned m Media Thickness Sensor m PATHICK Harness 2 Recalibrate the sensor See page 6 4 Complete Go to Step 3 Did the calibration pass 3 Check the PATHICK Harness continuity Go to Step 4 Replace the Is the harness conductive harness 4 Check for 5 V to the sensor Replace the Go to Step 5 Disconnect PATHICK at the Front Sensor sensor Recalibrate Board the sensor Is there 5 V across PATHICK 3 lt gt following ground replacement 5 Check for 5 V to the Front Sensor Board Replace the Front Go to Step 6 Disconnect FSNS at the Motor Driver Sensor Board see Board Book 1 Is there 5 V across FSNS 10 and 14 lt gt ground 6 Check the FSNS Harness continuity Replace the Motor Replace the FSNS Is the harness conductive Driver Board see Harness Book 1 General Troubleshooting 3 43 Paper Not Available Load Tray 3 4 5 6 with size type
203. t CN6 2 persists go to Step 6 6 Test the Shift Motor Clock Sensor Go to Step 8 Replace the Run the Shift Motor Clock Sensor test sensor Does the sensor function correctly T Test the sensor signal Replace the Replace the wiring Does the voltage change on CN15 5 when Finisher Control If the error persists the sensor is actuated Board page 5 46 replace the Engine Control Board page 8 112 3 32 Phaser 7400 Color Printer Options Service Manual Close Right Door C for Tray 3 4 5 6 The Door C Detect Sensor for one of the option trays indicates that Door C is open Initial Actions Ensure that the door is free of obstructions and fully closed Verify that the Detect Sensor Actuator molded into the Door is not damaged Cycle printer power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Door C m Door C Detect Sensor m Option Feeder Board Motor Driver Board Troubleshooting Procedure Table m Print Engine Map 3 page 10 6 m Options Map 5 Paper Tray Controller Board m Options Paper Tray Sensors and Interconnect Wiring Wiring and Plug Jack References Step Actions and Questions Yes No 1 Check the following for evidence of fault or Replace any Go to Step 2 damage damaged parts m Door C Detect Sensor Actuator m Door C Detect Sensor Holder m Door C Detect Sensor Is there any damage or misalignment 2 Test the D
204. t Motor Clock Sensor m Options Map 8 Finisher Sensor Locator 2 2 m Upper or Lower Limit Sensors m Options Finisher Controller to Sensors 2 3 m Lift Belts m Options Finisher Controller to Switches Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the following for evidence of fault Replace any Go to Step 2 damage obstruction or debris damaged parts m Upper Output Tray m Lift belts and actuators m Limit Sensors m Shift Motor Are there any defects or misalignment 2 Test the Limit Sensors Go to Step 4 Replace the Run the Service Diagnostics Tray Upper affected sensor If and Lower Limit Sensor tests the error persists Do the sensors function correctly go to Step 3 3 Test the sensor signals Replace the Replace the Does the voltage change on CN15 12 Finisher Control harness Upper and CN 15 9 Lower connector of Board page 5 46 the Finisher Control Board when the sensors are actuated 4 Test the Shift Motor Go to Step 4 Replace the motor Run the Service Diagnostics Shift Motor test Does the motor function correctly General Troubleshooting 3 31 Troubleshooting Procedure Table Continued Step Actions and Questions Yes No 5 Check for 24 V to the Shift Motor Replace the Shift Replace the Disconnect CN6 from the Finisher Control Motor page 5 59 Finisher Control Board Board If the error Is there 24 V CN6 1 lt g
205. t Sensor is mounted on a carrier located beneath the Registration Rollers near the clutch Caution Use care when removing the roller shaft bearings The bearings use a small clip to lock into a notch near the end of each roller shaft Use a small flat bladed screwdriver to release the clip from the shaft before attempting to remove the bearing Remove the Tray 2 Feeder page 5 136 Remove the Registration Clutch 2 page 5 140 Remove the 2 springs that tension the Registration Rollers Aa O N a Remove the bearings at each end of the rubber roller and then remove the roller Rubber Registration Roller Retainer Clip Tray 3 Feeder Assembly 7400 683 5 Release the hook that secures the sensor carrier to the feeder 6 Turn the sensor carrier over and then release the hooks that secure the sensor to the carrier 7 Disconnect the sensor connector P J41 Service Parts Disassembly 5 141 No Paper Sensor 1 Remove the Tray Feeder page 5 136 2 Remove 4 metal 23 mm screws that secure the brace Release the hook that secures the No Paper Sensor housing to the feeder 3 Turn the housing over and then release the hooks that secure the sensor to the housing Tray 3 No Paper Sensor Tray 3 Feeder Assembly s7400 684 4 Disconnect the sensor connector P J43 5 142 Phaser 7400 Color Printer Options Service Manual Registration Sensor 2 1 Remove the Tray Feeder page 5 136
206. t parts list 6 29 Staple Fold Drive Assembly parts diagram 6 14 Staple Fold Drive Assembly parts list 6 15 Stapler staple empty warning 3 88 stapler is empty 3 88 stapling front 1 point 2 23 middle 2 point 2 23 stapling position 4 17 stapling process 2 23 stop ring 5 35 T timing belt 4 14 5 35 Transfer Unit Entrance Sensor 2 37 Transfer Unit Motor 2 37 Transmission Sensor Units 5 28 Tray 24 V not available error 3 83 clear tray riser plate error 3 38 clock frequency error 3 86 firmware error 3 72 Index flash memory failure error 3 75 interface failure error 3 46 lift motor failure error 3 78 no paper warning 3 87 optional trays 1 6 2 11 out of paper error 3 39 Paper Exit Tray 5 7 unsupported ROM error 3 49 Tray Paper Sensor 2 21 troubleshooting diagnostic testing 3 2 error messages 3 6 measurement techniques 3 12 procedural instructions 3 11 U undocking 5 6 unit disassembly Punch Unit 5 24 Saddle Unit 5 36 Staple Fold Drive Unit 5 30 Stapler Unit 5 29 V voltage frequency ranges 1 7 input requirements 1 7 W warning messages 3 9 Waste Full LED Board removal 5 54 wrist strap 5 2 071 0876 00
207. t the end of the paper path the paper is then sent on to the Finisher Punching The Punch Unit is located in the pickup assembly of the Finisher It is designed to punch 2 holes 3 holes or 4 holes in sheets sent from the printer When the trailing edge of a sheet reaches the Punch Unit the inlet roller of the Finisher assembly stops the sheet long enough to punch a hole along the trailing edge of the sheet The Punch Unit is available in two unit types to accommodate the country of installation 2 and 3 hole punch Unit K1 or 4 hole Unit G1 or H1 The Punch Motor stops in relation to the count of the clock pulses from the Punch Motor Clock Sensor When the punch shaft rotates 180 degrees from its home position it initiates a single punching operation The 2 hole and 4 hole types punch a hole when the punch shaft rotates 180 degrees from the home position causing the punch to make a single rotation The 2 and 3 hole type punches a hole but the circumference of the punch shaft is divided into two one half for the 2 hole punch and one half for the 3 hole punch The Punch Motor Punch Unit and sensors comprise the Punch Slide Unit which moves to the front rear to accommodate the selected paper size The Finisher Punch Transfer Motor is a stepping motor that drives the movement to the front or rear 2 14 Phaser 7400 Color Printer Options Service Manual m 4 Hole Type The punching operation for the first sheet ends when the punch
208. tack feed rollers feed the paper stack to the stack folding and delivery position where the center of the stack stitched position is level with the paper pushing plate and paper folding roller d Folding Delivery The paper pushing plate pushes the center of the paper stack inward to feed it toward the paper fold rollers The paper fold rollers and bind delivery rollers then deliver the paper stack to the bind tray b Stitching a Paper Feed In gt 4 s7400 141 2 8 Phaser 7400 Color Printer Options Service Manual Paper Fold System The paper fold mechanism consists of a guide plate paper fold rollers and a paper pushing plate The Staple Fold Motor drives the guide plate paper fold rollers and paper pushing plate A combination of gears and cams transfer the drive force while the Staple Fold Motor Sensor monitors the operation Until the paper stack reaches the folding position the guide plate covers the paper fold rollers to act as a paper path through which the paper stack feeds into the Saddle Unit preventing the paper stack from touching the rollers A Folding Home Position Sensor detects the positions of the paper fold rollers and paper pushing plate The bind delivery rollers deliver and folds the paper stack with the paper fold rollers The Staple Fold Motor drives the bind delivery rollers A Bind Tray Sensor on the bind tray can then detect the presence of the paper stack fy Sensor Flag
209. te Go to Step 2 1 Close the Interlock Switches for test 2 Run the Service Diagnostics Finisher Bundle Motor tests Does the motor operate 2 Check for 24 V to the Exit Motor Replace the Exit Go to Step 3 Disconnect CN59 Motor page 5 64 Is the 24 V across CN59 1 and 2 lt gt ground 3 Check Finisher Control Board for 24 V Replace the Exit Replace the 1 Disconnect CN13 on the Finisher Motor Harness Finisher Control Control Board Board page 5 46 Is the 24 V across CN13 1 and 2 If the ene persists go to Step 4 4 Check the Inverter Interface Cable for Replace the Inverter Replace the cable continuity Power Supply Disconnect CN1 and CN2 from the Finisher page 5 56 Control Board and the opposite end from the Inverter Is the cable conductive 3 60 Phaser 7400 Color Printer Options Service Manual Finisher Punch Backup RAM Failure An error was detected in the Punch Unit s backup RAM Applicable Status Code Code F138 Punch Unit s backup RAM failure Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m Punch Control Board m Options Map 2 Punch Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Punch Control Board Go to Step 2 Reseat or connections reconnect the Are P J20
210. tep 3 Does the sensor operate 3 Test the Staple Motor Replace the Go to Step 4 1 Close the Interlock Switches for test Finisher Control 2 Run the Service Diagnostics Staple ie page 5 46 Motor tests If the error persists go to Step 4 Does the motor operate 4 Check for 24 V to the Staple Motor Replace the Stack Replace the Disconnect CN59 Handling Motor harness If the Is there 24 V across CN59 1 and 2 lt gt page 5 60 error persists go ground to Step 5 5 Check all pins of the Inverter Interface Replace the Inverter Replace the cable Cable for continuity Disconnect CN1 and CN2 from the Finisher Control Board and the opposite end from the Inverter Is the cable conductive Power Supply page 5 56 General Troubleshooting 3 55 Finisher Staple Motor Failure An error was detected in the Staple Motor Applicable Status Code Code F110 Staple Motor Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Finisher Staple Motor m Finisher Control Board Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 1 Finisher Controller Board m Options Finisher Controller to Switches Step Actions and Questions Yes No 1 Test these sensors Go to Step 2 Replace the m Staple Clock Sensor sensor If the error m Fold Home Position
211. that appear in the removal and replacement procedures may not match the names that appear in the Parts List For example a part called the Registration Chute Assembly in a removal procedure may appear on the Parts List as Assembly Chute REGI When working on a removal procedure ignore any prerequisite procedure for parts already removed Caution Many parts are secured by plastic tabs DO NOT over Flex or force these parts Do not over torque the screws threaded into plastic parts Always use the correct type and size screw Using the wrong screw can damage tapped holes Do not use excessive force to remove or install either a screw or a printer part Warning Unplug the AC power cord from the wall outlet before removing any printer part 5 2 Phaser 7400 Color Printer Options Service Manual Notations in the disassembly text m The notation item X points to a numbered callout in the illustration corresponding to the you disassembly procedure being performed m The notation PLX X X indicates that this component is listed in the FRU Parts List E Bold arrows in an illustration show direction of movement when removing or replacing a component Replacement Note Underneath the lower output tray are are three spare k clips of various sizes These clips are small and easy to lose Keep them in a location near your work area in case you need them Fastener Types The following table lists the primary types of Posi Dri
212. the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Remove the Punch Motor Assembly page 5 46 Remove the screw metal flange 6 mm oOo oa fF O N Remove the harness from the harness guide on the board and then detach the cover P Board Cover Bra IS SE gt fm BS KO Board Cover A 4 a Guide Harness Service Parts Disassembly 5 5 7 Disconnect the connector to remove the Photosensor Board Photosensor Board OD KX Connector s7400 264 5 52 Phaser 7400 Color Printer Options Service Manual Punch LED Board Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Remove the Waste Case Box Disconnect the connector Remove the harness from the harness guide Remove the metal screw metal flange 6 mm Remove the screw metal flange 6 mm to detach the base cover O ON OO FP WN Disconnect the connector to remove the Punch LED Board Connector ets S LED Board s7400 265 Service Parts Disassembly 5 53 Waste Full LED Board Remove the Rear Cover page 5 11 Remove the Front Door page 5 8 Remove the Upper Cover page 5 13 Remove the screw metal flange 6 mm oF O N Disconnect the connector to remove the board Waste Full LED Board 7400 268 5 54 Phaser 7400 Color Printer Opt
213. the Shift Lower Limit Sensor CN48 7 B 839 Connects to the Shift Clock Sensor Wiring Diagrams 7 5 Finisher Sensor Designators Continued P J Map Coord Remarks CN73 7 F 838 Connects to the Full Stack Sensor CN30 8 E 838 Connects to the Processing Tray Sensor CN23 7 C 838 Connects to the Aligning Plate Front Home Position Sensor CN36 8 E 836 Connects to the Aligning Plate Rear Home Position Sensor CN41 8 F 837 Connects to the Stack Feed Roller Home Position Sensor J2006 8 G 836 Connects to the Waste Full Sensor CN31 8 E 837 Connects to the Delivery Belt Home Position Sensor CN51 8 F 836 Connects to the Paddle Home Position Sensor SSS 7 F 836 Connects to the Stapler Safety Interlock Switch CN52 7 B 839 Connects to the Staple Fold Cock Sensor CN40 8 C 838 Connects to the Folding Home Position Sensor CN47 7 F 839 Connects to the Bind Tray Sensor CN39 8 G 838 Connects to the Folding Position Sensor Inverter Sensor Designator P J Map Coord Remarks P J13 9 H 837 Connects to the Inverter Docking Sensor SNSCN2 9 H 836 Connects to the Inverter Door Open Interlock Switch P J10 9 F 835 Connects to the Inverter Upper Paper Present Sensor P J12 9 G 839 Connects to the Inverter Lower Paper Present Sensor P J11 9 F 835 Connects to the Inverter Paper in Sensor 7 6 Phaser 7400 Color Printer Options Service Manual Map 1 Finisher Controller Board Locator Diagram LED3
214. ummary The following illustration shows the various printing processes and process decisions that the finishing components handle on command from the printer On Command from Printer wo i N Duplexer Processing Print Engine Finisher Y O Paper Inverted N Punch y Process epee ee ee ee ee ee ee ee fee ee ee ee ee ee eH HH as E 3 Hole es pop ae Booklet Seer Se Process _ Booklet i Folding Process N Staple Stack Booklet Stacking Process Process Rear Staple simple Stacking Front Staple ae Offset Stacking Exit Tray Bind Tray 7400 546 Theory of Operation 2 13 The finishing processes include six major functions 1 Inverting Folding Punching Stacking Stapling O a A W N Delivery Inverting The sole purpose of the inverter function is to position the paper for stacking or folding On command from the printer The Inverter receives paper from a printer or a Duplex Unit for inversion if needed and sent on to the Finisher The Inverter receives commands from the printer to receive and position entering media A Paper in sensor detects the presence of paper If the paper is not to be inverted it merely transfers to the Finisher If the paper is to be inverted or prepared for stacking or folding a solenoid is energized to divert the paper into the inversion path Sensors in the upper and lower paper paths detect the leading and trailing edges of the selected media A
215. un the Service Diagnostics Level Sensor Sensor If the error test for the appropriate tray persists go to Does the sensor function correctly Step 4 3 Test the Lift Motor Go to Step 4 Replace the Lift Run the Service Diagnostics Lift Motor test Motor If the error for the appropriate tray persists go to Does the motor function correctly Step 4 4 Check for 24 V to the Lift Motor Go to Step 5 Replace the Option Is there 24 V across GDDC 1 lt gt Control Board ground 5 Test the OPTIF Harness continuity Replace the Engine Replace the Is the OPTIF Harness conductive Control Board see harness Book 1 3 38 Phaser 7400 Color Printer Options Service Manual Out of Paper Load Tray 2 3 4 5 6 with size type The tray s No Paper Sensor indicates the tray is empty Initial Actions m Inspect the tray to ensure that it is free of obstructions is loaded with supported media and the guides are adjusted correctly m Cycle printer power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m No Paper Sensor m No Paper Actuator Troubleshooting Procedure Table Wiring and Plug Jack References Print Engine Map 12 see Book 1 Print Engine Feeder Board see Book 1 Options Map 5 Paper Tray Controller Board Options Map 6 Paper Tray Feeder Board Options Paper Tray Motors and Clutches Step Actions and Questions Yes No 1 Check the followi
216. ust from the printer m Use only an approved toner vacuum Clean all rubber rollers with a lint free cloth dampened slightly with cold water Inspect the interior of the printer for damaged wires loose connections toner leakage and damaged or obviously worn parts Replace damaged or empty Toner Cartridges with new customer supplied ones Step 3 Find the Cause of the Problem 1 Use the troubleshooting procedures to find the cause of the problem Use Service Diagnostics to check printer and optional components Use the wiring diagrams and plug jack locator to locate test points Take voltage readings at various test points as instructed in the appropriate oF W PY Read and understand the theory of how the printer operates troubleshooting procedure Use the Test Prints described on page 5 4 to isolate problems to the Engine or the Image Processor Board Step 4 Correct the Problem il 2 Use the Parts List to locate a part number Use the Disassembly Procedures to replace the part Step 5 Final Check Test the printer to be sure you have corrected the initial problem and verify there are no additional problems present General Troubleshooting 3 3 Jam Locator The following illustrates the Door designators that key the jam location error codes and messages Refer to this diagram when questions arise regarding the area of the jam OD s7400 696 3 4 Phaser 740
217. ve screws used to assemble the printer The procedures provide dimensional specifications for screws being removed Posi Drive Screw Types used in the Printer Type Application Shape Characteristics Self tapping 1 Black colored plastic 2 Screw thread is coarse compared to metal screw Yj Coarse p cas 3 Screw tip is thin Parts etc Plastic Sheet Metal 1 Silver colored silver 2 Diameter is uniform 3 Typically 6 mm in length Parts etc Sheet metal Sheet Metal 1 Silver colored with flange 2 It has a flange 3 Diameter is uniform Parts etc Sheet metal Caution Use care when installing self tapping screws in plastic To properly start the screw in plastic turn the screw counter clockwise in the hole until you feel the screw engage the threads and then tighten as usual Failure to properly align or over tighten the screw can result in damage to previously tapped threads Service Parts Disassembly 5 3 Standard Orientation When needed the orientation of the option is called out in the procedure for locating parts refer to the orientation graphic for locating the right left front and back sides of the printer 7400 339 5 4 Phaser 7400 Color Printer Options Service Manual Finisher Disassembly The Finisher disassembly is presented in the following categories E Base Unit and Inverter m Tray and Covers m Subassemblies m Field Replaceable Units Removing Inverter Base Unit fro
218. vels from the printer CN3 1 1 834 Connects to the front and rear alignment motor signals CN4 1 K 836 Connects to front door Door J upper cover Door H and home position sensors CN5 1 K 838 Connects to rear home position tray paper delivery belt position and processing tray sensors CN6 1 D 834 Connects to the Lift Motor and the staple fold motor CN7 1 K 835 Supplies required voltages for the Stapler unit CN8 1 B 834 Connects to the Stapler Safety Front Door Door J and Joint switches CN9 1 H 841 Connects to swing guide home position staple fold clock and paddle home position sensors CN10 1 F 834 Connects to the paddle motor and feed motor signals CN11 1 J 841 Receives detect signals from the Stapler unit CN12 1 A 838 Supplies required signals for 1 2 of the punch unit optional CN13 1 J 834 Connects to the delivery motor signals CN14 1 A 836 Supplies required signals for 1 2 of the punch unit optional CN15 1 K 838 Connects to shift limit Lift Motor clock and bind tray sensors CN16 1 A 840 Connects to Inlet stack feed roller folding home position and folding position sensors 7 2 Phaser 7400 Color Printer Options Service Manual Finisher Plug Jack Designators Continued P J Map Coord Remarks CN17 1 A 841 Connects to signal ground transmit and receive data DSR and DTR signals and reset CN18 1 E 834 Supplies 24 volts to the
219. ver 5 19 Inverter Top Cover 5 23 Paper Tray Covers 5 134 Processing Tray Upper Cover 5 15 D delivery Delivery Belt Home Position Sensor 2 24 Delivery Motor 2 24 delivery process 2 24 Tray 2 24 Index disconnecting base unit 5 5 Door C jam error 3 13 open error 3 33 Door D jam error 3 16 open error 3 34 door designators 3 4 Door C Detect Door C Sensor 5 141 Door C Paper Tray 3 thru 6 Detect Sensor 2 32 Door F Inverter Door Open Interlock Switch 5 101 Door F Inverter Left Side Door 5 21 Door F Inverter Open Interlock Switch 2 30 7 6 Door G Finisher Right Side Door 5 10 Door H Upper Cover Sensor 2 28 7 5 Door I Inverter Right Side Door 5 22 Door J Finisher Front Door 5 8 Door J Front Door Switch 2 28 7 5 Door J Front Door Switch and Sensor 5 74 Door F open error 3 35 Door G jam error 3 26 Door H jam error 3 21 open error 3 36 Door J open error 3 37 Duplex Fan fan failure error 3 80 removal 5 131 Duplex Unit 1 6 24 V not available error 3 81 clock frequency error 3 84 close Door D error 3 34 Connector removal 5 132 Cover Plate removal 5 124 Duplex Entrance Roller 2 36 Duplex Solenoid 2 36 Index entrance jam error 3 18 Entrance Sensor 2 31 fan failure error 3 80 Fan removal 5 131 firmware error 3 73 flash memory failure error 3 76 front and rear duplex sensors 2 31 interface failure error 3 45 jam error 3 16 motor and solenoid wi
220. ver to Clear 3 18 FN1 Jam at Finisher Punch Unit Open Door H to Clear 3 20 FN2 Jam at Finisher Door H Open Door H to Clear 3 21 FN4 Jam at Finisher Upper Output Tray Remove paper from Finisher 3 22 FN5 Jam at Finisher Saddle Stapler Open Door G to Clear 3 23 FN6 Jam at Finisher Upper Output Tray Open Door H to Clear 3 24 FN7 Jam at Finisher Stapler Open Door G to Clear 3 25 FN8 Jam at Finisher Door G Open Door G to Clear 3 26 FN9 Jam at Finisher Saddle Stapler Open Door G to Clear 3 27 FN10 Jam at Finisher Upper Output Tray Remove paper from Finisher Output 3 28 IN1 IN4 Jam Inside Finisher Open Door F and Door to Clear 3 29 IN6 IN7 IN5 IN8 Jam at Finisher Entrance Separate Finisher Base from Printer 3 30 FT Finisher Output Tray Jammed Remove Obstruction to Clear 3 31 Door and Cover Errors Close Right Door C for Tray 3 4 5 6 3 33 3 6 Phaser 7400 Color Printer Options Service Manual Error Control Panel Message Page a Close Door D Close Finisher Door F Close Finisher Door H Close Finisher Door J Tray and Media Errors Clear Tray 8 4 5 6 Riser Plate Out of Paper Load Tray 8 4 5 6 with size type Finisher Lower Output Tray is Full Unload Paper Finisher Upper Output Tray is Full Unload Paper Remove Paper from Tray 2 3 4 5 6 Media Mismatch Errors Wrong Paper Size Load Tray 3 4 5 6 with size type Paper Not Available Load Tray 3 4 5 6 with size type General Troubleshooting 3 34 3
221. wer m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Punch Box Sensor Emitter Board m Punch Box Sensor Receiver Board m Punch Box Sensor Harness Troubleshooting Procedure Table Wiring and Plug Jack References m Options Map 2 Punch Controller Board m Options Punch Controller to Sensors Step Actions and Questions Yes No 1 Test the Punch Box Set Sensor Go to Step 6 Go to Step 2 Run the Service Diagnostics Punch Box Set Sensor test Does the sensor state change when the emitter is blocked 2 Check the Punch Box Sensor Harness Go to Step 3 Connect the connections harness Is P J1005 connected to the Punch Control Board Are P J2005 and P J2006 connected to the Emitter and Receiver boards 3 Check the Punch Box Sensor Harness Go to Step 5 Replace the continuity harness Is the harness conductive 4 Check the Punch Box Sensor Emitter Go to Step 5 Replace the Board Punch Box Is the LED illuminated Sensor Emitter Board 5 Check for 5 V to the Punch Box Sensor Replace the Replace the Disconnect P J2006 Punch Box Sensor Punch Control Is there 5 V across J2006 1 lt gt Receiver Board Board J2006 2 page 5 50 6 Replace the Finisher Control Board Replace Engine Complete page 5 46 Does the error still occur General Troubleshooting Control Board see Book 1 3 89 Finisher Away From Base The Finisher Sw
222. wo plugs and replace the connector a Options Connector Jo 7400 509 Service Parts Disassembly 5 133 Tray Covers and Tray Door Door C Note If optional trays are installed either remove the printer from the optional tray s or lift the right hand side of the printer to provide sufficient clearance to remove 4 screws and pull the Tray Feeder from the frame To remove or replace any of the clutches motors or sensors you must first remove either or both the Rear Cover and the Right Side Cover and in some cases you will need to remove the tray itself on the front of the unit or open the Tray door Door C To replace the Rear Cover or the Right Side Cover 1 Remove five screws metal flange 6 mm fastening each plastic cover to the chassis frame 2 With a screwdriver press down inside of the tab slots to pop the plastic cover away from the frame Lower Rear Cover eo T Tab Slot 57400 525 3 On some disassembly of sensors or diagnostic testing you may need to open the Tray Door Door C 5 134 Phaser 7400 Color Printer Options Service Manual 4 To locate and open Door C see the following illustration 7400 717 Door C ci V F LGV 7 5 135 Service Parts Disassembly Tray Feeder 1 Remove Tray 2 2 Remove the Right Side Cover and Rear Cover page 5 134 3 Remove the paper tray 4 Remove 12 metal 10 and 6 mm screws to remove the Tray 2 Feeder
223. y OPTRY24 Disconnect the OPTRY24 Harness Harness Is the OPTRY24 Harness conductive 6 Check for 24 V from the LVPS Replace the Motor Go to Step 7 Disconnect POW24 Driver Board see Is there 24 V at POW24 1 lt gt ground Book 1 T Check the LVPS 24 V output Replace the Engine Replace the LVPS 1 Close the Interlock Switches 2 Disconnect CN2 Is there 24 V at CN2 1 and lt gt ground Control Board see Book 1 see Book 1 General Troubleshooting 3 79 Duplex Unit Fan Failure The Duplex Fan rotation signal indicates the Duplex Fan has stopped rotating Applicable Status Code Code 918 The Duplex Fan has failed Initial Actions m Cycle the printer s power If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Duplex Unit Fan m Duplex Unit Control Board m Duplex Unit m Print Engine Map 5 see Book 1 m Print Engine Motor Driver Board 5 6 see Book 1 m Options Map 4 Duplex Unit Controller Board Wiring and Plug Jack References m Options Duplex Unit Motors and Solenoid Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Duplex Unit connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Test the Duplex Unit Fan Go to Step 3 Replace the Run the Service Diagnostics Duplex Fan Duplex Unit test page 5 122 Ifthe Does the Fan
224. y 6 Feeder Board CPU clock frequency is inaccurate Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts m Option Feeder Board m Engine Control Board PL1 1 4 m Print Engine Map 3 see Book 1 m Print Engine Motor Driver Board 6 6 see Book 1 Wiring and Plug Jack References m Options Map 5 Paper Tray Controller Board Troubleshooting Procedure Table Step Actions and Questions Yes No 1 Check the Option Tray connector for Replace the Go to Step 2 damage connector Is the connector damaged 2 Check all pins on the OPTIF Harness for Replace the Option Replace the continuity Disconnect OPTIF from the Engine Control Board and Option connector Is the harness conductive Feeder Board If the error persists replace the Engine Control Board see Book 1 OPTIF Harness 3 86 Phaser 7400 Color Printer Options Service Manual No Paper in Tray 2 3 4 5 6 The No Paper Sensor indicates that the named tray is empty Initial Actions m Cycle the printer s power m If the problem persists follow the procedure below Troubleshooting Reference Table Applicable Parts Wiring and Plug Jack References m No Paper Sensor m No Paper Actuator m Print Engine Map 12 see Book 1 m Print Engine Feeder Board see Book 1 m Options Map 5 Paper Tray Controller Board m Options Map 6 Paper

Phaser 7400 Color Printer Options Service Manual

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