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Service Manual Phaser® 7700

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1. K T T OG SLUSE STN Hila Yo L90k NLGAS Gea _ C6tor OIA 96 IVF TVSO9d a30 egar ABLE FEOF in a ei E Tia 92 1901 UNSHaDda 6694S 2 leer Tak SG 1801 VS09d 919 2430 SEE AWS 97 1901 NDILNIAS 8 et Pasesr nya se or Agia EERAn 4 2669r Rao se 1901 vso9d lt 2 450 6esr OIA 92 1901 UND Kee OIA 92 1901 AND Ch 6 94 D 94 ITST OIA 92 1901 NISAS 8 a b m E e eg SLITT 13A 92 1901 A SOSNFGT Se Leer AUD 92 1901 AS g Sl DIE ETT ST OIA 92 1901 NIYAS 4 Se Kess TaA 92 1901 MISOSN GT 8 SC VOTTST AUD Ge 1901 Act 8 FF ease OIA 92 T90T NIGAS a DE st aoe TOOT GE l 789 57 ELF TA SG OJSOSN UT 6 MECE nia 92 1901 EC H ff eren aA 92 1 LOFTET kD 92 1901 AS 8 El gsesr Mma 92 1901 NIBAS jezod E L2 seer OI 9e I ETT Sr OIA 92 1901 NIUAS 4 S EZI SLUTTET Tax 94 1901 WSOSN GT 4 Zz Leer AD 92 1901 Ar S 4 Race TSA 92 1901 AINODGSGT S m Keren 13492 1901 WINODOdS AT 9 S D na 92 TOOT AGF L 1 zt gt TTIF US vo LINN ezer TSA OJINOOd AT by na 92 1901 DRESCH gece REIWEN S7oesr TSA 92 ont INOOdSAT GL O PT gt nia 92 1901 amp 194 ITOT OIA ba 22 HISVT RE zor TSA 92 1901 anssal Viopr 9 O ma oz 1501 aer al 789 Po r TSA 92 E m g lt casesr ia 92 1901
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3. 1 116 1080 00 1 Lower Tray Deck LTD 2 116 1079 00 1 High Capacity Feeder HCF 3 116 1184 00 1 Lower Tray Deck LTD cover LH Cover Assembly LH 3 4 116 1185 00 1 Han eee feeder HCF cover LH Cover Assembly 5 116 1091 00 1 Universal Paper Tray 6 116 1090 00 1 High capacity Feeder Tray 3 7 116 1089 00 1 High capacity Feeder Tray 4 Phaser 7700 Color Laser Printer Service Manual 8 273 PL 8 23 Lower Tray Deck LTD FRUs Zen Male ad BCEE 57700 107 Figure 8 23 Lower Tray Deck LTD FRUs Phaser 7700 Color Laser Printer Service Manual 8 274 Table 8 23 Lower Tray Deck LTD FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1100 00 1 Aux Feeder Motor Assembly Motor Assembly 3TM 2 116 1219 00 1 LTD Control Board PWB Assembly 3TM 3 116 1206 00 2 Caster Locking 4 116 1221 00 2 Caster 5 116 1126 00 1 Switch Assy Paper Select Tray 2 3 Paper Size 110K12990 Switch also 4 5 on LTA Phaser 7760 compatible Phaser 7700 Color Laser Printer Service Manual 8 275 PL 8 24 Lower Tray Deck LTD FRUs cont d 7700 459 Figure 8 24 Lower Tray Deck LTD FRUs cont d Table 8 24 Lower Tray Deck LTD FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1167 00 1 Chute Lower 2 116 1160 00 1 Feed Assembly Paper 8 276 Pha
4. 7700 031 Figure 7 20 Fuser Unit Removal 1 Open the Left hand Door Caution The Fuser Unit may be hot 2 Unscrew the two thumb screws securing the Fuser Unit 3 Using the pull handles pull the Fuser Unit out of the printer 7 174 Phaser 7700 Color Laser Printer Service Manual RRP 20 Registration Transport Assembly 7700 126 Figure 7 21 Registration Transport Assembly Note Turn the printer power Off and unplug the power cord Removal 1 Partially remove the MPT 2 Remove the two screws from the plastic flanges that secure the assembly in the printer frame using a stubby screwdriver Caution Note the wiring harness routing in the above figure Make certain the wires are routed behind the black plastic cover on the Registration Transport Assembly 3 Disconnect the wiring harness 4 Remove the registration transport assembly Phaser 7700 Color Laser Printer Service Manual 7 175 RRP 21 Shutter Solenoid Assembly 7700 183 Figure 7 22 Shutter Solenoid Assembly Removal 1 Partially remove the MPT RRP 12 on page 7 166 2 Partially remove the Left Hand Cover Assembly Left Door RRP 14 on page 7 168 3 Remove the Registration Transport Assembly RRP 20 on page 7 175 Note Note the wiring 4 For easier access remove the Duplex Chute RRP 15 on page 7 170 5 Disconnect the wiring harness from the front frame connector 6 Note the locating pin then loosen the one scr
5. s7700 564 Figure 7 65 Tension Spring Location 4 Align the triangle marks on the Gears and the Rack by lifting the Gear Assemblies on their mounting posts until they disengage from the rack and rotating them until the triangles align Reseat the Gear fully on its post s7700 565 Figure 7 66 Front and Rear Gears Aligned 7 224 Phaser 7700 Color Laser Printer Service Manual RRP 56 Auxiliary Feeder Covers Figure 7 67 Auxiliary Feeder Covers Left Side Door 1 Remove the four screws securing the left hand outer cover and remove 2 Remove the screws securing the straps 3 Remove the one screw holding the front side pivot bracket and remove the left hand door Rear Cover 1 Remove the four screws securing the cover 2 Remove the Rear Cover Phaser 7700 Color Laser Printer Service Manual 7 225 RRP 57 Auxiliary Feeder Cover Assembly LH Cover SE E 9 Interlock Switch RH Pivot Bracket 7700 105 Figure 7 68 High Capacity Feeder HCF Cover Assembly Removal 1 Open the High Capacity Feeder HCF Cover Assembly 2 Remove one screw from each of the support straps 3 Remove one screw from the cover s right hand pivot bracket 4 Remove the cover assembly from the left hand pivot 7 226 Phaser 7700 Color Laser Printer Service Manual RRP 58 High Capacity Feeder HCF Tray 3 Tray 3 Stopper Bracket lt 87700 210 Figure 7 69 High Capacity Feeder
6. Code Fink Front Panel Message 30 04 346 ERROR 30 Accumulator Belt HOME POSITION TOOK TOO LONG Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the NVRAM Access Clear Tech Rep Fault Clear lt 04 346 gt is run Ensure the Accumulator Belt shipping restraints have been removed Enter Service Diagnostics Mode Service Diagnostics on page 2 35 Run the Clear Tech Rep Fault procedure on page 6 149 Lower the Main Release Lever and return to the upright position to reestablish electrical connections to the belt Open the RH Door and defeat the interlock switch Look for rotation of the Accumulator Belt during the following test Enter Adjustments Calibrations menu Run the Belt Edge Learn test Did the Accumulator Belt rotate Yes No Remove the Accumulator Belt Assembly RRP 35 on page 7 196 CautionRemoving the Accumulator Belt Assembly allows ambient light into the print cartridge area Avoid exposing the print cartridge drums to light Manually rotate clockwise the drive gear of the Accumulator Belt Assembly Does it move freely Yes No Inspect the Accumulator Belt Cleaner Waste Auger for packed toner Is the area inside the auger relatively clear of toner Yes No Notelt is easy to spill toner in the next step Remove the Waste Toner Cartridge Run the Agitator Motor Test Does the Waste Toner Agitator Motor rotate Yes N
7. 1 From the Service Diagnostics menu highlight the Adjustments Calibration menu and press OK 2 Highlight Regi Con 685 Setup Cycle and press OK 3 At the prompt Which DC685 procedure highlight 1 Fine Skew Setup and press OK The front panel now displays lt PostScript will do 685 1 gt 4 The printer now reboots and runs the test Wait for approximately 10 seconds after the motors turn off and the display indicates Ready To Print then cycle power and enter Service Diagnostics Enter Adjustments Calibration gt Regi Con 685 Results and press OK Wait until the test results are displayed as follows oo DC685 1 Passed A Out Blocks 24 B Out Blocks 4 lt Press Ok for more Data gt Note If the block counts are not the same number as presented here the printer has a print quality problem Please refer to section Streaks in Direction of Paper Travel on page 3 111 to resolve the print quality problems before proceeding further with RegiCon 7 Press OK to see the second panel data If an adjustment is needed adjust by the smounts displayed on the front panel Be sure to tap the screw that was adjusted with a heavy screwdriver to ensure that the adjustment remains true Skew Corr Y 7 clicks CCW Skew Corr M 7 clicks CW Skew Corr C 5 clicks CCW Skew Corr K 12 clicks CCW If the Belt Edge Learn procedure fails see If RegiCon Coarse Skew Fails on page 4 136 Phaser 7
8. Sensor trn full 130E91010 Sensor Assembly Edge A 130K60830 Sensor Assembly 130K60851 Sensor Assembly ATC 130K61281 Sensor Assembly T A 130K61510 116 1300 00 ARRWWAARWNY Hardware Screw 26E17890 Screw 113W20657 Screw 153W17855 Screw 158W27655 Screw 158W27663 Screw 158W27855 Screw 158W27863 e clip 354W21251 065 0592 00 Repackaging Kit 065 0601 00 Internal Repackaging Kit 8 282 Phaser 7700 Color Laser Printer Service Manual Manual Packs amp Service Manual Table 8 31 Manual Packs amp Service Manual Part Number Qty Name and Description 061 4413 00 1 Manual Pack English 061 4414 00 1 Manual Pack French 061 4415 00 1 Manual Pack Spanish 061 4416 00 1 Manual Pack Brazilian Portuguese 061 4430 00 1 Manual Pack Italian 061 4431 00 1 Manual Pack German 061 4432 00 1 Manual Pack Simplified Chinese 061 4433 00 1 Manual Pack Traditional Chinese 061 4434 00 1 Manual Pack Russian 061 4435 00 1 Manual Pack Dutch 061 4436 00 1 Manual Pack Swedish 061 4437 00 1 Manual Pack Danish 061 4438 00 1 Manual Pack Norwegian 061 4439 00 1 Manual Pack Finnish 061 4440 00 1 Manual Pack Czech 061 4441 00 1 Manual Pack Hungarian 061 4442 00 1 Manual Pack Polish 061 4444 00 1 Manual Pack Korean 061 4445 00 1 Manual Pack International English 061 4448 00 1 Manual Pack Japanese 071 0860 00 1 Pha
9. Exit Exits to PostScript without running POST Phaser 7700 Color Laser Printer Service Manual 2 45 Error Codes and Messages Troubleshooting Some Error Codes create Tech Rep Faults which must be cleared see Clear Tech Rep Faults on page 6 149 Voltage Measurements Many voltage measurements are required for expeditious troubleshooting The following illustration is provided at this location for your convenience in locating most of the connectors pins from which voltage measurements are taken Cross references links are provided A13 Al A15 Al A8 Al A15 Al P404 P407 P405 P406 P408 P411 P409 B1 B13 B1 B15 B1 B8 B1 B15 1 S 1 B20 P401 TE Gan Al A20 B20 Bi Bi B14 B1 B15 A1 A15 87700 428 Figure 2 1 Voltage Measurement Point Locations 2 46 Phaser 7700 Color Laser Printer Service Manual Fuser Connector Pin Locations RN Fig2 2 Fuser Connector Pin Locations 87700 427 Phaser 7700 Color Laser Printer Service Manual 2 47 Error Chain Code Link Front Panel Message 10 06 380 ERROR 10 LASER UNIT FAILURE 06 381 06 382 06 383 06 385 Warning Do not operate the Laser Unit outside the printer The invisible light from the laser can cause permanent eye damage Remove Rear Cover RRP 1 on page 7 154 Discon
10. mererererrsrersvonrsvvvevevernsvenerennen Resetting All Printer Default Settings NVRAM ssssssssssessissessersresrssrneeren Resetting Engine NVRAM ererrrrrrvrsrsvrsrsvrsrsvvsrsnrsrenvsrenvsrenrsrsnesrensrsesrenesrssenenne Resetting Job Defaults osnorrrnorrrrorrrrerrrvrrrsnrnnnennnrsrsnrsrs aia Resetting Network Setup Values to Default srororonererrrvororeresvsrsvereresvevener Resetting Accumulator Belt Life s oerrrrrrnrrrrrrrrnrrvrnrrsrnrrsrnersrnennrnennrnrnnnne Resetting Belt Cleaner Assembly fe Resetting Transfer Roller Life 0 0 cc ccseccseeecsseecseeecseeecseseeessetessesesaseeseees Service Diagnostics NVRAM Resets ccccccssscssssesescsstecessesesecessssesesececesseecnees PostScript NVRAM Reset cccccscsescsscecscseececscsesesesececscsesecesessesesesasaeseees Clear Tech Rep Faults c cccccccccscsesccscsesescsscscscsesssesessesesesacssecsusesesasseeeeaees Reset CRU Life Counters meveseeeevmnmeevmeeemmmeemeieene Reset Engine NV RAM eelerer Store Engine NVRAM ersrerrvonrsvsvovorerosvsvereresvsvsvenerenvsvereresssvenevesesvsnenerensssenene Phaser 7700 Color Laser Printer Service Manual Removal and Replacement Procedures 7 151 Xvi Rear Cover Assembly 7 154 Right Side Cover Assembly c cescscscsesscscsesecssscsescsesececscsesececsesesesaeass 7 155 Top Kale UE 7 156 Front Panel ASsembly E 7 157 Rear Cover Top Rear Power Switch Cover and LH Rear Mid Cove
11. oon a Generate a 100 Solid Fill Test print from the front panel Is the test print blank Open the door in the middle of the print job Is there toner on the print unit and or Accumulator Belt Cycle the printer power Using the Service Diagnostics Test Menu Functions beginning on page 2 35 test the shutter solenoid to ensure it opens and closes correctly Remove a print cartridge and see the shutter open and close Inspect the wiring harness for loose or disconnected wiring connectors check connectors P400 and P401 at the Engine Control Board Replace the High voltage Power Supply RRP 44 on page 7 208 Replace the Image Processor Board RRP 39 on page 7 202 Replace the Engine Control Board RRP 42 on page 7 206 3 108 Phaser 7700 Color Laser Printer Service Manual One Color is Faded or Missing 3041 39 1 Is the Toner Low Message being displayed on the front panel Under high toner coverage conditions toner may be depleted during the toner low state but before the toner out message is displayed 2 Ensure that the loaded media matches the front panel settings 3 Run the Calibrate for Paper routine From the Front Panel s Support ene select Improve Print Quality then select Calibrate for Paper enu Note Check the transfer setting before running calibrate paper If the value is 4 you need to adjust the transfer settings 4 Swap the print unit of the bad color with th
12. page 4 130 Belt Edge Learn Refer to Processes of the RegiCon Adjustment on page 4 127 Phaser 7700 Color Laser Printer Service Manual 2 43 Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition RegiCon 685 Setup Refer to Processes of the RegiCon Cycle Adjustment on page 4 127 RegiCon Results Display Refer to Processes of the RegiCon Adjustment on page 4 127 ATC Sensor Setup Refer to ATC Sensor Setup on page 4 142 TRC Adjust Engineering use only ADC Output Check Measuring This tests the Automatic Density Result 0 Correction sensor The highlighted Stop Status 0 ADC Sensor Fail 0 ADC shutter Fail 0 line indicates test results Tone Up Down Measuring Result 0 Status 0 ATC Sensor Fail None ATC Limit Warn None ATC Change Warn None This tests the Automatic Toner Calibration sensor The highlighted line indicates test results Y OK M OK C OK K OK YMCK OK YMCK CycUp OK Laser Power Check This tests the laser output PWM Mapping Data Read Engineering use only Coarse RegiCon Init Refer to Coarse RegiCon Initialization on page 4 140 Maintenance Engine maintenance functions Clean Fuser Fuser Cleaning Sheets Runs five clean sheets through the fuser Clean Accumulator Note To avoid damage to belt Belt disengage Do you wish to c
13. 1 2 3 8 9 Remove the Rear Cover Assembly RRP 1 on page 7 154 Remove the Right Cover Assembly RRP 2 on page 7 155 Remove the 3 3 VDC and 5 VDC Low voltage Power Supply Bracket Assembly RRP 45 on page 7 210 4 Remove the 24 VDC Low voltage Power Supply RRP 47 on page 7 212 5 Remove the T2 High voltage Power Supply RRP 48 on page 7 213 6 7 Remove the two screws securing the finisher connector now accessible Disconnect the wiring harness to the Print Engine Drive Assembly after removing the Right Cover Assembly and let it hang loose Remove the screw that is accessible through the frame access hole near the finisher connector now accessible after removing the Right Cover Assembly Remove the remaining seven screws that secure the Print Cartridge Drive Assembly to the printer frame 10 Lift the Print Cartridge Drive Assembly up and out of the printer Phaser 7700 Color Laser Printer Service Manual 7 219 RRP 54 Tray 1 Paper Select Switches 87700 442 Figure 7 60 Tray 1 Paper Select Switches 1 Remove the T1 and T3 high voltage power supply RRP 44 on page 7 208 1 Remove the 3 3 VDC and 5 VDC low voltage power supply RRP 45 on page 7 210 Disconnect the wiring harness from the tray 1 paper select switches 3 Remove the two screws that secure the mounting bracket to the printer frame and remove the switch N 7 220 Phaser 7700 Color Laser Printer Service Manua
14. Caution Before removing the Electrical Chassis Assembly it is recommended to store Engine NVRAM data on the Hard Drive see Store Engine NVRAM on page 6 150 Remove the Right Cover RRP 1 on page 7 154 Remove the Top Cover RRP 3 on page 7 156 Remove the Rear Cover RRP 5 on page 7 158 Remove all three Shields RRP 10 on page 7 164 Remove the Image Processor Board RRP 39 on page 7 202 Disconnect the nine wiring harnesses along the edges of the engine controller board Seven of these harnesses are in front of the controller board The other two are on the left side our GO b i ch Note Two of the engine control connectors have connector locks There is one harness clip to release 7 204 Phaser 7700 Color Laser Printer Service Manual 7 Undo the harness retainer Disconnect the wiring harness to the relay board connector P300 and the front panel cable to P564 8 Remove the two mounting screws towards printer rear but only loosen the two mounting screws towards the printer front Note The two screws toward the printer front serve as a guide for reinstallation 9 Lift and tilt the cage assembly to release it from the engine control interface board connector below the cage assembly and remove the assembly Replacement Note Before re installing the assembly widen the gap in each of the two white nylon retainers to ensure that they successfully engage the interface board bracket Mis alignment pre
15. JOSAVMVSMVLVPEST 19 AVMV IMVL t 2 Teer NEO ST TOT AEF vres L cn ol LESd 2 1 Leed o m D T vesd D gt O m DD O gt H HEN NIA 92 eZ20r DINOSTI G 3 EEER Kaes aver ezer Herd 9774 9 L z JELE nia oe GE OINOSIH ezzr E Seed S7aTest NYO ou ZZe0r Aver eeen 2 seed secu t ares DR 9e e2c0l W NO 13 ezzr p 22 beed e gtlesr NHO 90 cLOL Ave ezzr l peed F cH REEL iS teed L gtlesr NHO 92 TLL Ave ezzr ced eee OG SFT EST Aud Se add AST Toads 25557 6L SVT EST OI Ge eL OL NIMAS 809d9 Ierger DL oviesr 80849 Le09r deyi eer 80949 8091 8 QVTeST TSA Ge endt veunsmXsON 809d9 9Lg09r SI oviesr 80849 2900 Pi Qviesr 80949 Le091 ELVES BE It aeuNSWXSON 809d gt Leoaer 2 Syreer daa Ge endr Nosvedsidom 809d9 beren LL Arer 13A 92 2220 NOSHZA31H0N 809 R a ge ER OLYE Abd Sa SEH ASF 80949 H 028097 SQVYTest Olm 92 elddt NLUAS 80949 1 28091 8oviesr 80949 8 goa 4oviesr 80949 e091 9 VLEST DA O GL OL VI UNSHXEON 809d st 9 8091 SQViesr 80949 goa vb oviesr oap 4 a00r fevresr 1A de ele0l AlUNSHIXGON 80949 Keren z VLEST aA 92 Gin NOSVWLGS 1980N 809d e z se oof VYTEST Tax Ge eleor_NoSardaTaow 8094S 8097 8094 ane er El 2a0858r nl se 1901 SNSIONIE el eagoesr nl se 1901 WNSLOWLAI ee OES NYO 1901 GAINDEVNODSIO Ol Zeng
16. Q PQ 7700 385 Figure 1 5 Auxiliary Feeder Control Board Phaser 7700 Color Laser Printer Service Manual 1 9 Print Engine Sensors and Switches Transfer Roller Sensor Tray 1 Take Away Sensor Transparency Sensor Registration Sensor Paper On Belt Sensor MPT No Paper Sensor Tray 1 No Paper Sensor Level Sensor MPT Paper Size Sensor 87700 287 Figure 1 6 Print Engine Sensors and Switches 1 10 Phaser 7700 Color Laser Printer Service Manual Print Engine Sensors and Switches cont d Environment Sensor Automatic Density Control Sensor Duplex Wait Sensor Kar Mark On Belt Sensor Accumulator Belt Home Sensor Waste Cartridge Full Sensor Accumulator Belt Edge Sensor Automatic Toner Correction Sensor K C M Y Tray 1 Paper Size Sensor 87700 288 Figure 1 7 Print Engine Sensors and Switches cont d Phaser 7700 Color Laser Printer Service Manual 1 11 Auxiliary Feeder Sensors and Switches Tray 4 Take Away Sensor Paper Size Switch Assembly Tray 2 Tray 3 Take Away Sensor Tray 3 Tray 4 R Take Away Sensor AAR Paper Size Switch Assembly No Paper Sensor Level Sensor Tray 2 Tray 2 Paper Size Switch Assembly Tray 3 Tray 3 E Ze Ze Tray 4 2 HCF 4 3 Tray 3 Take Away Sensor Tray 4 Take Away Sensor 57700 316 Figure 1 8 Auxiliary Feeder Sensors and Switches 1 12 Phaser 7700 Color Laser Printer Service Manual Auxiliary Feeder Actuators and
17. on the Engine Control Board Does the voltage measure 0 VDC Yes No d Replace the Engine Control Board RRP 42 on page 7 206 emove the Print Cartridge Plate Cover RRP 24 on page 7 179 Inspect the wiring harness between the Engine Control Board and the Developer Housing Assembly Is the wiring harness in good condition Yes No Repair or replace as necessary eplace the Developer Housing Assembly RRP 27 on page 7 185 Replace the Engine Control Board RRP 42 on page 7 206 Note Run approximately 10 pages of solid fill full page prints of this primary color to ensure this error is cleared Phaser 7700 Color Laser Printer Service Manual 2 51 Error Chain gode Link Front Panel Message 15 09 383 ERROR 15 BLACK ATC SENSOR FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the NVRAM Access Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Note If necessary enter Service Diagnostics Mode and run the Clear Tech Rep Fault procedure on page 6 149 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P534 11 see figure page 2 46 on the Engine Control Board Does the voltage measure between 1 VDC and 3 VDC Yes No Measure the voltage at P534 12 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Repl
18. s Support Menu select Improve Print Quality then select Calibrate for Paper Menu Note Printing on some specialty papers such as some glossy finish papers may show background contamination 3041 50 3 Inspect the print cartridges for contamination Replace the print cartridges if necessary 4 If the Bias Transfer Roller or Belt Cleaner Assembly is near the end of its life replace that part 5 If the background contamination is a primary color and that primary color is missing from the print the high voltage wire leading to that color s developer housing is grounded Inspect the high voltage wiring harnesses Phaser 7700 Color Laser Printer Service Manual 3 115 Unfused Image or Image Easily Rubs Off of Page The toner image is not completely fused to the paper The image easily rubs off The printer displays no error code 1 Make sure that the paper you are using is the correct type for the printer and is correctly loaded in the printer in the correct tray From the front panel s Printable Pages Menu select Print Paper Tips Page 2 Make sure that the paper loaded in the tray matches the paper type selected on the printer s front panel 3 If the problem continues set the paper type in the front panel to the next heaviest type of paper than what you are using Below is a list of paper types from the heaviest weight to the lightest Thick Cover Index Thin Cover Index Hea
19. 00 Gear 26T 24 116 1234 00 11 H Transport Interlock Sensor 25 Bracket 26 116 1267 00 1 Paper Guide 27 Roll 28 Bracket 29 H Transport Frame Phaser 7700 Color Laser Printer Service Manual 11 355 Top Cover and Eject Roll FRUs 7700 301 Figure 11 32 Top Cover and Eject Roll FRUs 11 356 Phaser 7700 Color Laser Printer Service Manual Table 11 8 Top Cover and Eject Roll FRUs List No Part Number Qty Description 1 116 1262 00 1 Top Open Cover Assembly 2 Arm Assembly 3 Bearing 4 Bracket 5 Spring 6 Support 7 Bracket 8 Shaft 9 116 1302 00 1 Eject Pinch Roll 10 1 Eject Chute 11 116 1272 00 1 Stack Height Sensor Assembly Item 12 14 12 1 Actuator 13 Bracket 14 116 1253 00 1 Stack Height Sensor 15 Shaft Set Clamp 16 Link 17 116 1264 00 1 Actuator 18 Collar 19 116 1258 00 1 Clutch 20 116 1303 00 1 Gear 282 21 Eject Roll 22 116 1301 00 1 Gear 202 23 Bearing 24 Eject Shaft 25 116 1302 00 1 Eject Roll Assembly Item 21 24 REP 17 6 2 26 Link 27 Eliminator Phaser 7700 Color Laser Printer Service Manual 11 357 Paper Transport Assembly FRUs 7700 302 Figure 11 33 Paper Transport Assembly FRUs 11 358 Phaser 7700 Color Laser Printer Service Manual Table 11 9 Paper Transport Assembl
20. 11 3 x 16 1 in 2 in 2 in SP Folio 215 x 315 mm 205 x 305 mm 5 mm 5 mm Oficio 215 x 340 mm 205 x 330 mm 5 mm 5 mm B6 JIS 128 x 182 mm 118 x 172 mm 5 mm 5 mm B5 JIS 182 x 257 mm 172 x 247 mm 5 mm 5 mm B4 JIS 257 x 364 mm 247 x 354 mm 5 mm 5 mm 1 28 Phaser 7700 Color Laser Printer Service Manual Table 1 11 Print Area cont d Paper Page Size Image Area Margin Sides Top Bottom RA3 305 x 430 mm 297 x420mm 5mm 4mm SRA3 320 x 450 mm 303 x 432 mm 9mm 8 5 mm Official 10 4 13 x 9 5 in 3 73 x 9 1 in 2 in 2 in Envelope 105 x 241 mm 95 x 231 mm 5mm 5mm 9 1 2 Booklet 9x 12 in 8 6 x 11 6 in 2 in 2 in DL Envelope 110 x 220 mm 100 x 210 mm 5mm 5mm B6 Envelope 125 x 176 mm 115 x 166 mm 5mm 5mm B5 Envelope 176 x 250 mm 166 x 240 mm 5mm 5mm B4 Envelope 250 x 353 mm 240 x 343 mm 5mm 5mm C6 Envelope 114 x 162 mm 104 x 152 mm 5mm 5mm C5 Envelope 162 x 229 mm 152 x 219 mm 5mm 5mm C4 Envelope 229 x 324 mm 219 x 314 mm 5 mm 5 mm 9 02x 12 8 in 2 in 2 in a SRA3 paper size and A3 full bleed imageable area are supported through the Multi Purpose Tray MPT print quality outside the imageable area is not guar anteed Phaser 7700 Color Laser Printer Service Manual 1 29 1 30 Phaser 7700 Color Laser Printer Service Manual Diagnostics Error Codes and Messages Error Messages The Control Panel displays error codes when it encounters certain system failures or anomalies otherwise
21. 1946 00 Hi capacity Toner Cartridge CRC 1 Yellow 016 1891 00 Customer Replaceable Consumable 1 Waste toner cartridge 016 1222 00 Customer Replaceable Consumable 1 Staple pack 016 1887 00 Customer Replaceable Consumable 1 Fuser 110V 016 1888 00 Customer Replaceable Consumable 1 Fuser 220V 8 284 Phaser 7700 Color Laser Printer Service Manual Table 8 34 Accessories Part Number Accessories Qty Name Description ZMC128 A 128 Mbytes RAM N A Additional Memory ZMC256 A 256 Mbytes RAM N A Additional Memory 116 1091 00 Trays1 4 N A Universal Tray 7700TD A Lower Tray Deck N A Includes three Universal trays 7700HCF A High Capacity Feeder N A Includes one Universal tray and two High Capacity Letter A4 trays 7700FNS A Finisher N A Includes one Finisher Output Tray and staplers ZCARTC A Printer Cart N A Available for printers without a Lower Tray Deck or High Capacity Feeder Recommended Service Tools The following service are recommended as a start for servicing the printer As additional tools are needed visit the following URL for help http cpid opbu xerox com hardwaretools html Table 8 35 Recommended Tools List Part Number Description 003 0293 00 Driver Magnetic 0 25 drive no bits 8 Shank 003 0335 00 Tip 1 Philips Bit 0 25 Drive 003 0336 00 Tip 2 Philips Bit 0 25 Drive 640600 Mag 27020 Tip 2 5 mm Hex Bit 0 25 Drive 600T2123 He
22. 275 Table 8 24 Lower Tray Deck LTD FRUs List eontgd 1 8 276 Table 8 25 High Capacity Feeder FRUS et 8 277 Table 8 26 High Capacity Feeder FRUs List eontd 1 8 278 Table 8 27 High Capacity Feeder FRUs List eontd 1 8 279 Phaser 7700 Color Laser Printer Service Manual xxi Table 8 28 High Capacity Feeder FRUs List cont d orovorerrrrorororrsversvenrrennnr 8 280 Table 8 29 High Capacity Feeder FRUS cont d emeveersnorovorerrrrovereresversvenerennnr 8 281 Table Det Kits stave EE EE 8 282 Table 8 31 Manual Packs A Service Manual 8 283 Table 8 32 Software 0 cccscscscscscsssecscsesecescsesesesssecscsesesesessesesasseecsesasescessesecesasaes 8 284 Table 8 33 Suppliesu Aausstsnstkessdkskee EE 8 284 Table 6 34 ACCESSONGS 2i 26 c5 thas distal eisai dela EES 8 285 Table 8 35 Recommended Tools Uert 8 285 Table 11 1 Finisher Specifications s snnsnsnnsnnnnennniennnnsinnnsinsnsrnsnsnssnsnssnneeenn 11 315 Table 11 2 Finisher Unit Main Assemblies FRUS List rnrnrrrrnvrrrrnrsnrvrrrrnrrnrnrr 11 346 Table 11 3 Finisher Covers FRUS Uert 11 347 Table 11 4 Finisher Stand FRUS et 11 349 Table 11 5 Gate Unit FRUS Uert ccc ccsessssssesssesssensssessseseeessesseeetssesecsseesess 11 351 Table 11 6 Horizontal Transport Assembly FRUS et 11 353 Table 11 7 Horizontal Transport Assembly FRUs List contg le 11 355 Table 11 8 Top Cover and Eject Roll FRUS List eeorerrrovorevosrorsvorrsrerereresvrnen 11 357 Ta
23. 5 VDC Yes No Replace the Engine Control Board RRP 43 on page 7 207 If the problem persists repair or replace the harness between Engine Control Board and the 24 VDC LVPS Fan Replace the 24 VDC LVPS Fan RRP 47 on page 7 212 2 66 Phaser 7700 Color Laser Printer Service Manual Error Chain code Eins Front Panel Message 60 04 640 ERROR 60 DRUM MOTOR FAILURE Enter Service Diagnostics Mode and run the Print Cartridge Motor test Does the motor run Yes No Remove the Rear Cover RRP 1 on page 7 154 the Rear Cover Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Connect the power cord and enter Service Diagnostics Mode Measure the voltage at the Print Engine Controller Interface Board P407 4 see figure page 2 46 and frame ground Is the voltage 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at the Print Engine Controller Interface Board P407 6 see figure page 2 46 and frame ground Does the voltage measure 24 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at the Print Engine Controller Interface Board P407 1 see figure page 2 46 and frame ground Is the voltage 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 un the Print Cartridge Motor test Does the voltage still measure 5 VDC at P407 1 Yes No Replace the Print Car
24. Clearances 1 24 Phaser 7700 Color Laser Printer Service Manual Table 1 7 Functional Specifications Characteristic Specification Printing Process The Printer uses laser print heads with an electrophotographic four color CMYK tandem architecture and intermediate transfer printing process Color Medium Four toner cartridges each containing one of four colors CMYK Addressability 600 x 600 x 1 bit dpi OHP 1200 x 600 x 1 bit dpi standard 600 x 600 x 3 bit 1 level dpi photo Print Speed Normal Letter A4 LEF Long Edge Feed 22 pages per minute Tabloid A3 SEF Short Edge Feed 11 pages per minute Legal SEF 13 pages per minute Duplex Letter A4 LEF 18 pages per minute Tabloid A3 SEF 8 pages per minute Legal SEF 9 pages per minute Minimum Margins 5 mm 0 2 in on all sides Tray Capacities Main Tray Standard paper 500 sheets Transparency 100 sheets Lower feeder deck Standard paper 1 500 sheets 3 x 500 Multi purpose tray Standard paper Letterhead 100 sheets High capacity feeder Standard paper 2500 1 500 sheets 2 867 sheets 3 1133 sheets Table 1 8 Electrical Specifications Characteristic Specification Primary Line Voltage 115 127 VAC 10A 10 200 240 VAC 5A 10 Line Frequency Range 100 127 VAC 50 60 Hz 220 240 VAC 50 60 Hz Power Consumption Energy Star 45 watts Standby 130 watts Ready 220 watts Conti
25. Clutches Left hand cover interlock switch actuator Paper feed sensor actuator tray 3 Paper detect One way d sensor actuator clutch tray 2 LTD tray 2 tray 3 tray 3 tray 4 Paper feed sensor actuator tray2 tray 4 tray 3 tray 4 Friction Paper detect p clutch sensor actuator Paper size Left hand cover tray 2 tray 2 switch interlock switch actuator actuator tray 3 tray 4 HCF One way clutch One way Sch tray4 clutch i tray pt N tray 3 Is 3 Sy IN r ZS Paper detect L D Friction sensor actuator tray 4 clutch Paper size tray 3 switch Friction actuator clutch tray 3 tray 4 PERA Figure 1 9 Auxiliary Feeder Actuators and Clutches Phaser 7700 Color Laser Printer Service Manual 1 13 Print Engine Solenoids Actuators and Clutches CW Duplex clutch ccw er clutch H Registration SY clutch Feed clutch CS One way TO clutch s Friction clutch Be SI One way ZH S Exit tray full sensor actuator ke Paper detect sensor actuator tray 1 Paper detect sensor actuator MPT 7700 387 Figure 1 10 Print Engine Solenoids Actuators and Clutches 1 14 Phaser 7700 Color Laser Printer Service Manual Print Engine and Auxiliary Feeder Interlocks and Sensors Left hand Right hand cover Main power Cover interlock interlock switch switch switch Fuser exit G2 switch Front cover interlock switch d amp NK D Duplex cover switch wm Left hand lo
26. Color Laser Printer Service Manual 6 149 Reset Engine NVRAM Reset NVRAM allows PostScript to write stored data from the hard drive to engine NVRAM You must restore engine NVRAM after replacing the Engine Control Board 1 Enter Service Diagnostics Verify switch 2 is Down 2 Highlight NVRAM Access and press OK 3 Highlight Reset Engine NVRAM and press OK Store Engine NVRAM This function reads values from the engine NVRAM and writes values to the hard drive It overwrites NVRAM values stored on the hard drive You must store values to the hard drive before any of the following parts are replaced or procedures performed m Engine Control Board Internal Hard Drive Laser Unit movement Calibrate for margins procedure Developer replacement Print Cartridge Cover Plate movement m Mark On Belt Sensor replacement You must store engine NVRAM values to the Internal Hard Drive after replacement of the Internal Hard Drive 1 Enter Service Diagnostics Verify switch 2 is Down 2 Highlight NVRAM Access and press OK 3 Highlight Store Engine NVRAM and press OK 6 150 Phaser 7700 Color Laser Printer Service Manual Removal and Replacement Procedures This topic illustrates how to remove and replace printer Field Replaceable Units FRUs For more detailed removal replacement procedures refer to the Phaser 7700 Color Laser Printer Service amp Support Resources CD ROM For specific assemblies and parts refer to the FRU Parts
27. Connector Pin Locations 2 47 Troubleshooting 3 87 Troubleshooting Network Problems ursnsvnvrnnvrrrs venns vrsnsvrsnsvrsnsnrsnennsnennsnesnsnennnn 3 88 Operating System and Application Problems esranvonrrrnrnvorerrrvsverenenvsrsvennne 3 88 Media Jams and the Paper Path cccccccccscccsececssceceeceseeesecesseeesesseesaees 3 88 Print Image Quality Problems sererrrsvorsvenrvenvrvererrsrsverevesvrrsvoverenrsneverssesnener 3 88 Troubleshooting Power Supplies and Interlocks sesrororonrsrnrsvorerrnvoveveresvsvsvenenn 3 89 Troubleshooting AG POWer eeech egedeetee ee eel Eed EE EES 3 89 Troubleshooting the Low voltage Power Supplies sranorerrorsvorovorerrsvorerenenn 3 89 Troubleshooting the 3 3 VDC and 5 VDC LVPS eesrsnerevorvsvsvoverenrsveversnesvener 3 90 Troubleshooting the 24 VDC LVPS eeesnsvenrvrsvovereresvsverevesnsvsveverenssvenevssesnenen 3 90 Interlock Circuit EL 3 91 The 24 VDC Interlock Circuit 00 0 cccecccssseescsscsescscsececscsesecescsescsusaeecseaes 3 91 The 5 VDC Interlock Circuit eroeeenvrsvorerrrrrvererervsversvenerrsvererevrsrsvavenesrnvsvener 3 92 Troubleshooting When the Printer Does Not Come to a Ready State 3 93 Printer Does Nothing When Power Switched On seeveverevesvorererrrrererrsesvener 3 93 Fans On Front Panel LED Never On 3 93 Fans On Front Panel LED is Red No Front Panel message e ennssssin
28. Finisher Control Board and the Front Corner Sensor Phaser 7700 Color Laser Printer Service Manual 2 83 Error Chain code Eni Front Panel Message 123 12 281 FINISHER ERROR 123 SET CLAMP FAILURE Continued A B C D Measure the voltage at the Set Clamp Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Yes No Measure the voltage between the Finisher Control Board P849 7 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No d Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Set Clamp Sensor Replace the Set Clamp Sensor RRP 75 on page 11 334 Repair or replace the wiring harness between the Finisher Control Board and the Set Clamp Sensor Replace the Finisher Control Board RRP 77 on page 11 336 Replace the Finisher Control Board RRP 77 on page 11 336 124 12 350 FINISHER ERROR 124 COMMUNICATION FAILURE There are no diagnostics routines or test procedures for problems involving serial communica tions It is recommended to address the following suspect components assemblies in order e Replace the Finisher Control Board RRP 77 on page 11 336 e Replace the Engine Controller Board RRP 42 on page 7 206 e Perform a continuity check on the pertinent wires harnesses involved in serial communication between the Printer and
29. H L Paper present Sensor H Paper not present OHP Left OHP is L Overhead Projection Sensor Sensor Right OHP is L L Paper or OHP present H Paper or OHP Band not present Duplex Sensor Duplex is L H Paper present L Paper not present Tray Feed Feed Out 1 is L H Paper present Sensors Take Away F O 2 is L L Paper not present Feed Out 3 is L Feed Out 4 is L Stack Full Stack Full is H H Output Stack not full Sensor L Output Stack full Fuser Exit Fuser Exit is L H Paper present Sensor L Paper not present 2nd BTR 2nd BTR Retract is L H In contact Retract L Retracted Sensor Fuser Present Fuser is Present Change soon Change Need to cycle power to get the results to change when installing a new fuser 2 38 Phaser 7700 Color Laser Printer Service Manual Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Read Fuser Fuse 1 is Open 50 page fuse Fuses Fuse 2 is Open 90 day fuse Fuse 3 is Shorted Mis Use fuse Open indicates Fuse is blown Accum MOB MOB sensor is L Accumulator Mark On Belt Sensor Engineering use only Belt Edge Edge is nnn current value Approximately 500 25 Sensor Engineering use only BTR Sensors BTR YisL H Error BTR Mis L L No error BTRCisL BTR Kis L 2nd BTR is L ADC Sensors ADC is H ADC Automatic Density Correction Engineering use only Go t
30. HCF Tray 3 Removal 1 On the left side of the HCF remove one screw from the Tray 3 Stopper bracket and remove the bracket 2 Pull Tray 3 out of the printer Phaser 7700 Color Laser Printer Service Manual 7 227 RRP 59 High Capacity Feeder HCF Tray 4 and Paper Transport Paper Transport Tray 4 Stopper 7700 211 Figure 7 70 High Capacity Feeder HCF Tray 4 and Paper Transport Removal 1 Open Tray 4 2 Remove the two screws that secure the Tray 4 Stopper 3 Remove the two screws securing the paper transport and slide it back in 4 Pull Tray 4 out of the printer 7 228 Phaser 7700 Color Laser Printer Service Manual RRP 60 Auxiliary Feeder Control Boards 57700 441 Figure 7 71 LTD Control or HCF Control Board Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Disconnect the wire harnesses 3 Remove the four screws securing the control board and remove the board Phaser 7700 Color Laser Printer Service Manual 7 229 RRP 61 Auxiliary Feeders Motor Assemblies HCF only transport Ea a motor T 87700 110 Figure 7 72 Transport Motor Assembly Removal 1 Remove Rear Cover RRP 1 on page 7 154 2 Disconnect the wire harness 3 Remove the two screws securing the motor assembly 4 Remove the motor assembly 7 230 Phaser 7700 Color Laser Printer Service Manual RRP 62 Auxiliary Feeder Paper Select Switches Universal Tray Paper S
31. Laser Printer This manual contains a Field Replacement Unit Parts List FRU and Removal and Replacement Procedures RRPs For information on troubleshooting and error codes for the finisher option see Diagnostics Error Codes and Messages on page 2 31 Topics such as the Finisher theory of operation and Configuration Page details etc are located on the companion Printer Service amp Support Resources CD ROM Finisher Overview m The Finisher is a customer installed option that contains a Horizontal Transport Stapler Compiler and Stacker m The Finisher docks with the Print Engine and Finisher Stand m The Finisher s built in power supply takes 24 VDC from the printer and provides all the DC voltages required 11 314 Phaser 7700 Color Laser Printer Service Manual General Information Table 11 1 Finisher Specifications Category Specification Configuration User installed option The Finisher provides stapling up to 50 sheets print job offset and stacking up to 1 000 sheets of paper The Finisher docks with the Printer and Stand All Finisher operations are controlled by the Finisher Control Board Paper Feed Paper leaving the Exit section of the Printer is fed to the Paper catch area then directly into the Horizontal Transport The Horizontal Transport then delivers the paper to the Finisher where stapling offsetting jogging and stacking occur Power The Printer provides 24 VDC to the F
32. List on page 8 235 This section contains the removal and replacement procedures for selected parts of the printer Not all Replacement Procedures are included in this Quick Reference Guide In most cases to reinstall a part simply reverse the Removal Procedure shown In some instances the Replacement Procedure is included because it may contain special steps This section covers the print engine and Auxiliary Feeders only For Removal and Replacement of the Finisher see the Phaser 7700 Light Finisher on page 11 323 Phaser 7700 Color Laser Printer Service Manual 7 151 Contents RRP 1 Rear Cover Assembly 7 154 RRP 2 Right Side Cover Assembly 0 0 00 c eee eee eens 7 155 RRP 3 Top Cover Assembly 7 156 RRP 4 Front Panel Assembly 0 00 0 c cece eect ens 7 157 RRP 5 Rear Cover Top Rear Power Switch Cover and LH Rear Mid Cover 7 158 RRP 6 Left Hand Lower Cover Assembly 0 00 0 c uence ee eees 7 160 RRP 7 Front Cover Assembly 0 00 c cece cece eee eens 7 161 RRP 8 Fuser Front Cover 7 162 RRP 9 Rear Shield ARENS Ee a a a 7 163 RRP 11 24 VDC Power Supply Shield onnan nananana 7 164 RRP 10 Rear Shield Bracket 7 165 RRP 12 Multi Purpose Tray MPT Assembly 00 0 cece eens 7 166 RRP 13 Multi Purpose Tray Paper Pick Rollers 7 167 RRP 14 Left Hand Cover Assembly Left Hand Door 7 168 RRP 15 Duplex Chute 7 170 RRP 16 Duplex Unit Assembly 0 0 ccc ee
33. Multi Purpose Tray FRUs 7700 045 Figure 8 16 Multi Purpose Tray FRUs Phaser 7700 Color Laser Printer Service Manual 8 261 Table 8 16 Multi Purpose Tray MPT FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1157 00 1 Multi Purpose Tray MPT Assembly 2 116 1158 00 1 MPT Tray Pinch Roller Assembly 1 w 10 11 13 14 16 Pinch Roller Assembly 2 w 13 17 Pinch Roller Assembly 3 w 11 13 16 3 116 1159 00 1 Paper Pick Roller MPT Feed Roller Assembly Feed Roller Cam Cam Shaft Assembly 4 116 1166 00 1 Pad Assembly Retard 5 116 1212 00 2 MPT Pick Rollers 8 262 Phaser 7700 Color Laser Printer Service Manual PL 8 17 Paper Feed FRUs 87700 040 Figure 8 17 Paper Feed FRUs 8 263 Phaser 7700 Color Laser Printer Service Manual Table 8 17 Paper Feed FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1160 00 116 1109 00 1 1 3 Paper Feeder Assembly Feeder Assembly Paper Feed Motor Assembly Roller Feed Nudge Retard Paper Feed Motor only Motor Assembly 116 1161 00 Transport Assembly Inverter Transport Inv 116 1163 00 Roller Assembly Feed Nudge Retard Roll Assembly 116 1164 00 Ny ad Transport Assembly Registration Transport AV OPB Bearing Bearing Drive Roll Gear 22T Paper Guide REGI Chute REGI Clutch Bearing Earth Plate
34. Replace the Engine Control Board RRP 42 on page 7 206 Replace the Accumulator Belt Assembly RRP 51 on page 7 217 Replace the Accumulator Belt Assembly RRP 51 on page 7 217 Cautionif the Accumulator Belt is damaged determine the cause of the damage before installing a new Accumulator Belt Assembly Visually inspect the Accumulator Belt area inside the printer and inside the LH door for foreign object or damage parts It may be necessary to query the user for additional information as to likely causes If the problem persists replace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 57 Error Chain Gode Pins Front Panel Message 32 04 348 ERROR 32 UNEXPECTED Accumulator Belt EDGE SENSOR FAILURE Remove the Accumulator Belt Assembly RRP 51 on page 7 217 Inspect the connector for damage Is the connector in good condition Yes No Replace the Accumulator Belt Assembly RRP 51 on page 7 217 Inspect the mating connector inside the printer for corresponding damage Repair or replace the harness between the Accumulator Belt and connector J605 see figure page 2 46 Reinstall the Accumulator Belt Assembly Switch printer power ON Remove the Rear Cover RRP 1 on page 7 154 Remove the Rear Shield RRP 9 on page 7 163 Measure the voltage between the Engine Control Interface Board P533A 2 see figure page 2 46 and frame ground Does the voltage
35. Replacement Caution Never run the printer without the belt cleaner installed or severe damage to the Accumulator Belt will occur Caution Ensure that the Accumulator Belt is fully inserted or severe printer damage will result NEVER FORCE THE MAIN LEVER 7 198 Phaser 7700 Color Laser Printer Service Manual RRP 37 Waste Auger Assembly 7700 438 Figure 7 42 Waste Auger Assembly Removal 1 Remove the Right Side Cover RRP 2 on page 7 155 1 Remove Waste Toner Cartridge and lower the main lever 2 Remove Accumulator Belt assembly 3 Return the main lever to its upright position 4 Remove the two screws securing the Waste Auger Assembly 5 Shift the Waste Auger Assembly to remove the drive shaft from the bearing and remove the waste auger assembly Note Be careful not to knock the bearing out of its seat Caution When reinstalling be sure to return the main lever down before reinstalling the Accumulator Belt Assembly Phaser 7700 Color Laser Printer Service Manual 7 199 RRP 38 Laser Unit F VE Cp NS _ A 87700 145 Figure 7 43 Laser Unit Assembly 7 200 Phaser 7700 Color Laser Printer Service Manual Removal 1 Remove the Rear Cover RRP 1 on page 7 154 1 Remove the Right Hand Cover RRP 2 on page 7 155 2 Disconnect the wiring harnesses at engine board P400 and 401 3 Undo the retainers and undo the wiring harness Note Note the routing of the laser uni
36. Roll Exit 2 N Pinch Roll Exit 3 t CA Upper Exit Chute D 116 1313 00 Compiler Entrance Sensor oa Plate Spring O Bracket N Eliminator Phaser 7700 Color Laser Printer Service Manual 11 369 Electrical FRUs Figure 11 39 Electrical FRUs Table 11 15 Electrical FRUs List ve AX 7700 308 No Part Number Qty Description 1 Board Cover 2 116 1235 00 1 Finisher Board 3 116 1314 00 1 ROM 4 PWB Bracket 5 DC Harness 6 Cable 7 116 1233 00 1 Switch 8 116 1253 00 1 Docking Interlock Switch 9 Plate Spring 10 Bracket 11 370 Phaser 7700 Color Laser Printer Service Manual 18 21 Jenueyy 221185 181ULd 18587 10 09 0022 JASEYd 99U9319 1 JO SL 10 Joo yoes aoe pue bed eau oun uo Duuufeg seadde yjog weiperq BuniM Jeysiul4 AU gz pue wesbeig yoo g Jost AU sweibep om JO pasudwo SI UONDAS siy L swesbeig Hui 194Ys1UI4 90t 00225 enue 211495 19jUlld JAS 10 09 0022 J8StYd CZE I JSYSIUl4 4 JO WEJHeIp yolg Let eunbig JOJON J YDLIS JOJO ano Jejdes Josuas SAN Joie vvsr d 2v8r d 9v8f d ever d I S8P d oser d L_ 6ber d EBI St8f d plousjog aye Josuas eoue
37. Sensor Setup Test and press OK Note the current values for the tag numbers on the front panel display They should correspond to the tag numbers of the developers actually installed 5 Select the color of the developer you installed 6 Enter the tag number You can only modify the lower two digits Use the Back and Info keys to select which digit you want to change Use the Up and Down keys to actually modify the digit Press OK to enter the data in engine NVRAM Press any button to abort the test RON ch on Additional Information For information on the following topics see Service Diagnostics Test Menu Functions on page 2 36 m TRC Adjust For Engineering Use Only ADC Output Check Check ADC Sensor Fail 0 Tone Up Down Check ATC Sensor Fail None Laser Power Check PWM Mapping For Engineering Use Only 4 142 Phaser 7700 Color Laser Printer Service Manual Cleaning and Maintenance Service Preventive Maintenance Procedure Perform the following procedures whenever you check service or repair a printer Cleaning the printer as outlined in the following steps assures proper operation of the printer and reduces the probability of having to service the printer in the future The frequency of use and the type of paper a customer prints on determines how critical cleaning the machine is You should thoroughly inspect and clean these printers Recommended Tools m Toner vacuum cleaner m Clean wat
38. UNSHGONL 2194 99 DER TSA be 22 H ke 17 asesr Nia 9e 1901 NISAS 2194 S9 Keesen OIA be Z D e O aI Lord gt eren Ma 92 T90T vslona Zidd 4 9 ITOT matez e TSA 92 rap ad s Tila 92 1901 CEE S Kesecnmg Ag be z T t asesr nia 921901 MINDYNOOSION3 Z 19 d Tier NHO vz 22 S 13A 97 ai m 9 ER Keng SE Z nia 92 1501 ONINDAWOOSLONI Gg 9 3 oz Toor VA e O gasesr nia 92 1901 WNSLOWS 12194 gt 2 Keser Ma rezz A REDS E 6 Pasesr Na 92 1901 ANSLOWS 219d gt Tier Mma ve z oS AHD 92 1901 N VIVAASGT al W s Im 7 AUD 92 1901 O VINGASAT S Zz 912S ve ISA 92 1901 HO WIVGASGT VIOPT S m gesd e AN 923757 z 19A 92 1901 Ovan VTOFT gt IO BE R FEST er AMD Gu 1901 ONV VTOPT gt re SE z EE an a G t Ge dreck el Z vb OVSEEr ENER Ast 0194 S S Aa 927 o oes 2 S El deser wis ve 2201 UNSFAONN lorod oc S oror REISEN EE AW 9z 1901 OPMTLNIASE WE OPT zi DYEEST Geesen CECR 9197 Seen Lest AHO 92 FSO OMILNIAS WOOT I Q H DvsesT Wid be eZe0r TJOS QI3EISW 019d lt s gt Dar nia 92 I w o Dager wa ve eZz0r Aver oroa SS r TET NHO 921 O D Aeren EVERS Nune toroa S l oror OI Set gt Wee wie ve eZe0r TENSWazSl 0194 S4 Lorar ELSEN DI LI VSEST wa ve eZe0r near toroa lt 8 _ oro AUD 92 I U SU Se EE 9 Dagar N Sovsesr Wa ve 22201 ne ss S O TTOT RES VEZ Wang ECKE ansema red gS rror A ve 2 KR VSEST Mia ve 22201 NIHAS Ltd EEST OIA v2 ZZ iessen Wid ve ZZe0r VEER Tea Ee CHECK N DV sesr
39. VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Decurler Cam Home Sensor Phaser 7700 Color Laser Printer Service Manual 2 81 Error Chain Gode Link Front Panel Message 122 12 267 FINISHER ERROR 122 DECURLER FAILURE Continued A B C D Measure the voltage at the Decurler Cam Home Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Yes No Measure the voltage between the Finisher Control Board P849 1 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No d Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Decurler Cam Home Sensor eplace the Decurler Cam Home Sensor Repair or replace the wiring harness between the Finisher Control Board and the Decurler Cam Home Sensor Replace the Finisher Control Board RRP 77 on page 11 336 Replace the Finisher Control Board RRP 77 on page 11 336 2 62 Phaser 7700 Color Laser Printer Service Manual Error Chain Gode Link Front Panel Message 123 12 281 FINISHER ERROR 123 SET CLAMP FAILURE Remove the Finisher Rear Cover RRP 72 on page 11 330 Enter Service Diagnostics Mode From the Main Menu select Sensor Tests Finisher Sensors Miscellaneous Manuall
40. Waste Cartridge Cover Waste ei Cartridge Cartridge Sensor Holder A 57700 015 Figure 7 24 Waste Cartridge Waste Cartridge Cover and Waste Cartridge Sensor Holder Removal 1 Open the Front Door 2 Open the Waste Cartridge Cover Caution To avoid a toner spill and subesquent cleanup use great care in removing the Waste Cartridge Remove the Waste Cartridge Remove the e clip and remove cover Remove the screw securing the waste cartridge pivot hinge and remove the hinge 6 Remove the Waste Cartridge Sensor Holder disconnecting wire harnesses if needed to replace the sensor TR oO 7 178 Phaser 7700 Color Laser Printer Service Manual RRP 24 Print Cartridge Plate Cover 7700 446 Figure 7 25 Print Cartridge Plate Cover plastic Removal Print Cartridge Plate Cover 1 Open the Front Door 2 Remove Fuser Front Cover RRP 8 on page 7 162 3 Lower the main lever 4 Remove the four screws 5 Remove the plastic Print Cartridge Plate Cover Phaser 7700 Color Laser Printer Service Manual 7 179 RRP 25 Dispense Assembly Use a piece of wide tape to cover the toner access Close Shut Off Gate 7700 168 87700 167 Figure 7 26 Dispense Assembly Removal Note After replacing the Print Cartridge Plate Assembly you must perform the RegiCon adjustment to the printer on page 4 130 Caution Use only a type II toner vacuum to clean up toner spills Note Have a large s
41. at each end of the Developer Housing Assembly and remove the assembly cover 3 Cut open the package of Developer mix Carefully pour the entire contents of Developer mix as evenly as possible over the two augers Do not let the developer mix accumulate heavily on the roller Keep the Developer Housing Assembly level 4 Reinstall the cover making sure that the rear tabs are all engaged in their respective slots while positioning the wire harness under the snap tab Press firmly until you hear a positive snap sound for each tab indicating each snap tab is securely fastened 5 Tear off the ATC sensor tag label Peal off the protective backing and adhere the label to the appropriate or corresponding Print Cartridge Plate connector Make sure the ATC sensor tag label can be located if needed later Caution Itis important to re enter the ATC value when replacing a developer Not doing so could result in poor color balance and shortened developer life Note The ATC sensor tag is not accessible once the developer has been installed Remove the label prior to installation Phaser 7700 Color Laser Printer Service Manual 7 187 RRP 29 Toner Dispense Motor Assembly 57700 169 Figure 7 31 Toner Dispense Motor Assembly Removal 1 2 3 a gt Remove Right Cover RRP 2 on page 7 155 and the Top Cover Assembly RRP 3 on page 7 156 Remove the Dispense Housing Assemblies RRP 25 on page 7 180 Remove the two screws tha
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43. for corresponding damage Repair or replace the harness between the Accumulator Belt and connector J605 einstall the Accumulator Belt Assembly Switch printer power ON Remove the Rear Cover RRP 1 on page 7 154 Remove the Rear Shield RRP 9 on page 7 163 Measure the voltage between the Engine Control Interface Board P533A 6 see figure page 2 46 and frame ground Does the voltage measure between 1 VDC and 3 VDC Yes No Measure the voltage between the Engine Control Interface Board P533A 7 see figure page 2 46 and frame ground Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between the Engine Control Interface Board P533A 5 see figure page 2 46 and frame ground Does the voltage measure 0 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 eplace the Accumulator Belt Assembly RRP 35 on page 7 196 If the problem persists repair or replace the wiring harness between the Engine Interface Board and the Accumulator Belt Assembly If the problem persists replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 34 09 351 ERROR 34 Accumulator Belt DRIVE LOGI
44. harness between the Finisher Control Board and the Front Corner Sensor eplace the Front Corner Sensor Repair or replace the wiring harness between the Finisher Control Board and the Front Corner Sensor Replace the Finisher Control Board RRP 77 on page 11 336 Replace the Finisher Control Board RRP 77 on page 11 336 2 78 Phaser 7700 Color Laser Printer Service Manual Error Chain Gode Link Front Panel Message 120 12 260 FINISHER ERROR 120 EJECT CLAMP HOME SENSOR ON FAILURE 121 12 262 FINISHER ERROR 121 EJECT CLAMP HOME SENSOR OFF FAILURE Remove the Finisher Rear Cover RRP 72 on page 11 330 Remove the sensor from the top of the eject motor mount bracket RRP 76 on page 11 335 Enter Service Diagnostics Mode From the Main Menu select Sensor Tests Finisher Sensors Miscellaneous Manually actuate the Eject Clamp Home Sensor and observe the display Does display indicate the Eject Clamp Home Sensor toggling between H amp L Yes No Yes No Yes No Yes No Remove the Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P849 5 see figure page 2 46 and Finisher frame ground Again manually actuate the Stack Height Sensor Does the voltage toggle between 5 VDC and 0 VDC Measure the voltage at the Eject Clamp Home Sensor pin 2 yellow and Finisher frame ground Once again manually actuate the Eject C
45. high 5 mm replace the Laser Unit RRP 38 on page 7 200 3 112 Phaser 7700 Color Laser Printer Service Manual Random Missing Spots There are small areas of the image that are extremely light or are missing entirely These missing areas form spots that are localized to small areas of the page The printer displays no error code A small number of occasional missing spots is normal 1 If a toner low message is displayed replace the toner cartridge in question 2 Ensure that the loaded media matches the front panel settings 3 Run the Calibrate for Paper routine From the front panel s Support Menu select Improve Print Quality then select Calibrate for Paper Menu 4 Run the solid fill test pages From the front panel s Printable Pages Menu select Service 3041 46 Pages then select Print Solid Fill Pages 5 If the missing bands only occur in a single primary color replace the Developer Housing Assembly RRP 27 on page 7 185 Random Spotting 3041 47 There are spots of toner randomly scattered across the page The printer displays no error code Single Color 1 Remove the toner cartridge of the suspect color and shake it 2 Check the print cartridges Phaser 7700 Color Laser Printer Service Manual 3 113 All Colors Inspect the paper path Inspect the Accumulator Belt Cleaner and replace if necessary RRP 36 on page 7 198 ECH the Bias Transf
46. identified at power up or when a door is closed completing the 24 VDC circuit and the Engine Control Board interrogates the Print Cartridge NVRAM If the Print Cartridges are present then the Waste Toner Cartridge is missing by default 1 With all doors closed and printer power on check for 5 VDC between P536 4 of the Engine Control Interface Board and frame ground If not present check the LD Relay and the LH Cover Interlock Switch 2 Check for 5 VDC between P536 6 of the Engine Control Interface Board and frame ground If not present check the Front Cover Interlock Switch 3 Check for 5 VDC between J568 7 top pin of the LD Power Relay and frame ground If not present check the RH Cover Interlock Switch 4 Check for 5 VDC between P536 1 of the Engine Control Interface Board and frame ground If not present check the LD Power Relay and the circuit through the Waste Cartridge Sensor and the four Print Cartridge connectors 5 If 5 VDC is present then replace the Engine Control Board RRP 42 on page 7 206 3 92 Phaser 7700 Color Laser Printer Service Manual Troubleshooting When the Printer Does Not Come to a Ready State Printer Does Nothing When Power Switched On Refer to Troubleshooting AC Power on page 3 89 Fans On Front Panel LED Never On m Check the Image Processor Board DIP Switches see You can print a service Diagnostics menu map by highlighting Print Service Menu Map using the arrow key and
47. letters and O are not used D alpha numerically indicates the day of manufacture ranging from 1 to X representing 1 to 31 the letters and O are not used M alpha numerically indicates the month of manufacture ranging from 1 to C representing 1 to 12 Y numerically indicates the last digit of the year of manufacture ranging from 0 to 9 Phaser 7700 Color Laser Printer Service Manual 8 235 PL 8 1 Accumulator Belt FRUs 7700 051 Figure 8 1 Accumulator Belt FRUs Table 8 1 Accumulator Belt FRUs List Parts Part Number Qty Name and Description vendor description 1 016 1889 00 1 Accumulator Belt cleaner Assembly Kit Belt Assembly IBT 2 116 1207 00 1 Accumulator Belt Shipping Restraint 3 116 1094 00 1 Belt Cleaner Assembly Cleaner Assembly IB 4 116 1180 00 1 Waste Auger Assembly 8 236 Phaser 7700 Color Laser Printer Service Manual PL 8 2 Left Hand Door FRUs 7700 042 Figure 8 2 Left Hand Door FRUs Phaser 7700 Color Laser Printer Service Manual 8 237 Table 8 2 Left Hand Door FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1161 00 1 Transport Assembly Inverter 2 116 1182 00 1 Regi Chute Assembly 2a 116 1317 00 1 Left Hand Cover only Cover Assembly L H2 3 016 1890 00 1 Transfer Roller Roll Assembly 2nd E 4 116 1098 00 1 Duplex Chute DUP Chute 5 116 1542 00 1 Damper 1 2 Gear 6 116 1540 0
48. measure between 1 VDC and 3 VDC Yes No Measure the voltage between the Engine Control Interface Board P533A 3 see figure page 2 46 and frame ground Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between the Engine Control Interface Board P533A 1 see figure page 2 46 and frame ground Does the voltage measure 0 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 eplace the Accumulator Belt Assembly RRP 35 on page 7 196 If the problem persists repair or replace the wiring harness between the Engine Interface Board and the Accumulator Belt Assembly If the problem persists replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Engine Control Interface Board RRP 43 on page 7 207 2 58 Phaser 7700 Color Laser Printer Service Manual Error Chain code Pinks Front Panel Message 33 09 350 ERROR 33 UNEXPECTED Accumulator Belt HOME SEN SOR SIGNAL Remove the Accumulator Belt Assembly RRP 35 on page 7 196 Inspect the connector for damage Is the connector in good condition Yes No Replace the Accumulator Belt Assembly RRP 35 on page 7 196 Inspect the mating connector inside the printer
49. mode on CMY units Toner Cartridge Extended 24 Months 12k at 5 coverage Black Standard 24 Months 5k at 5 coverage Toner Cartridge Extended 24 Months 10k at 5 coverage C M Y Standard 24 Months 4k at 5 coverage 2nd Transfer Roller Kit 24 Months 100k less w duplex printing Fuser Assembly 24 Months 60K Letter A4 pgs 24 Ib paper Accumulator Belt 24 Months 300K Accumulator Belt Cleaner 24 Months 100k Waste Toner Cartridge 24 Months 6k less with media pick jams Phaser 7700 Color Laser Printer Service Manual 1 5 Engine Control Interface and Power Supply Boards Engine ControNnterface Board High Voltage Power Supply T1 Board High Voltage Power Supply T3 Board High Voltage Power Supply T2 Board AC Drive Board Noise Filter Board 7700 317 Figure 1 2 Engine Control Interface and Power Supply Boards 1 6 Phaser 7700 Color Laser Printer Service Manual Power Supplies ae 24 V Low voltage L O g power supply DS 24 V Low voltage power supply fan AC Power Chassis 3 3 V Low voltage power supply 5 V Low voltage power supply 87700 261 Figure 1 3 Power Supplies Phaser 7700 Color Laser Printer Service Manual 1 7 Engine Control and Image Processor Boards Figure 1 4 Engine Control and Image Processor Boards 1 8 Phaser 7700 Color Laser Printer Service Manual 7700 381 Auxiliary Feeder Control Board LTD Board 3T HCF Board TT D
50. network reset available for troubleshooting Network problems To print an Event Log Runtime Log or Configuration Page Enter normal Customer Mode From the main menu highlight Support Menu and press OK Scroll and highlight Network Questions and press OK Highlight the appropriate menu item from the list and select OK The page should now print ORON Phaser 7700 Color Laser Printer Service Manual 3 105 Media Jams and the Paper Path Media based Problems 1 Check that the correct type of media is being used Supported Paper Weights Page Sizes and Print Area on page 1 27 for the correct media types and weights The customer should be using a quality laser printer paper The printer may have trouble picking slick finish paper Only Phaser 7700 series transparency film should be used in this printer Inspect the paper for bent torn or folded corners Ensure that the correct media type is set in the front panel Ensure that the paper guides are set correctly Ensure that the media is a supported type for the tray picked from Tray 1 supports paper transparencies and thin cover index paper Trays 2 4 support paper only The MPT supports all types Multiple sheet Pick 1 Ensure that the paper is in good condition and appropriate for a laser printer quality office laser printer paper works best Ensure that the printer is printing within its environmental specifications by using the built in servi
51. on page 7 200 Note Whenever the mounting screws for the Laser Unit have been loosened it is necessary to recalibrate the unit by performing the RegiCon Adjustment Procedure beginning on page 4 124 If the problem persists replace the Engine Control Board RRP 42 on page 7 206 2 48 Phaser 7700 Color Laser Printer Service Manual Error Chain code Pink Front Panel Message 12 09 380 ERROR 12 YELLOW ATC SENSOR FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the NVRAM Access Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Note If necessary enter Service Diagnostics Mode and run the Clear Tech Rep Fault procedure on page 6 149 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P534 2 see figure page 2 46 on the Engine Control Board Does the voltage measure between 1 VDC and 3 VDC Yes No Measure the voltage at P534 3 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board emove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P534 1 see figure page 2 46 on the Engine Control Board Does the voltage measure 0 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 emove the Print Cartridge Plate Cover RRP
52. or the Feed Lift Motor with one from another tray and retest Inspect the wiring harness for damage and continuity Replace the Auxiliary Feeder Control Board RRP 60 on page 7 229 Replace the Engine Control Board RRP 42 on page 7 206 NO Phaser 7700 Color Laser Printer Service Manual 3 95 Tray 2 3 and 4 Will Not Lift or Printer Will Not Recognize the Auxiliary Feeder There are two circuits connecting the printer to the auxiliary feeder the Power Circuit and the Serial Data Link 1 Check that the auxiliary feeder is properly connected to the back of the printer 2 From the Front Panel check to see if the auxiliary feeder is recognized by the printer 3 Remove the rear panel of the auxiliary feeder Check for presence of 5 VDG 24 VDC and 3 3 VDC at the auxiliary feeder control board P555 2 4 and 6 Check for continuity of the DC return lines 4 Check the continuity of the serial data link circuit by verifying continuity between Engine Control Board P407B 9 10 11 12 13 and 14 and the auxiliary feeder Board P541 1 2 3 4 5 and 6 5 Replace the Auxiliary Feeder Control Board RRP 60 on page 7 229 6 Replace the Engine Control Board RRP 42 on page 7 206 Printer Will Not Recognize the Finisher The Finisher is connected to the printer by a complementary pair serial data link The Finisher also generates its own 5 VDC from 24 VDC supplied by the printer 1 Check that the Finisher is p
53. printer is shipped aligned registered and calibrated The major disruption that can affect registration is when the NVRAM that contains the registration parameters is cleared requiring that registration be redone For information on resetting NVRAM see Resetting NVRAM on page 6 145 Internal Hard Drive The Phaser 7700 Printer has a standard hard drive installed in every printer The hard drive boots most of the firmware There is a special file on the hard drive that stores the specific calibration values for various sensors and for the unique positioning of the laser in the printer m During manufacturing the calibration values from the engine NVRAM have been written to the hard drive The stored values can be written back to the engine NVRAM by performing a front panel Reset Engine NVRAM Now reset procedure m If resetting engine NVRAM does not restore correct color registration the laser geometry has probably moved in the printer and the registration procedure must be performed After completing the registration process perform the engine NVRAM store function to store the new engine NVRAM values to the hard drive m If the hard drive needs to be replaced there is an engine NVRAM store function in the service diagnostics that enables the current engine NVRAM values to be written to the new hard drive m If the engine control board is replaced the NVRAM values on the hard drive need to be restored to the new board
54. the Finisher Refer to the Printer and Finisher Wiring Diagrams 125 12 399 FINISHER ERROR 125 STAPLE MODE LOGIC FAILURE There are no diagnostics routines or test procedures for problems involving serial communica tions It is recommended to address the following suspect components assemblies in order e Replace the Stapler Assembly RRP 82 on page 11 342 e Replace the Finisher Control Board RRP 77 on page 11 336 e Perform a continuity check on the wiring harness between the Finisher Control Board and the Stapler Refer to the Finisher Wiring Diagram 2 84 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Link Front Panel Message 124 07 250 TRAY COMMUNICATION FAILLURE Check the voltage on the Tray Module PWB between J 555 1 and ground Is the voltage 5VDC Yes No Using the wiring diagrams check and repair the 5VDC circuits to Tray Module PWB J555 1 Check the voltage on the Tray Module PWB between J 555 3 and ground Is the voltage 24VDC Yes No Using the wiring diagrams check and repair the 24VDC circuits to Tray Module PWB J555 3 Do all of the resistances indicate continuity Yes No Check for broken wires or bad contacts on connections that are not 1 ohm or less Change the following parts in the order of priority as listed 1 Interface Board 2 Tray Module Circuit Board 3 Engine Control Board 4 Image Processor Board Turn off the power Check for continuity be
55. the Top Cover 3 4 Open the Image Processor Board Cover to gain access to the 4 thumb Open the Front Cover and remove the front screw holding the Top Cover screws that secure the Image Processor Board metal cover 5 Remove the Image Processor Board metal cover 6 7 Remove the Top Cover Disconnect the front panel cable from the Relay Board P564 7 156 Phaser 7700 Color Laser Printer Service Manual RRP 4 Front Panel Assembly gt NF g i A a Z Z Z E og GE ee Vg lt 2 gt ai Gs EI EL Z Es Se Gr Ca A ll Access Holes 87700 270 Figure 7 4 Control Panel Assembly Removal Warning Turn Off the printer and disconnect the power cord 1 Open the Front Door 2 Release the Front Panel Assembly by inserting a screwdriver or key into the two access holes indicated in the illustration and push the tangs inward to release 3 Lift up the panel slightly and unplug the cable connected to the Front Panel 4 Release the two tabs on the left hand end of the Front Panel Assembly and remove Phaser 7700 Color Laser Printer Service Manual 7 157 RRP 5 Rear Cover Top Rear Power Switch Cover and LH Rear Mid Cover Left Hand Rear Mid Cover Cover Top Rear PS Sy Rear Cover LET i W FAA M ei SS P Cover Left Hand Rear Low 7700 092 Figure 7 5 Top Rear Power Switch Cover and Left Hand Rear Mid Cover Removal Top Rear Pow
56. to the engine board using the Service Diagnostics procedure Reset Engine NVRAM on page 6 150 7 206 Phaser 7700 Color Laser Printer Service Manual RRP 43 Engine Control Interface Board 7700 185 Figure 7 49 Engine Control Interface Board Removal Method 1 1 Remove the Engine Control Board RRP 42 on page 7 206 2 Disconnect the eight wiring harnesses Note Two connectors J537 J536 have locks to release before pulling on the harnesses 3 Remove the two screws that secure the Engine Control Interface Board mounting bracket to the printer frame 4 Remove the Engine Control Interface Board and mounting bracket from the printer frame Method 2 1 Lower the HVPS assembly to a horizontal position 2 Disconnect the eight wiring harnesses Note Two connectors J537 J536 have locks to release before pulling on the harnesses 3 Remove the two screws that secure the Engine Control Interface Board mounting bracket to the printer frame 4 Remove the Engine Control Interface Board and mounting bracket from the printer frame Reverse these steps to install the Engine Control Interface Board Note Ensure that the interface board is reinstalled as high up as possible to ensure full contact properly seated Phaser 7700 Color Laser Printer Service Manual 7 207 RRP 44 T1 and T3 High voltage Power Supplies 7700 18
57. voltage between P530 1 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure 24 VDC Yes No Replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between P530 4 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure 0 VDC Yes No Replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between P530 3 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists repair or replace the harness between Engine Control Board and the Fuser Fan eplace the Fuser Fan Assembly RRP 34 on page 7 195 Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 11 on page 7 165 Measure the voltage between P530 5 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure 24 VDC Yes No Replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between P530 8 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure 0 VDC Yes No Replace the Engine Control Interface Board RRP 43 on page 7 207 Measure the voltage between P530 7 see figure page 2 46 on the Engine Control Board and frame ground Does the voltage measure
58. with the engine NVRAM reset function Phaser 7700 Color Laser Printer Service Manual 4 123 Registration Control RegiCon Adjustment Overview The DC685 RegiCon tests are the means by which registration is accomplished Registration means establishing the alignment of the four primary colors with regard to horizontal and vertical positioning tilt or skew length of lines and linearity When the registration process is completed all color planes are positioned properly Note For any registration procedure to succeed the printer must print with no image defects Verify by printing color solid fill pages see Print Color Test Prints on page 9 289 To resolve a print image problem see Print Image Quality Problems on page 3 108 The printer registration process consists of the Belt Edge Learn Coarse Skew Adjustment Fine Skew Adjustment In Out Skew Adjustment and Center Skew Adjustment with each test reporting success On failure of any of Skew Adjustment the Coarse RegiCon Initialization must be performed Coarse RegiCon Initialization Coarse RegiCon Initialization is the procedure by which the printer aligns the magenta yellow and black vertical and horizontal scan lines to the cyan reference scan line Horizontal and vertical alignment ensures that the magenta yellow and black lines are superimposed on Cyan Figure 1 Horizontal and Vertical Margins Cyan 57700 460 Figure 4 1 Coarse RegiC
59. x 420 mm SP Folio 215 x 315 mm Oficio 215 x 340 mm B6 JIS 128 x 182 mm B5 JIS 182 x 257 mm B4 JIS 257 x 364 mm RAS 305 x 430 mm SRAQ3 320 x 450 mm a Thin Cover Index paper cannot be used in Trays 2 4 Phaser 7700 Color Laser Printer Service Manual 1 27 Table 1 10 Specialty Paper Paper Type and Size Tray 1 Trays Multi High 2 4 Purpose Capacity Tray Feeder Phaser 7700 Premium Transparency Labels Paper Envelopes all sizes e Table 1 11 Print Area Paper Page Size Image Area Margin Sides Top Bottom Statement 5 5x8 5in 5 1 x 8 1 in 2 in 2 in Executive 7 25 x 10 5 in 6 85 x 10 1 in 2in 2 in 8x10 in 8x10 in 7 6x9 6 in 2 in 2 in UK Foolscap 8x13in 7 6 x 12 6 in 2 in 2 in Letter 8 5 x 11 in 8 1 x 10 6 in 2in 2 in 215 9 x 279 4 mm 205 9 x 269 4m 5mm 5 mm m US Folio 8 5 x 13 in 8 1x 12 6 in 2in 2 in Legal 8 5x 14 in 8 1 x 13 6 in 2 in 2 in 216 x 356 mm Tabloid 11x17in 10 4 x 16 4 in 2 in 2 in 279 x 432 mm 269 x 432 mm 5 mm 5 mm Tabloid Extra 12 x 18 in 11 6 x 17 6 in 2 in 2 in A6 105 x 148 mm 95 x138 mm 5 mm 5 mm A5 148 x 210 mm 138 x 200 mm 5 mm 5 mm 5 83 x 8 27 in 5 43 x 7 87 in 2 in 2 in A4 210 x 297 mm 200 x 287 mm 5 mm 5 mm 8 3 x 11 7 in 7 9 x 11 3 in 2 in 2 in A3 297 x 420 mm 287 x 410 mm 5 mm 5 mm 11 7 x 16 5 in
60. 0 1 Damper Gear 7 116 1541 00 1 Damper 8 116 1543 00 1 Switch Fuser Exit 9 116 1544 00 1 Sensor Paper on Belt 830E62811 Sensor Bracket compatible with Phaser 7760 8 238 Phaser 7700 Color Laser Printer Service Manual PL 8 3 Media Trays FRUs 7700 048 Figure 8 3 Media Trays FRUs Table 8 3 Media Trays FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1091 00 1 Universal Paper Tray 2 116 1093 00 1 Universal Paper Tay Stopper 2a 2 Spacer Phaser 7700 Color Laser Printer Service Manual 8 239 PL 8 4 Duplex Unit FRUs 57700 064 Figure 8 4 Duplex Unit FRUs Table 8 4 Duplex Unit FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1097 00 1 Duplex Unit Transport Assembly DU 8 240 Phaser 7700 Color Laser Printer Service Manual PL 8 5 Cover FRUs Figure 8 5 Cover FRUs Table 8 5 Cover FRUs List 7700 058 Parts Part Number Qty Name and Description vendor description 1 116 1178 00 1 Front Cover Assembly Cover Assembly Front 1 Front Cover 2 Magnet 2 Strip 1 Rod Cleaner Assembly 1 Rod Cleaner 1 Cleaner Base 1 Label 1 Label 2 116 1095 00 1 Right Cover Cover Assembly R MN 3 116 1187 00 1 Front Cover Strap Strip 4 116 1116 00 1 Laser Lens Cleaner Assembly Cleaner Rod Assembly 5 116 1117 00 1 Laser Lens Cleaner Base Cleaner Assembly Base 6 116 1317 00 1 Cover Assy LH PH2 P
61. 00T Ethernet connector 8 Bi directional parallel high density connector m DIP Switches The following figure illustrates the rear connections panel of the printer USB Parallel Ethernet DIP Switches Figure 1 18 Printer Rear Connections Table 1 4 Rear Panel DIP Switch Settings 57700 416 Function Switch 1 Switch 2 Switch 3 Switch 4 Normal Customer operating UP UP UP UP mode Service mode UP DOWN UP UP Reset printer UP UP UP DOWN then UP Disaster Recovery mode DOWN UP DOWN UP engineering use only Development mode engineering DOWN DOWN DOWN UP use only Recommended DIP switch position If DIP switch 4 is left in the down position the printer will not turn Off Phaser 7700 Color Laser Printer Service Manual 1 23 Printer Specifications Physical Dimensions and Clearances Table 1 5 Physical Dimensions of the Printer Dimension Value Height 493 mm 19 4 in Print Engine 857 mm 48 in with lower tray deck Width 644 mm 25 4 in Depth 682 mm 26 9 in Weight 82 kg 180 Ibs with consumables installed 122 kg 267 Ibs with lower tray high capacity feeder Table 1 6 Physical Dimensions of Lower Tray Feeder Dimension Value Height 41 4 cm 16 3 in Width 56 cm 22 in Depth 56 cm 22 in Weight 23 5 kg 52 Ibs 160 4 cm 63 1 in 1 96 in 106 1 cm 41 8 in 7700 417 Figure 1 19 Printer
62. 163 3 Remove the Rear Shield Bracket RRP 10 on page 7 164 4 Remove the four screws securing the 24 VDC Power Supply Shield to the printer 5 Remove the 24 VDC Power Supply Shield Note The left hand tab fits behind the Rear Shield bracket to provide the threaded hole for this screw Phaser 7700 Color Laser Printer Service Manual 7 165 RRP 12 Multi Purpose Tray MPT Assembly 57700 132 Figure 7 12 MPT Assembly Removal Note Complete MPT removal is not necessary when doing jobs such as shutter solenoid or main motor assembly replacement Remove the two MPT screws step 5 below and let the MPT hang by the wire harness for partial removal 1 Remove the Top Mid and Rear Covers RRP 5 on page 7 158 Note Note the routing of the MPT Assembly wiring harness The wiring harness feeds through the access hole at the pivot point and up to the connector When assembling be sure the wire harness is behind the mounting tab Release the wiring harness clip from the printer s frame Pull the MPT Assembly wiring harness through the access hole Close the Left Hand Cover Assembly Left Door Remove the two screws that secure the MPT Assembly then pull the assembly out of the printer A slight lift on the right hand side of the MPT Assembly may help remove it from the printer TROND Caution The Duplex Chute RRP 15 on page 7 170 must be in the up position to install the MPT Raise the Duplex Chute by rea
63. 2 ERROR 83 ENGINE LOGIC BOARD NVRAM FAILURE Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Image Processor Board RRP 42 on page 7 206 84 04 371 ERROR 84 CONTROLLER TO ENGINE LOGIC BOARD TIME FAILURE Replace the Engine Control Board RRP 42 on page 7 206 If the problem persists replace the Image Processor Board RRP 42 on page 7 206 85 04 344 ERROR 85 ENGINE LOGIC BOARD MICRO PITCH FAILURE 1 Turn printer power Off then On 2 Ifthe problem persists replace the Engine Control Board RRP 42 on page 7 206 86 04 345 ERROR 86 HIGH VOLTAGE POWER SUPPLY FAILURE Replace the T3 High voltage Power Supply RRP 42 on page 7 206 If problem persists replace the Engine Control Board RRP 42 on page 7 206 87 07 281 TRAY LIFT FAILURE 07 282 07 283 07 284 07 291 07 292 07 397 2 70 Phaser 7700 Color Laser Printer Service Manual Error Chain code Pinks Front Panel Message One at a time pull out and reinsert each paper tray Listen for tray lift Is there an Auxiliary Feeder Lower Tray Deck or a High capacity Feeder installed Yes No H Refer to Tray 1 2 3 or 4 Will Not Lift section page 3 95 in Troubleshooting o any of the Auxiliary Feeder LTD or HCF Trays lift correctly Yes No Refer to Auxiliary Feeder not recognized section page 3 96 in Troubleshooting efer to Tray 1 2 3 or 4 Will Not Li
64. 20 Lift Components FRUS c cccccsccsscsescsessescscsesecetscsescsesacecseseeeessees 8 268 Figure 8 21 Wiring FRU Siirsin nnana genes aa a 8 270 Phaser 7700 Color Laser Printer Service Manual XXV Figure 8 22 Auxiliary Feeder FRUS AA 8 272 Figure 8 23 Lower Tray Deck LTD FRUS nreroverovorrrrrvovereresvovererrrnerereresvsnsnenenn 8 274 Figure 8 24 Lower Tray Deck LTD FRUs eontd 1 8 276 Figure 8 25 High Capacity Feeder ERUN 8 277 Figure 8 26 High Capacity Feeder FRUS cont d ececeseseeeseeeeeeeeeeeeettteees 8 278 Figure 8 27 High Capacity Feeder FRUS cont d eceseeeseeeseceeteeeeeeceetteteees 8 279 Figure 8 28 High Capacity Feeder FRUS cont d seceseeeseeeseeeeeeeeeeeeetteteees 8 280 Figure 8 29 High Capacity Feeder FRUS cont d ceceseeeeeeeseceeeseeeeeeeteereees 8 281 Figure 11 1 Phaser 7700 Color Laser Printer with the Finisher Option 11 313 Figure 11 2 Dimensions of the Finisher esernsnrrrrnerverrsveresvererverrsnerssversssennr 11 315 Figure 11 3 Assemblies of the Finisher msrssrsnsvrsnsvrsverrsverrsvererverrsnersrsernsnennr 11 317 Figure 11 4 Internal Assemblies of the Fieber 11 318 Figure 11 5 Horizontal Transport Sensor Interlock and Switch Locator Map 11 319 Figure 11 6 Finisher Sensor Interlock and Switch Locator Map 00 11 320 Figure 11 7 Finisher Sensor Interlock and Switch Locator ou 11 321 Figure 11 8 H
65. 20V Bracket AC Drive Board Clamp Noise Filter GFI Breaker Wire Harness Wire Harness Wire Harness Wire Harness Screw Wire harness 3 116 1231 00 1 Main Power Switch 4 116 1186 00 1 Outlet Assembly 8 254 Phaser 7700 Color Laser Printer Service Manual PL 8 13 Motors Drivers FRUs 1 5 7700 034 Figure 8 13 Motors Drivers FRUs Phaser 7700 Color Laser Printer Service Manual 8 255 Table 8 13 Motors Drivers FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1102 00 1 Print Cartridge Drive Assembly Drive Assembly Drum 1 Motor 1 Gear Bracket Assembly 2 116 1103 00 1 Accumulator Belt Drive Assembly Drive Assembly IBT 1 Accumulator Motor Assembly 1 Gear Bracket Assembly 3 116 1105 00 1 Main Drive Assembly Drive Assembly main 4 116 1106 00 1 Developer Drive Assembly Drive Assembly Dev 1 Motor 1 Developer Gear Assembly 116 1107 00 Developer Gear Assembly without motor 5 116 1104 00 1 Steering drive assembly Drive Assembly Steer 1 Steering Drive Motor 1 Plate Assembly 6 116 1101 00 1 Agitator Motor Assembly Motor Assembly Agt 7 116 1539 00 1 Clutch Black Developer 8 256 Phaser 7700 Color Laser Printer Service Manual PL 8 14 Electrophotographic Components FRUs 7700 013 Figure 8 14 Electrophotographic Components FRUs 8 257 Phaser 7700 Color Laser Printer Service Manual Table 8 14 Electrop
66. 24 on page 7 179 Inspect the wiring harness between the Engine Control Board and the Developer Housing Assembly Is the wiring harness in good condition Yes No Repair or replace as necessary eplace the Developer Housing Assembly RRP 27 on page 7 185 Replace the Engine Control Board RRP 42 on page 7 206 Note Run approximately 10 pages of solid fill full page prints of this primary color to ensure this error is cleared Phaser 7700 Color Laser Printer Service Manual 2 49 Error Chain gode Link Front Panel Message 13 09 381 ERROR 13 MAGENTA ATC SENSOR FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the NVRAM Access Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Note If necessary enter Service Diagnostics Mode and run the Clear Tech Rep Fault procedure on page 6 149 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RAP 9 on page 7 163 Measure the voltage at P534 5 see figure page 2 46 on the Engine Control Board Does the voltage measure between 1 VDC and 3 VDC Yes No Measure the voltage at P534 6 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board Measure the voltage at P534 0 see figure page 2 46 on the Engine Control Board Does the voltage measure 0 VDC Yes No Replace the Engine Con
67. 253 FINISHER ERROR 115 REAR TAMPER FAILURE Address this problem by investigating and replacing as necessary the following compo nents assemblies in order e Motor Assembly Tamper PL10 15 item 2 for the appropriate motor per error code e Tamper Home Sensor PL 10 15 item 4 for the appropriate sensor per error code e Finisher Controller Board RRP 77 on page 11 336 e Compiler Tray Assembly PL 10 15 item 1 2 74 Phaser 7700 Color Laser Printer Service Manual Error Chain Gode Link Front Panel Message 116 12 254 FINISHER ERROR 116 STACKER HEIGHT SENSOR OFF FAILURE Is the Finisher Stacker Tray installed Yes No Install Finisher Stacker Tray Switch printer power Off then On Inspect the Stack Height Sensor Actuator for proper installation or damage Is the Stack Height Sensor Actuator installed correctly and in good condition Yes No Reinstall or replace the Stack Height Sensor Actuator Switch printer power OFF then ON Enter Service Diagnostics Mode From the Main Menu select Stacker Tests Finisher Sensors Stacker Remove the two screws holding the access door halves together Manually operate the Stacker Height Sensor by moving the actuator Does the display indicate the Stack Height Sensor toggling between H amp L Yes No Remove the Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P850B 5 see figure page 2 46 and Finisher
68. 4 Figure 7 50 T1 and T3 High voltage Power Supplies Removal 1 Remove rear cover and shield RRP 9 on page 7 163 Note Do not disconnect the T1 wire harness at P572 blue connector Disconnect the wiring harness at P J501 and P J574 Disconnect the high voltage wires to the Transfer Roller and at DTS J801 3 Remove the three screws that secure the high voltage power supply assembly to the printer frame and tilt the entire high voltage assembly down nm Note If complete removal is not required there is a restraining strap on the back side of the assembly to hold the assembly in a horizontal position 4 Disconnect the T1 high voltage wire harness at P580 and remove the wiring harness from the clip grommet 5 Disconnect the T3 high voltage wire harness at P581 and remove the wiring harness from the clip grommet Remove the high voltage power supply assembly Disconnect the interconnecting wiring harness at P573 on the T3 power supply board 8 Remove the appropriate power supply board s from the assembly NOD 7 208 Phaser 7700 Color Laser Printer Service Manual Replacement Note Connect the high voltage 2nd BTR and P J 801 wires before securing the assembly to the printer to ensure they are not forgotten Note The grounding point requires the chrome plated screw not a black screw Phaser 7700 Color Laser Printer Service Manual 7 209 RRP 45 3 3 VDC and 5 VDC Low Voltage Power Supplies and
69. 57 Figure 3 2 Toner Cartridge Gear Phaser 7700 Color Laser Printer Service Manual 3 97 Checking the Toner Auger System 1 Power up the printer in Service Diagnostics mode 2 Override the Front Cover Interlock Switch 3 Examine the toner port of the system in question Usually the port should be completely filled to the rim s7700 558 Figure 3 3 Toner Cartridge 4 If toner is not level at the port then the toner in the Toner Dispense Assembly has been augered into the Developer but no fresh toner is being delivered from the Toner Cartridge to the Toner Dispense Assembly Note The Auger Toner level may also appear low if it was recently emptied by heavy printing and has not yet been completely filled up by successive dispense cycles 3 98 Phaser 7700 Color Laser Printer Service Manual Leaving the Toner Cartridge out of the printer run the Toner Dispense Motor test for the system in question Look at the far end of the Toner Cartridge cavity and observe the Dispense Motor Gear rotate Also look along the right side of the Toner Cartridge cavity You should see the Drive Shaft of the Toner Auger System rotate as the Toner Motor operates Inspect the Drive Shaft mechanism and the Motor wiring m Replace the Toner Dispense Motor RRP 29 on page 7 188 if it or its wiring is bad m Replace the Toner Dispense Base Assembly RRP 25 on page 7 180 if the Shaft Drive mechanism is bad 7700 239 Figure 3 4 Toner Di
70. 7 163 Reconnect power and enter Service Diagnostics Mode Measure the voltage at the Engine Control Interface Board P532A 14 see figure page 2 46 Perform the 2nd BTR Motor several times Does the voltage toggle between 5 VDC and 0 VDC when the test is run Yes No Replace the Transfer Roller Retract Sensor eplace the Engine Control Board RRP 42 on page 7 206 21 09 343 ERROR 21 TRANSFER ROLLER RETRACT FAILURE Enter Service Diagnostics Mode Perform the 2nd BTR Motor test Listen for a short run of the motor Did the motor run Yes No Remove the Left Hand Rear Mid Cover RRP 5 on page 7 158 Inspect the Left Hand Cover Assembly wiring harness for damage and ensure all connectors are properly seated If the problem persists replace the Engine Control Board RRP 42 on page 7 206 If the problem continues to persist replace the entire Left Hand Cover Assembly RRP 6 on page 7 160 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Reconnect power and enter Service Diagnostics Mode Measure the voltage at the Engine Control Interface Board P532A 14 see figure page 2 46 Perform the 2nd BTR Motor several times Does the voltage toggle between 5 VDC and 0 VDC when the test is run Yes No Replace the Transfer Roller Retract Sensor eplace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 53 Error Chain
71. 7 185 Figure 7 30 Developer Housing Assembly Recharge rsrsnrnrsvrnrsvrnnrnrnvrrrnnrnennnnn 7 186 Figure 7 31 Toner Dispense Motor Assembly esrrnenrrvrnrrnrrvenrrvenrrrrrsrrrrsrnennrne 7 188 Figure 7 32 Steering Drive Assembly nmmensnsvnvererrrrsvereresvsvsvovererrsnererevesvsrsvenenn 7 189 Figure 7 33 Waste Toner Agitator Motor Assembly rrsnrnrrnrnrrvrnrrrrnrrrrnnrnennrnn 7 190 Figure 7 34 Mark On Belt Sensor cccsesescscsscscscsesecetscsescsesscecscsesececsesesesaeees 7 191 Figure 7 35 Exit Transport Assembly sesnanrsverrrverrrnerrrnerrrverrrnerrrnerssnersrnesssnenne 7 192 Figure 7 36 Reconfigured Inverter ssesrsnrrrsverrrverrrverrrnerrsnenrrnerrrnerssserssnesssnennn 7 193 Figure 7 37 Parts No Longer Installed ncccesiianunossssanan iurant 7 193 Figure 7 38 Interlock Actuator and Spacers c cccccssscssescscsesecetscseesessceescseseeees 7 194 Figure 7 39 Fuser Fan Assembly cccsccceecccescsesssscescesereseedeeserssssevessensssensseenss 7 195 Figure 7 40 Accumulator Belt Assembly cece ccceeeecsseecsseecseeeceeseesseesaeesaees 7 196 Figure 7 41 Belt Cleaner Assembly cccccesescsseseecsesseecscsesecescsesesesscecacseseeees 7 198 Figure 7 42 Waste Auger Assembly ceccsccsesecsessceeecessececsecesaesecaeeesaeeesnees 7 199 Figure 7 43 Laser Unit ASSembly sironnan i 7 200 Figure 7 44 Laser Unit Label 7 201 Figure 7 45 Image Processor Board Assembly srrvenvrn
72. 700 Color Laser Printer Service Manual 4 137 Step 4 RegiCon 2 In Out Skew Adjustment This test makes magnification adjustments for registration Magnification is the length of the scan line for the four colors so that each scan line for each color is the same length The data output can indicate PASSED or READJUST PASSED or FAILED If the result is READJUST the indicated adjustment values for the skew adjustment should be done It should not be necessary to rerun the test after making this adjustment 1 From the Service Diagnostics menu highlight Adjustments Calibration menu and press OK 2 Select Regi Con 685 Setup Cycle and press OK 3 At the prompt Which DC685 procedure select 2 In Out Skew Setup select YES and press OK The front panel now displays lt PostScript will do 685 2 gt 4 The printer now reboots and runs the test Wait for approximately 10 seconds after the motors turn Off and the display indicates Ready To Print then cycle power and enter Service Diagnostics Enter Adjustments Calibration gt Regi Con 685 Results and press OK Wait until the test results are displayed as follows oo DC685 2 Passed A Out Blocks 24 B Out Blocks 0 lt Press Ok for more Data gt Note If the block counts are not the same number as presented here the printer has a print quality problem Please refer to section Streaks in Direction of Paper Travel on page 3 111 to resolve the pr
73. 700 Color Laser Printer Service Manual 9 291 9 292 7700 293 Grid 1 dot This print is especially useful in the manual process of registration when the automatic process consistently fails due to excessive process and lateral margin adjustment There are some printer laser positioning situations where the intrinsic error in lateral margin offset is too great for the DC685 1 test to automatically compensate for and a manual adjustment is required The Adjustments Calibrations Menu Coarse RegiCon Init Test is required to make these adjustments manually before the DC685 1 test can pass When the YMK vertical lines are within 1 2 mm of the cyan line DC685 1 should pass It is recommended that after doing the Coarse RegiCon Init adjustments of the lateral margin offsets make another grid 1 dot print There have been some printers that corrupt the NVRAM and the lines do not end up where you intended them to go You may have to experiment with a different order of moving two or more lines to get the desired results all four colors within a 1 2 mm vertical line Things to look for m Mis registration Phaser 7700 Color Laser Printer Service Manual Fast Scan 8 These four prints of the primary colors are test prints that seem to be intended to find any laser ringing behavior The beam is stepped through 8 halftones in the scan line S
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75. Bracket 7700 193 Figure 7 51 3 3 VDC and 5 VDC Low Voltage Power Supplies Removal Note If removing only one of the low voltage power supplies disconnect the associated wiring harness from the printer and remove the 4 screws that secure the low voltage power supply to the mounting bracket 1 Lower the T1 and T3 power supply to horizontal RRP 44 on page 7 208 2 Disconnect P Js 8 12 15 amp 16 from the low voltage power supplies 3 Loosen the four screws the secure the mounting bracket to the frame 4 Lift the bracket up and out to remove 7 210 Phaser 7700 Color Laser Printer Service Manual RRP 46 LD Power Relay a Fig 2 87700 431 Figure 7 52 LD Power Relay Removal 1 Remove rear cover and shield RRP 9 on page 7 163 2 Disconnect the wiring harness 3 Remove the two screws securing the LD power assembly 4 Remove the LD power assembly Phaser 7700 Color Laser Printer Service Manual 7 211 RRP 47 24 VDC Low voltage Power Supply Fan and Bracket 7700 187 Figure 7 53 Low voltage Power Supply Fan and Bracket Removal 1 Remove the rear cover and 24 VDC shield RRP 11 on page 7 165 2 Remove the Top Power Switch Cover Left Hand Power Switch and Left Hand Rear Mid Covers RRP 6 on page 7 160 Note If only the power supply needs to be removed disconnect the wiring harness and loos
76. C FAILURE Replace the Accumulator Belt Drive Assembly RRP 35 on page 7 196 If the problem persists replace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 59 Error Chain Gode Link Front Panel Message 40 10 348 ERROR 40 FUSER MAIN LAMP FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the Clear Tech Rep Fault Clear lt 10 348 amp 10 350 gt is run Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 4 see figure page 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 1 see figure page 2 46 and P404A 2 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser eplace the Engine Control Board RRP 42 on page 7 206 41 10 349 ERROR 41 FUSER STS FRONT FAILURE Warning Fuser may be very hot Use extreme caution to prevent burn
77. Cyan line being the reference line m Itis best if the default paper tray contains A size paper Top 7700 464 b Figure 4 6 Grid 1 Dot Pattern Orientation for A size Paper 4 140 Phaser 7700 Color Laser Printer Service Manual m Note the leading edge of the paper when removing the test print from the tray Use a pen or pencil to note the leading edge as the TOP of the print Grid 1 Dot pattern annotations on page 4 141 With TOP up note the direction of scan from left to right as the FAST direction The direction from the bottom of the print to the top is referred to as the SLOW direction Up Top Leading edge into output tray Left Fast Right D Oo Down 57700 465 Figure 4 7 Grid 1 Dot pattern annotations m Notice which vertical line color s on the print needs to be moved right or left to line up as closely as possible with the cyan color line m Measure how much each line needs to move in millimeters and whether it must be moved left or right Note Cyan is the reference color and does not move Make the adjustments of M Y and K toward Cyan 4 From the Adjustment Calibrations menu select Coarse RegiCon Init test This time answer No to the Set Factory Defaults Yes No but answer Yes to the Do you want to adjust NVRAM Yes No question Answer No to Set Skew Error threshold Yes No Answer Fast to the Which scan direction Fast Slow 5 Select which color o
78. FO HCF Chute Assembly Inlet 3 116 1167 00 1 Chute Lower HFC Chute Lower Phaser 7700 Color Laser Printer Service Manual 8 279 PL 8 28 High Capacity Feeder FRUs cont d 7700 413 Figure 8 28 High Capacity Feeder FRUs cont d Table 8 28 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1127 00 2 HCF Paper Select Paper Select Switch Assembly Switch 110K11081 Assembly PS Phaser 7760 compatible 2 116 1126 00 1 Switch Assy Paper Select 8 280 Phaser 7700 Color Laser Printer Service Manual PL 8 29 High Capacity Feeder FRUs cont d 57700 414 Figure 8 29 High Capacity Feeder FRUs cont d Table 8 29 High Capacity Feeder FRUs cont d Parts Part Number Qty Name and Description vendor description 1 116 1171 00 1 Bracket Assembly Gear LH HFC 2 116 1170 00 1 Bracket Assembly Gear RH HFC Phaser 7700 Color Laser Printer Service Manual 8 281 Kits Table 8 30 Kits Parts Part Number Name and Description vendor description 116 1210 00 Sensor Flag Kit Sensor Actuator Actuator 120E11971 Actuator Sensor 120E18141 Actuator Sensor 120E18160 116 1211 00 Tray Roller Kit Roll Assembly Kit Pick Nudge Retard Rollers 22K56820 116 1212 00 MPT Pick Roller Kit Roll Assembly Kit 116 1299 00 Sensor Kit Sensor Kit DBP Photo Sensor 130E82190
79. ISHER ERROR 117 STACKER TRAY FAILURE Contin ued While watching the display interrupt the Stack A and Stack B sensors Does the display indicate H amp L for both sensors Yes No Does the display indicate H amp L for one sensor Yes No Replace the Finisher Controller Board RRP 77 on page 11 336 ddress the following components assemblies in order The unresponsive sensor The Finisher Control Board RRP 77 on page 11 336 The wiring harness between the sensors and the Finisher Control Board Replace the Engine Control Board RRP 42 on page 7 206 in the printer 118 12 256 FINISHER ERROR 118 STAPLER FRONT CORNER SENSOR ON FAILURE 119 12 257 FINISHER ERROR 119 STAPLER FRONT CORNER SENSOR OFF FAILURE Open the Front Door Defeat the Front Door Interlock Enter Service Diagnostics Mode From the Motors Fans Tests Finisher Motors Stapler Move Motor test menu select Move Front to move the Stapler to the front of the Finisher From the Main Menu select Sensor Tests Finisher Sensors Stacker Manually move the Stapler Assembly so as to interrupt the Stapler Front Corner Sensor Does the Front Panel LCD show Front Corner toggling between H amp L Yes No Remove the Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P850A 2 see figure page 2 46 and Finisher frame ground Again manually move the Stapler Assembly so as to int
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81. Kit 2 116 1132 00 1 Laser Shutter Solenoid Assembly 3 116 1299 00 1 Paper Feed Sensor part of Sensor Kit mounted on LH Lower Cover 4 116 1299 00 1 LH Lower Cover Sensor part of Sensor Kit 5 116 1299 00 1 Transfer Roller Position Sensor part of Sensor Kit mounted on Left Hand Cover behind Transfer Roller Assembly 6 116 1299 00 1 Paper Detect Sensor MPT part of Sensor Kit 7 116 1210 00 1 Exit Tray Full Sensor Flag part of Sensor Flag Kit mounted on the Exit Assembly 8 116 1299 00 1 Transport Exit Sensor part of Sensor Kit mounted on the Exit Assembly 9 116 1545 00 1 Sensor Front Door Open 8 248 Phaser 7700 Color Laser Printer Service Manual PL 8 10 Circuit Boards FRUs 7700 095 Figure 8 10 Circuit Boards FRUs Phaser 7700 Color Laser Printer Service Manual 8 249 Table 8 10 Circuit Board FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1145 00 1 Chassis Assembly Elec Chassis E B 2 116 1144 00 1 Engine Control Board PWBA MCU 3 671 5268 02 1 Image Processor Board 4 1 RAM SODIMM 156 4832 00 128 MB 156 4663 00 256 MB 5 650 4199 01 1 Internal Hard Drive Programmed 7700 8 250 Phaser 7700 Color Laser Printer Service Manual PL 8 11 Power Supplies FRUs 7700 053 T1 Control bd Figure 8 11 Power Supplies FRUs 8 251 Phaser 7700 Color Laser Printer Service Manual Table 8 11 Power Su
82. Move Sensor Replace the Finisher Control Board If the problem persists replace Printer Engine Control Board RRP 42 on page 7 206 If the problem continues to persist verify the ground continuity between Finisher frame ground and Printer frame ground 2 72 Phaser 7700 Color Laser Printer Service Manual Error Chain code Pins Front Panel Message 113 12 244 FINISHER ERROR 113 STAPLER FAILURE Open the Finisher Front Door Verify the Stapler Carriage is its full home position Enter Service Diagnostics Mode Run the Stapler Head Home sensor test to verify home position Does the sensor indicate home position Yes No Remove the Finisher Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between Finisher Board connector P852 2 see figure page 2 46 and Finisher frame ground while interrupting the Home Sensor Does the voltage toggle between 0 VDC and 5 VDC Yes No Measure the voltage between Finisher Board connector P852 1 see figure page 2 46 and Finisher frame ground Does the voltage measure 5 VDC Yes No Disconnect to the Stapler Unit Assembly Measure again the voltage between Finisher Board connector P852 1 see figure page 2 46 and Finisher frame ground Does the voltage now measure 5 VDC Yes No Replace the Finisher Control Board Replace the Stapler Unit Assembly Measure the voltage between Finisher Board connector P852 5 see figure page 2 46 and Finisher fra
83. OL NOWIAS d NIHAPE d ae sours i OIA Bt ZO0r NIU 0008da NIUS RIIT 4 Wide R ON 90084 S Gy AS 80Vr z2 Liva F ON 90087 g Kee ar 2 r NHO BI ZOOL Ave 5008d Z Z LIN ON 8997 S ON good NIGASE 899d SET 2 2 OIA ee Z001 lune Side Tila ze 001 Avr 899d OIA ze 2001 HIE 899d Si HHC YAMOd M1LNI E GEN 0 0L ENUEN 3011195 18jUd 18587 10 09 0022 1 SVYd Dau ud JO Main 1831 Dipog SdM DAA pz pue peog 01UO UONIBUUO AH J8j OY JAJSUE1I seig pueog eau joNUOD aUbuJ peog joNUOD aulbu3 w A gt BE GJER pJEeog SdAH LLE H 2 J0J28UU09 JsYsiul4 L G05 0L enuep 221185 Jeu JSC 10 09 OOLZ 19S2Yd Ajquassy aseg asuadsiq 13u01 SdATIOAEE UI SdAT 90A EE Ul dig A To yi c emm FF pa FSH Jg ol ZOE OL ENUE 3211185 JajUlld 18587 10 09 0022 18SEUd 491uLd JO 4291 S10 60 0L enuepy 201195 J8jUld 19587 10 09 002Z JASEYd 100q H7 Aiquiassy 18409 pueH y 7 pue LdIN 3 LLE OL Jenueyy 32114858 JajUlld JASET 10 09 0022 J9SEYUd Ajquiassy 103014 Aea Jamo pue pieog A Ajquiassy JOJO Aes 18M07 pueog Ajqwassy A1 JaMOT Phaser 7700 Finisher Figure 11 1 Phaser 7700 Color Laser Printer with the Finisher Option Phaser 7700 Color Laser Printer Service Manual 11 313 This Service Manual contains information useful in troubleshooting repair and maintenance of the Finisher Option for the Xerox Phaser 7700 Color
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85. Phaser 7700 Color Laser Printer Service Manual 2 41 Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Offset Motor Direction Forward Press Up Down to change setting Backward Developer Developer Motor is On CMY only Motor Turn Motor Off All Motors Off Dispenser Disp Motor Yellow Caution Only run this test Motors Magenta once per power cycle Cyan to avoid excessive Black toner forced inside the developer and destroying it Agitator Motor Motor On Press OK to run test Motor Off Fuser Fan Fuser Power Supply Fan is On Turn Motor Off All Motors Off Press Up Down to change setting Paper Path No Pick NoPaperRun Init Runs a complete print cycle only no paper is picked and no toner is dispensed Finisher Motors Optional Miscellaneous Main Eject Forward Eject Release Stacker Motor Up Motor Down Tamper Rear Tamper Low Front Rear Tamper Middle Front Rear Tamper High Front Rear Tamper Low Rear Rear Tamper Middle Rear Rear Tamper High Rear Front Tamper Low Front Front Tamper Middle Front Front Tamper High Front Front Tamper Low Rear Front Tamper Middle Rear Front Tamper High Rear Stapler Close Reverse Move Front Move Rear Press Up Down to change setting 2 42 Phaser 7700 Color Laser Printer Service Manual Table 2 2 Service Diagnostics Test Menu Functions cont d Tes
86. PostScript will do 685 4 gt The printer now reboots and runs the test When the test is complete wait for approximately 10 seconds after the motors turn Off and the display indicates Ready To Print then cycle power and enter Service Diagnostics To display the results you must re enter Service Diagnostics Mode Enter Adjustments Calibration gt Regi Con 685 Results Display and press OK Wait until the test results are displayed as follows DC685 4 Passed A Out Blocks 0 B Out Blocks 4 lt Press Ok for more Data gt Note If the block counts are not the same number as presented here the printer has a print quality problem Please refer to section Streaks in Direction of Paper Travel on page 3 111 to resolve the print quality problems before proceeding further with RegiCon 8 Press OK to see the second panel of data If an adjustment is needed perform the adjustments displayed on the front panel Be sure to tap the screw that was adjusted with a heavy screwdriver to ensure that the adjustment remains true Skew Corr Y 7 clicks CCW Skew Corr M 7 clicks CW Skew Corr C 5 clicks CCW Skew Corr K 12 clicks CCW Note If the test procedure passes no adjustments need be made Continue directly to RegiCon 1 Fine Skew Adjustments Phaser 7700 Color Laser Printer Service Manual 4 135 If RegiCon Coarse Skew Fails This indicates that the horizontal alignment is s
87. R on the Front Panel and blinks the LED 1 2 second On Off continuously The boot Loader then runs POST diagnostics POST turns Off the health LED Post checks the Front Panel If keys have been pushed the front panel displays Processing Input The front panel LED cycles Green Yellow Red Off The graphic panel turns On the LED turns Green and the POST tests are run Power On Self Test POST The following tests are performed when the printer is powered On after the boot loader runs and before the operating system is loaded and initialized Post diagnostics are intended to provide a quick means of isolating a defective subsystem associated with the Image processor board and SDRAM POST Diagnostics Test Descriptions on page 2 34 POST returns control of the boot loader and the operating system is loaded The operating system then loads the imaging processing software If Post detected any soft errors a message is printed in a red box on the start page If POST detects any hard errors both the front panel and health Led blink the error code pattern see LED Blink Patterns on page 2 33 2 32 Phaser 7700 Color Laser Printer Service Manual POST Faults There are two kinds of faults Soft and Hard A soft fault is any fault that is discovered by POST but does not prevent the operating system from initializing and becoming available as a tool for troubleshooting These POST faults do not stop execution and are repor
88. REGI Roll REGI sensor Screw OHP Sensor R L REGI support Wire Harness 5 011E10711 compatible with Phaser 7760 Interlock Actuator not shown 8 264 Phaser 7700 Color Laser Printer Service Manual PL 8 18 Paper Feed FRUs cont d 7700 044 Figure 8 18 Paper feed FRUs cont d Phaser 7700 Color Laser Printer Service Manual 8 265 Table 8 18 Paper Feed FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1165 00 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Transport Assembly Exit OCT Transport Assembly Exit Cover Bearing Pin Exit roller OCT Actuator Bracket Assembly Full Paper Stack Sensor Latch Assembly Spring Pinch Roller Pinch Roller LH Cover Interlock Switch Bracket Eliminator Offset Motor Wire Harness Screw Front Bracket Frame Assembly 2 116 1196 00 1 Exit cover 8 266 Phaser 7700 Color Laser Printer Service Manual PL 8 19 Fans FRUs 7700 408 Figure 8 19 Fans FRUs Table 8 19 Fans FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1176 00 1 Fuser Fan Assembly Fan Fuser 2 116 1175 00 1 24 VDC LVPS Fan Assembly Fan Assembly PSLV Phaser 7700 Color Laser Printer Service Manual 8 267 PL 8 20 Lift Components FRUs 7700 050 Figure 8 20 Lift Components FRUs 8 268 Phaser 7700 Color Laser Printer Ser
89. Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 1 see figure page 2 46 and P404A 2 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser einstall the Fuser Switch printer power ON Does the Fuser get warm Yes No Replace the Chassis AC Power Assembly RRP 49 on page 7 214 eplace the Engine Control Board RRP 42 on page 7 206 2 62 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Pink Front Panel Message 44 10 350 ERROR 44 FUSER SUB LAMP FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 7 see figure page 2 47 and P600 9 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the re
90. Service Manual Xi General Information 1 1 Phaser 7700 Printer Overview c ccccsscsscscssscssssssessssssescsssessseesssesssessceceseesesaeseaees 1 2 Printer RAM and Printer Capabilities 00 0 0 cccecesesescsseececseecsescseeeeeesseseees 1 4 CRC Life Counter Behavior ccccsssscccssssccscsssesssssssscsssssssscssccssesessesseeecaees 1 5 Engine Control Interface and Power Supply Boards seeveverevvrvereresvsvsvovrnerenne 1 6 PoWer SUPplies scires nania iia 1 7 Engine Control and Image Processor Boards c ccccscsssssssscsescsssececseseeceesees 1 8 Auxiliary Feeder Control Board srsrevevererrsvorererrsverovonrvesvoneravrsvsvarevvsvererenvsnener 1 9 Print Engine Sensors and Switches sesesronererrsnsvsvarrrvsvarenesvevsvenerenvsnenvsnsnen 1 10 Print Engine Sensors and Switches eontd 1 1 11 Auxiliary Feeder Sensors and Switches ccccscsesssssscscscseececsesesetscsescseaeees 1 12 Auxiliary Feeder Actuators and Clutches s snsnenesessnsnssnnennnennssesnsseseeenne 1 13 Print Engine Solenoids Actuators and Clutches nsernrvorvorornorornoresvnrerenr 1 14 Print Engine and Auxiliary Feeder Interlocks and Sensors srsnersvorvovererenne 1 15 Image Processor Board vii cs ccscietscscescsetacscrsesacacvarsdnatacsatscsacadeacnsdeaivernseseaseaeees 1 16 Assemblies of the Print Engine sossrsnrnrsverorverrrverrsverrsnerssverssnersrserssnesssnessene 1 17 Assemblies of the Pri
91. TEST INOW SINAVE BEST HIDAS z lt z AOVAYSALNI ges MIN 8d0 ABD ve 2001 Der OM er Z00L 30 OA ST Z001 NIMAS LEST OE Ss gg LER OI Br 2001 EREM Lesr gesd AYO 2 gS IT ST OIA 8r 2001 VI Er ABD e 2001 Sier Om er 2001 hi eS bist Avo OZ ZOOL seer OTINI eona FI Lar Aud ev 00 MIN GA QT ISF AMD BI ZOOL ES AGO LOGE KL ATTELLI DEG besdgeeteor AE KUO Ze 2001 ER Teor Set yorar om sr 2001 NIUACS Se BE WCS EISE Acer OGET eS VOL SF AUD BL ZOOL NlHAPE Ai l Gr SVO IST AUD BI ZOOL Aver 6 VOLST OIA 2001 NIUAS 8 8 AT S VOLSP oa et 2001 AS OOET S DOE b 13A 93 L901 AUMASWNNHO te9do gt z S PZIr Svo rer AUD er 001 NISE 006r E JAA 97 1901 Een Veed gt el rear 755 AUD SI ZOOL HIE DEE E KEISER EIERE vedr tQyorer om er mt Mat ODE FOE pS ESOP ons t901 NIHAEE VeSd gt o veer ZK LEI Om er 2001 Net OO ROE ayyog eg SSOP 13A ga 1901 NUMdSMNHD ER el O vesr REI VOLST Aud BI ZOOL AE ET 6 SSOP TSA 92 1901 MTOANO 29de vedr 73 Ly oror Ao er 200r 1 R ELIAN 13A 92 TOOT AVIVASNNUO FEI g GE 73 asor OlA 92901 WIES edd EZE OW AV 134 ON za S Glo 7298 gt Sova 75 GYVOE 8 ee T K TSA G2 1901 UMA 22d v 9 VS0PT aa oz 1901 MOSMNHO STII g HOSS300t4d amp gS VSOP ISA 82 1901 NVIVGSNNYD ZZ9d gt y 8 HK SOFT Olm oc 1901 VIDE Sie KEEN EEEEEESREEEKR JOvNI ZB VSOPT Jaa 9z 1901 OMTOSMNHO ZEIT SWSOFT 1aa sv 1901 OVIVSNNUO eu9d g Odd 81HS33S VSOVM Om se 1901 NINACE ZIAD e MEN N EE ON z g FO o 298 RER 73A T3NVd OA i T
92. Troubleshooting AC Power on page 3 89 If 5 VDC is present but 3 3 VDC is not Troubleshooting the 3 3 VDC and 5 VDC LVPS on page 3 90 If 3 3 VDC is present but 5 VDC and 24 VDC are not Troubleshooting the 3 3 VDC and 5 VDC LVPS on page 3 90 If 5 VDC is present but 24 VDC is not Troubleshooting the 24 VDC LVPS on page 3 90 Nn D gt OF CO N Phaser 7700 Color Laser Printer Service Manual 3 89 Troubleshooting the 3 3 VDC and 5 VDC LVPS Note Turn the printer power Off and disconnect the power cord 1 Remove the rear cover and rear shield 2 Disconnect the harnesses to connectors P501 P574 P801 and 2ndBTR of the T1 HVPS remove 3 screws and lower the T1 HVPS to horizontal RRP 44 on page 7 208 Connect AC Power and turn the printer On Check for proper AC Voltage at the connector at the bottom of the LVPS If not present go to the Troubleshooting AC Power section link 5 Check for 3 3 VDC or 5 VDC at the connector at the top of the LVPS If correct voltage is not present unplug the connector and retest If no voltage is present replace the LVPS If the voltage returns check the harness Image Processor Board Engine Board and Relay Board for shorts Troubleshooting the 24 VDC LVPS AU Note Turn the printer power Off and disconnect the power cord Note The 24 VDC LVPS requires a 5 VDC enable signal to operate Ensure proper operation of the 5 VDC LVPS before proceeding Remove the rea
93. VDC Interlock Circuit runs from the 24 VDC LVPS to the L H Door Interlock Switch the R H Door Interlock Switch and the Front Door Interlock Switch back to the Engine Control Interface Board then into the Engine Control Board Opening this circuit prevents the Laser Unit and the High voltage Power Supplies from operating 1 With all doors closed and printer power On check for 24 VDC between P535 2 of the Engine Control Interface Board and frame ground 2 If 24 VDC is not present see Troubleshooting the 24 VDC LVPS on page 3 90 to verify the 24 VDC LVPS is working 3 If working then check the LH Cover Interlock Switch the RH Cover Interlock Switch and the Front Cover Interlock Switch Phaser 7700 Color Laser Printer Service Manual 3 91 The 5 VDC Interlock Circuit The 5 VDC Interlock Circuit runs from the 5 VDC LVPS to the L H Door Switch then to the Engine Control Interface Board out to the R H Door Switch back to the Engine Control Interface Board out to the Front Door through the coil of the LD Power Relay and back to the 5 VDC LVPS This circuit helps identify which door has interrupted the 24 VDC circuit If the circuit is complete LD Power Relay activates and 5 VDC is sent to the Waste Cartridge Installed Interlock Switch and through all four Print Cartridge connectors and to the Engine Control Interface Board This signal merely confirms that all Print Cartridges are installed Individual missing components are
94. X C Displays current temperatures Temp Humidity Humidity is XX Fuser Front Temp is XXX C Displays current temperature Temperature Back Temp is XXX C Fault List No Faults Detected Power up only current static lt nn nnn gt Fault Text condition not a history log Front Panel Adjust Contrast Adjust Value 1 15 8 Default Adjust Yes 1 Highlight Yes and press OK No 1 Press UP Down to Adjust Backlight On 2 Press OK to accept new value and Yes exit No Jam Info No Static Jam Detected Location of Jam or Static Jam area name Built In Test Prints Prints pre defined images stored in the engine firmware for troubleshooting image quality problems Paper Path Options For Print Laser Check only Selects tray count of continuous sheets simplex duplex offset media type weight finisher staple Source tray Tray 1 4 MPT Yes No Press Up Down to change setting Current sheets is n Select new sheets Yes No 1 Press Up Down to change the number 2 Press Info to shift column Simplex Duplex Change Duplex setting Yes No Press Up Down to change setting 2 36 Phaser 7700 Color Laser Printer Service Manual Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Offset None Auto Front Rear Press Up Down to change setting Set a new offset Yes No Media Type Press Up Down to
95. X18 ve 2220L MO0 10NLI0 TEL Od lt SH l gt Lior N18 tZ Zz l LLAH 660 01 jenueyy SOA JOJUL JAS 10 09 0022 J8S8Yd ef fei tO gu L A1 s L E vL h OIA S LEOL NLYAS 6 D 8 v008d OIA 92 GLOL NLYAS g LEST I IWNOILdO 22777 TER HEER DICK NIuns Greer v008d z 4 LINN aoea arer is A CELE ELS Q8008d Azzo NOMOLINdINO aresro e a008d T13A 97 22201 1NdLNO OL NOW ELE YSHSINI4 2qooed aar ___ INdINO OL NOW alesry 3 g008d 13A 92 22201 DISSIOISSY k 9 D a008d 13A 9221201 EREECHEN g008d DA O 22201 JT8VNIHLNdLNO GLEST re ME ee EN EOSTTF AHD 92 L90L AE E avesr YNS 3ZIS uddvd L AVOL z Stir TSA 92 1904 UNSHHIZISL GVEST SSTTT Oe 1901 VIDE aveST EST NER ES 4 ONS ar SEIT 3 zera CEKA NS SEET oly ZEIT ease 13A 92 1901 WUNS FOlW_avesr zerr St gt Zerd OIA ee 1501 NIUAS apesr cel LEIT S L TETS AUD 92 1901 AS arer oly TEIT Wees JA 9 1901 OUNS FOlY_apesr LEIT LE Ld OIA 92 L90L NLYAS avesr LELH IN HNS T og LT O ld AHD 97 1901 AS avesr Cl EIT 5 RET Jaa oe 1501 NONSTJDIV SEEST oeir S amp verd OIA Se T907 NIUAS avesr og Lu Farr E t Sara AGS 9s 1901 I SEET O1V SST p 8 Bard TSA Se 1901 AUNS FOIW aresr 6clr ig g 6ztd OIA 92 L90L NLYAS avesr KO zi DR Zei Teer na ed 1e0r
96. XEROX Service Manual 701P28180 Phaser 7700 Color Laser Printer XEROX Service Manual 701P28180 Phaser 7700 Color Laser Printer Warning The following servicing instructions are for use by qualified service personnel only To avoid personal injury do not perform any servicing other than that contained in operating instructions unless you are qualified to do so This printing December 2006 Prepared By Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville OR 97070 O 2006 by Xerox Corporation All rights reserved Unpublished rights reserved under the copyright laws of the United States Contents of this publication may not be reproduced in any form without permission of Xerox Corporation Copyright protection claimed includes all forms and matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted including without limitation material generated from the software programs which are displayed on the screen such as styles templates icons screen displays looks etc Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale These materials may not be distributed copied or otherwise reproduced without prior written consent from Xerox Corporation XEROX CentreWare Phaser PrintingScout Te
97. Zest op ZSSF lt YNS TNS HINOL t EEIPAUD p eLeor EE IP HA ve eleot gt TeEIPOIA ve Z220 NHO ve 2Ze0r Drui BUET gt NHO pa 22201 IER BUET Ae OlA be 22201 NIHAPE SOM dg OIA ba eZ20r NIHAPE GOPr SL OIA va eZeor HIE voorr SE NHO ve 22201 BiinDAper VOT JOS H3 LLNHS s Kroer Mia pe e220 STSUSLINHS voorr og p egr0er NHO ba eleor Aver V9OOPT gt voer N1a ve eZZ0 dINSIOSHSLINHS VSOPr rou Z L wS0rd vrord x GYUVOHS 104LNO9 SNIDNI Lord 60d z z v90vd ov DN er ar DL aS VroPr AO Oe 1901 ASF Gl9d LIS TWP0Pr TEA OS 1901 MNHV ANS 619d VIE OIA OZ 1901 NIGAS 619d VPOPT 13A 921901 dWLAFANS GLOG Spor ON Ugen AUD ST TOOL AST GC Dae yr ane Teorano senges Om S gt yrorr Tan Ge Toor oS aang seeds Om S gt yrorr oinee Teor asna esas Om ror TaN WE TOOTSIS INOUA used Dror OIN ST TSOTaND Sis erra OG vor TaN VE TOOTSIS INOT eeoa Oe Leger on oe Te0TaND Sis vesa Gs sou 87077 3 G a20 13A be L001 AVUISANITLOH 6 a20 14A 2 100 1SG NOWdO 6 S 8Z0vr 1aA va 2004 HO AVEL 6 alorr AWO pe LOOT PHO AVEL 6 eg BLOF TIA va LOOT MON OLAVEL 6 azor 13A ve LOOT FAVHLOLNON 6 KR aort 13A be 2001 NVdrOMGG 0 98 HLOPP OIA zz 1901 NLUAP 0 SELOP NR OT 1901 DILNDAPGT 0 pS HLOPT Ola aa 1901 HIE o eg HLOPT AUD Ze 1901 ASF 0 zS WIOPT 13A va 2001 MOSONGd 0 8 8Z0Pr 13A va 2001 NOSIONGG 0 H
98. aaL SE TAA se 1901 z GAVYL LONIYE OIA 82 190r NIENS ee OIA 92 voor 3 ovner TAKE TOOT VEIDAE ral ES ELNETT 3 Virer 3A 92 1901 ESE TSA ba 22201 Mao Ala 82 F901 OFUNT WOOSLONS ei Ei fig va Z2z0b s LOW dN tyne Tia Se 1501 bruNDeNOOSINNG STE DECK gt a334 2 AvOL viver Jaa se 1901 VNSLONS aA ba eZe0r s Vist K IERE ENSLOWS i 13A ve 220r S 6 p ABD 82 1901 AVELOL NOW on Sr AUD se 1501 NOW OL AVEL DN 2 ON EEDI S TTET AHO 7 1501 FI AVL CED Sr TAA OZ TOOT 79 AVEL EED p SN ssor SE Parr TSK ST TOOT more EED OTET aA 92 1901 AVHLYSNILON ger lt t 699r NOILOANNOO YJLNIHd ON eB ON GL eco OM 22 Z00T RIMASE eoor 99 S ESSET DEER Acer eoor 9 RE OM ee Z00T RIES eoor S Ee Aessen ERZA ver ssor SE RE OIA ee 2001 TRIAS wor 92 EN AUD ee ZOO Aer goer st eoor enue 211495 19jUlld JASE 10 09 002Z J8StYUd p EZI 701P28180
99. ace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at P534 10 see figure page 2 46 on the Engine Control Board Does the voltage measure 0 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 emove the Print Cartridge Plate Cover RRP 24 on page 7 179 Inspect the wiring harness between the Engine Control Board and the Developer Housing Assembly Is the wiring harness in good condition Yes No Repair or replace as necessary eplace the Developer Housing Assembly RRP 27 on page 7 185 Replace the Engine Control Board RRP 42 on page 7 206 Note Run approximately 10 pages of solid fill full page prints of this primary color to ensure this error is cleared 2 52 Phaser 7700 Color Laser Printer Service Manual Error Chain code Pinks Front Panel Message 20 09 342 ERROR 20 TRANSFER ROLLER CONTACT FAILURE Enter Service Diagnostics Mode Perform the 2nd BTR Motor test Listen for a short run of the motor Did the motor run Yes No Remove the Left Hand Rear Mid Cover RRP 5 on page 7 158 Inspect the Left Hand Cover Assembly wiring harness for damage and ensure all connectors are properly seated If the problem persists replace the Engine Control Board RRP 42 on page 7 206 If the problem continues to persist replace the entire Left Hand Cover Assembly RRP 6 on page 7 160 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page
100. ake sure the Color Grayscale option has been selected 2 Check the version 3 Ensure the driver setting TekColor is not set to Monochrome mode Image is Rotated 90 Degrees 1 In the application s Page Setup make sure that the image is selected to print in portrait or landscape orientation to match the document Also ensure the selected paper size is correct 2 Ensure that the printer can print by printing an internal front panel test print Windows Printing Problems Image never prints Printer acts as if it is receiving data but nothing comes out of printer or the printer goes back to Ready mode with out printing image Try printing from the printer driver Try printing from another application Try printing to another printer Try printing from another computer Try printing an internal front panel test print OO P COM ch 3 104 Phaser 7700 Color Laser Printer Service Manual Troubleshooting Network Problems The Phaser 7700 printer maintains 4 logs in memory detailing network functions The logs contain TCP IP Netware and AppleTalk initialization events The logs can also be accessed remotely via CentreWare The logs list events chronologically The log is limited in length when the log is full the printer stops recording data to the log The logs are stored on the Hard Drive so only new data is stored each time the printer s power is cycled There is a Connection Setup Page Configuration Page and a
101. ble 11 9 Paper Transport Assembly FRUS List ccc ceseeeeeesseeesseeeeeees 11 359 Table 11 10 Paper Transport Assembly FRUs List cont d 11 361 Table 11 11 Staple Unit Assembly FRUS ei 11 363 Table 11 12 Compiler Tray Assembly FRUS Uert 11 365 Table 11 13 Stacker Elevator Assembly FRUS et 11 367 Table 11 14 Exit Assembly FRUS ei 11 369 Table 11 15 Electrical FRUS et 11 370 xxii Phaser 7700 Color Laser Printer Service Manual List of Figures Figure 1 1 The Phaser 7700 Color Laser Printer shown with the High Capacity Feeder 1 1 Figure 1 2 Engine Control Interface and Power Supply Boards cccccseeseeeeees 1 6 Figure 1 3 Power Supplies ccccsssssscssessscssssssssssssessecssscsssessssesseescaeseaesessseesees 1 7 Figure 1 4 Engine Control and Image Processor Boards ssssssssesssseesressesseeeeen 1 8 Figure 1 5 Auxiliary Feeder Control Board 1 9 Figure 1 6 Print Engine Sensors and Switches cccceseccscsesecsesesseececseseeeceesees 1 10 Figure 1 7 Print Engine Sensors and Switches cont d ccsesceeeeeeeeeeeeees 1 11 Figure 1 8 Auxiliary Feeder Sensors and Switches ssransvavorerrnvovereresvsvsvovenerrnne 1 12 Figure 1 9 Auxiliary Feeder Actuators and Clutches cccsccccceseeeeeeeeeeteeeeeees 1 13 Figure 1 10 Print Engine Solenoids Actuators and Clutches 1 14 Figure 1 11 Print Engine and Auxiliary Feeder Interlocks and Sensors 1 15 Figure 1 12 Ima
102. blies two on the left and one on the right side of the Printer 1 20 Phaser 7700 Color Laser Printer Service Manual Front Panel Description The Front Panel consists of one tricolor LED a display window and six functional keys These keys navigate the menu system perform functions and select modes of operation for the printer LED indicators m Green Ready to print printing m Flashing Green Receiving or Processing Data m Yellow Warning m Red Fatal Error Phaser 7700 57700 437 Figure 1 17 Front Panel Table 1 2 Front Panel Key Descriptions 1 LED Power Status 5 Up Arrow Button moves up the menu system 2 Graphic front panel display 6 Down Arrow Button moves down the menu system 3 Cancel Button 7 OK select Button 4 Back Button 8 SEH Button for additional explanation or elp Phaser 7700 Color Laser Printer Service Manual 1 21 Front Panel Shortcuts You can perform several service tasks by using the options shown in the table Table 1 3 Front Panel Shortcuts Mode Press this selection at Power On Skip execution of POST diagnostics OK Print service diagnostics map INFO Reset PostScript NVRAM BACK OK Password Bypass UP DOWN Enter Service Diagnostics BACK INFO 1 22 Phaser 7700 Color Laser Printer Service Manual Rear Panel Connectors The rear panel of the printer features the host interface connectors and DIP Switches m USB port m Twisted Pair 10 1
103. ce diagnostics temperature test Ensure that the paper is correctly loaded in the tray and the tray has not been over filled Try loading paper from a fresh ream Flip the paper over Clean the pick rollers with a clean dry lint free wipe Replace the paper pick rollers Check the tray s retard roller for damage Replace the paper tray Oo why ONO oo N Mis pick 1 Check that the correct type of media is being used 2 Try loading paper from a fresh ream Flip the paper over 3 Clean the pick rollers with a clean dry lint free wipe 4 Troubleshoot the pick roller assembly Skewed Image The image area is twisted or is not parallel with the sides of the page but the printer neither jams nor displays an error code 1 Ensure that the paper guides are set correctly 2 Check that the correct type of media is being used 3 Ensure that the tray has not been over filled Skewed images are a common defect when the MPT is filled too high 3 106 Phaser 7700 Color Laser Printer Service Manual Damaged Prints The printed page exits the printer either wrinkled creased or torn The printer neither jams nor displays an error code 1 Stop the paper in the paper path to determine where the media becomes damaged 2 Feed paper through the printer from each of the available trays Is the paper damaged when fed out of one tray but not when fed out of the others If so inspect the tray for damage ensure tha
104. cedure only needs to be performed if the Laser Unit has been replaced The RegiCon procedures are listed in the Adjustment Calibration Menu of Service Diagnostics as RegiCon 685 Setup Cycle and are split into several sections The should be performed in the order listed for optimal adjustments The test procedures should be performed in the following order Each test must be successful before proceeding to the next Refer to the RegiCon Flowchart on page 4 133 Check Print quality RegiCon will fail if there are any print quality problems or if the MOB Sensor is not functioning correctly 1 Select the Print Halftone pages from diagnostics and examine the page for any print quality problems Diagnose and repair any print quality problems before running any RegiCon procedure 2 Exame the shutter on the MOB Sensor and verify that it is not dislodged and moves freely without contacting any other parts 3 If RegiCon appears to run correctly but No Results is displayed one of the Sensors on the MOB Sensor Assembly or the Laser could have failed or the usrstart del snippet needs to be downloaded to the hard drive Note The preferred method to correct any color registration issues is to follow the Reset Engine NVRAM procedure page 6 150 This will write the stored original printer specific RegiCon values from the Hard Drive to Engine NVRAM If this does not restore Proper Printer Color Registration then proceed with RegiCon Adju
105. ch or short wires under the main drive assembly bracket Make sure that the red Bias Transfer Roller wire is connected near the right side of the main drive assembly to its mating connector on the frame 7 216 Phaser 7700 Color Laser Printer Service Manual RRP 51 Accumulator Belt Drive Assembly 7700 007 Figure 7 57 Accumulator Belt Drive Assembly Removal 1 Remove the Rear Cover and Shield RRP 9 on page 7 163 2 Lower the T1 and T3 power supply to horizontal RRP 44 on page 7 208 3 Remove any components covering the motor which is mounted to the frame at the rear top left corner 4 Remove the three screws that secures the motor and bracket assembly to the frame and remove the assembly Phaser 7700 Color Laser Printer Service Manual 7 217 RRP 52 Developer Drive Assembly 57700 008 Figure 7 58 Developer Drive Assembly Removal 1 Remove the 3 3 VDC and 5 VDC Power Supply and bracket assembly RRP 45 on page 7 210 2 Disconnect the wiring harness from the Developer Drive Assembly 3 Clear the high voltage lines 4 Remove the two black screws securing the Developer Drive Assembly to the printer frame and remove from the printer Note When reinstalling rotate the main drive to ensure the gears move freely 7 218 Phaser 7700 Color Laser Printer Service Manual RRP 53 Print Cartridge Drive Assembly Figure 7 59 Print Cartridge Drive Assembly Removal
106. change setting Set New Media Type Yes No Output Destination Press Up Down to change setting Change Output Setting Yes q P g Note This option is only No available with an optional finisher installed Stapling is Press Up Down to change setting Set new stapling options Yes BEES Note This option is only No available with an optional finisher installed Print Laser Fuser warming up This is a quick test for all four laser Check Laser Init colors including developer and toner Startup Imaging Delivering All four primaries are present on the Finishing page The print should appear grey Laser Done Print Halftones HalfTones Init Startup Imaging Delivering Prints 6 pages of 100 solid fill for Yellow Magenta Cyan Black Red Finishing and Green HalfTones Done Print Grid 1 dot Grid Init This print displays the four primary Startup Imaging Delivering color lines in a grid pattern Finishing Registration Control Procedures on Grid Done page 4 130 Print Fast Scan 8 Scan Init Prints four pages of eight tones for Tone Startup Imaging Delivering each primary color Finishing Note Use SEF to see all scans Scan Done Sensor Tests The technician should test the functionality of each sensor by blocking the sensor and watching its state change on the front panel Note Several jam sensors only change state if a jam has occurred All doors interlock switches must remain closed or defeated to
107. ching into the MPT installation hole Caution When reinstalling the MPT make certain you DO NOT pinch the wire between the left bracket and the left screw hole 7 166 Phaser 7700 Color Laser Printer Service Manual RRP 13 Multi Purpose Tray Paper Pick Rollers 57700 086 Figure 7 13 Multi Purpose Tray Pick Rollers Removal 1 Open the left side door Locate the pick rollers near the duplex chute 2 Slide the white retainers away from the pick rollers 3 Slide the pick rollers off the retaining pins 4 Lift and remove the pick rollers Phaser 7700 Color Laser Printer Service Manual 7 167 RRP 14 Left Hand Cover Assembly Left Hand Door 75 90 Plastic degrees Hamess Cover 87700 142 7700 127 Figure 7 14 Left Hand Cover Assembly Left Hand Door Partial Removal 1 Partially remove the Multi Purpose Tray RRP 12 on page 7 166 2 Remove one screw from the plastic harness cover inside the empty MPT slot and remove the plastic cover 3 Open the Left Hand Door 4 Remove the retaining clip from the restraint post 5 Support the Left Hand Door then remove the restraining bracket from the door 6 Carefully lower the Left Hand Door until it stops Complete Removal 1 Remove the MPT RRP 12 on page 7 166 2 Remove one screw from the plastic harness cover inside the empty MPT slot and remove cover 3 Open the Left Hand Door Note Note how the wiring harness is routed through the access
108. ctor in this harness J870 behind the Front Cover Remove Front Door to repair replace the harness Repair or replace the wiring harness between the Finisher Control Board and the Stack Height Sensor Replace the Stack Height Sensor RRP 73 on page 11 332 Repair or replace the wiring harness between the Finisher Control Board and the Stack Height Sensor Note There is an intermediate connector in this harness J870 behind the Front Cover Remove Front Door to repair replace the harness Replace the Finisher Control Board RRP 77 on page 11 336 Replace the Finisher Control Board RRP 77 on page 11 336 117 12 255 FINISHER ERROR 117 STACKER TRAY FAILURE Remove the Finisher Front Cover and Rear Cover RRP 72 on page 11 330 Defeat the Front Cover Interlock Enter Service Diagnostics Mode From the Main Menu Motors Fans Tests Finisher Motors Stacker Run Motor Up and Down tests Does the Stacker Tray move up and down Yes No Inspect the Stacker Motor Assembly and Belt Bracket Assembly for damage Replace as necessary Does the Stacker move now Yes No Replace the Finisher Control Board RRP 77 on page 11 336 roblem solved Drive the Stacker Tray to its highest position using the Motor Up test From the Main Menu select Sensor Tests Finisher Sensors Stacker 2 76 Phaser 7700 Color Laser Printer Service Manual Error Chain Gode Pink Front Panel Message 117 12 255 FIN
109. cumulator Belt to an inner position of the belt at approximately 1 3 the distance from the edge to calibrate the CENTER components of the scan line for the magnification balance adjustment page 4 139 Phaser 7700 Color Laser Printer Service Manual 4 129 Registration Control Procedures Note For the following procedures you must perform certain steps prior to during and after the tests are run The following information is vital to the process and must be followed in order for each procedure to function properly If the adjusting screws reach their maximum adjustment range either Clockwise or Counter Clockwise center the adjusting position of the screws and restart the RegiCon procedure The adjusting screws have 18 complete turns from fully CW to fully CCW To adjust the screws to the center position turn the screw to either limit and then turn it back 9 complete turns Table 1 RegiCon Procedure Step Actions and Questions Yes No 1 Print the Grid 1 Dot print from Diagnostics Complete The Go to step 2 Do all the colors align correctly This color registration means that all the colored lines will appear Problem is not merged when viewed with the naked eye If related to viewed under magnification all colors will RegiCon not overlap perfectly in all areas of the page 2 Perform the Reset Engine NVRAM Go to step 3 Perform the procedure page 6 150 using the Coarse RegiCon ORIGINAL Hard Drive from the printer I
110. ddle Shaft Figure 11 21 Paddle Shaft Removal 1 Remove the Rear Left and Right Covers RRP 72 on page 11 330 2 Remove the Cam Bracket Assembly RRP 81 on page 11 341 3 Remove the Staple Unit RRP 82 on page 11 342 4 Remove the e clips from both ends of the shaft 5 6 7 8 Remove the gear and bushing from the front end of the shaft Remove the bushing from the front and slide out the shaft Remove the Bushings and KL Clips from both ends Slide the shaft to the rear and slide out Phaser 7700 Color Laser Printer Service Manual 11 339 RRP 80 Paper Transport Motor Motor Assembly Main lt gt Nyre op 7700 338 Figure 11 22 Paper Transport Motor Removal 1 Remove the Rear Cover RRP 72 on page 11 330 2 Remove four screws 3 Undo the connector and lift the motor up and then out to free the belt 11 340 Phaser 7700 Color Laser Printer Service Manual RRP 81 Cam Bracket Assembly 87700 341 Figure 11 23 Cam Bracket Assembly Removal 1 Remove the Rear and Top Covers RRP 72 on page 11 330 2 Remove one screw securing the Decurler Cam Sensor 3 Remove one screw from the Eject Clamp Home Sensor 4 5 6 7 Disconnect the wiring harness from the Set Clamp Home Sensor Remove the wiring harness from the bracket Disconnect the wiring harness from the Eject Motor Remove four screws from the bracket and remove the Cam Bracket Assembly Note When reinstallin
111. ducts Phaser7700 Phaser7700Snipp ets html 5 The MOB Sensor could be malfunctioning Note Remember to re enable Netware after any RegiCon procedures have completed and new NVRAM values have been saved to the Hard Drive If you waited the required 10 seconds before re booting and did not get any results verify that the MOB Sensor is operating correctly by running the ADC Output check from the Adjustments Calibration menu The test provides results that indicate if the ADC Sensor shutter is working and if the Sensors are working and reading the ADC patches It also has an LD Illum warn and if a color CMYK is shown in the parentheses the Laser has probably failed Example of a Normal Result Note Values denoted with a are examples of results and will be different from printer to printer The ADC Output Check may need to be run several times to calibrate the Sensor as close to the target value as possible If the prints remain dark after running the ADC Output Check and teh Fast Scan 8 tone prints do not look similar replace the Engine Control Board page 7 207 The first two screens indicate that the test ran without errors Result 0 Stop Status 0 ADC Sensor Fail 0 ADC Shutter Fail 0 LD Illum War None ADC Patch Fail _None VBCR Warn None VBias Warn None The next four screens display values for each color The target value is a set value and the Ave and Ideal numbers are the readings for the Sensor and may change 4 128 P
112. e Communications Failure on page 2 70 Troubleshooting Printer Comes to a Ready State False LH Door RH Door or Front Door Open Messages See procedure for Troubleshooting the Interlock Circuit on page 3 91 False Load Paper in Tray 1 2 3 4 Message In order for the printer to recognize paper in the paper tray one or both of the top two Paper Size Switches must be closed the Tray Level Sensor must be actuated by the lift mechanism and the No Paper Sensor must be deactuated 1 Remove the Paper Tray and check for damage Check the No Paper Sensor actuator for damage and freedom of movement If it is a Universal Tray swap the tray with another if available 2 If available swap the Feeder Assembly with one from another tray Does not apply to HCF Tray 4 3 Enter Service Diagnostics Mode and run the sensor test Check sensor operation by lifting and lowering the No Paper Sensor Lever while observing the display 4 Verify continuity of the wiring between the No Paper Sensor and the Control Board 5 If the problem is with Tray 2 3 or 4 replace the Auxiliary Feeder Control Board RRP 1 59 6 Replace the Engine Control Board RRP 42 on page 7 206 False Tray 1 2 3 4 Missing Message In order for the printer to recognize the presence of a paper tray one or both of the top two Paper Size Switches must be closed Note There are special instances where a false Tray Missing error can be reported C
113. e Power Supplies and Bracket 7 210 LU Power Relay ses cesiss cscs ceecteedepctedteeses srstededebetseedticedelacstatendaewicideectectiaecst 7 211 24 VDC Low voltage Power Supply Fan and Bracket s s nn1s110101101 7 212 T2 High Voltage Power Supply 7 213 Chassis AC Power Assembly c cccccccsesecscsesesesssscscscsesececsesesssecseseenees 7 214 Main Drive ASSembly ccccceccceecscsecececcecseeceeecsececsecsesesacesaesesaeeesaees 7 215 Accumulator Belt Drive Assembly s rsrnrrrrnrvrrnrnrrnrnrrvenrrvenrrvenrrnensrnenne 7 217 Developer Drive ASSembly uc cccceccsccscsseecsseecssescececseeseessesessesesaeeesaees 7 218 Print Cartridge Drive Assembly sesnrnvorevrnvavererenvsvsvavenerrsvrrevenesvsverenenn 7 219 Tray 1 Paper Select Switches nemeneerrvervsvovovorerrrrsvereresvsrsvoveresnerenenne 7 220 Main Lever Assembly Right and Left Hand Jacks ccccccccsccscsscsessedesccstetesessesteseatesedtecedecsrstesteneanciedbesestess 7 221 Auxiliary Feeder Covers need 7 225 Auxiliary Feeder Cover Assembly smovenrvrnvrvererrrvsversvererenvovereresrsverenenne 7 226 High Capacity Feeder HCF Tray 3 7 227 High Capacity Feeder HCF Tray 4 and Paper Transport cccee 7 228 Auxiliary Feeder Control Boards c ccccccscsscccscsesssssscsescsesecessesesecesaees 7 229 Auxiliary Feeders Motor Assemblies 7 230 Auxiliary Feeder Paper Select Switches mmmmmmmmeemmemmee 7 231 A
114. e eens 7 171 RRP 17 Transfer Roller Assembly 2nd DIR 7 172 RRP 18 Duplex Transport Assembly 00 c cece cece ees 7 173 RRP 19 Fuser Unit 2 0 0 ccc eee eee tenn enees 7 174 RRP 20 Registration Transport Assembly 00 00 cece eee eee 7 175 RRP 21 Shutter Solenoid Assembly 0 0 ccc cece eee eee eee 7 176 RRP 22 Tray 1 Feeder Assembly and Paper Lift Motor 7 177 RRP 23 Waste Cartridge Sensor Holder 7 178 RRP 24 Print Cartridge Plate Cover 7 179 RRP 25 Dispense Assembly 0 00 cece eect eee ne ees 7 180 RRP 26 Print Cartridge Plate Assembly 7 182 RRP 27 Developer Housing Assembly 7 185 RRP 28 New Developer Housing Assembly Charging 5 7 186 RRP 29 Toner Dispense Motor Assembly 0 0 c eee e eens 7 188 RRP 30 Steering Drive Assembly 0 0 0 ccc eee eee ees 7 189 RRP 31 Waste Toner Agitator Motor Assembly 7 190 RRP 32 Mark On Belt MOB Sensor ee eeeeeee 7 191 RRP 33 Exit Transport Assembly 7 192 RRP 34 Fuser Fan Assembly 0 000 c cece eee eect eee eees 7 195 RRP 35 Accumulator Belt Assembly 0 0 00 cece eee eee ee 7 196 RRP 36 Belt Cleaner Assembly 0 0 0 0 cc cece cece eee eee eens 7 198 RRP 37 Waste Auger Assembly 0 000 cece cece nets 7 199 RRP 38 Laser Unit eee eee eee eens 7 200 RRP 39 Image Processor Board Assembly 0 00 cece eee 7 202 RRP 40 Internal Hard Drive 7 203 RRP 41 Electrical Chas
115. e one next to it Print units are not keyed to a particular color If the trouble follows the print unit replace it 5 Remove the print cartridge and verify that the laser shutter opens and closes using the Service Diagnostics Shutter Solenoid test 6 Inspect and test the toner auger system Ensure that the toner auger motor operates Ensure that the toner dispense assembly is carrying toner from the toner cartridge to the developer 7 Remove the Accumulator Belt Assembly and inspect the high voltage knife connectors on the back side to ensure they are not damaged RRP 35 on page 7 196 8 Replace the Accumulator Belt Assembly 9 Inspect the high voltage wiring leading to the Replace the Accumulator Belt Assembly for damage 10 Replace the Developer Housing Assembly RRP 27 on page 7 185 11 If the missing or faded primary color appears as speckle on the entire page the high voltage wire leading to that color s developer housing is grounded Inspect the high voltage wiring harness and power supply Repair replace as necessary 12 Replace the Laser Unit RRP 38 on page 7 200 13 Replace the T3 High Voltage Power Supply RRP 44 on page 7 208 14 Replace the T2 High Voltage Power Supply RRP 48 on page 7 213 Phaser 7700 Color Laser Printer Service Manual 3 109 Missing Band in Direction of Paper Travel There are areas of the image that are extremely light or are missing entirely These missing areas form wide bands t
116. easurements on page 2 46 on the Engine Control Board Alternately interrupt the Waste Cartridge Full Sensor again Does the voltage toggle between 5 VDC and 0 VDC Yes No Inspect the wiring harness between the Engine Board and the Waste Cartridge Full Sensor Repair or replace the harness as necessary eplace the Engine Control Board RRP 42 on page 7 206 80 04 341 ERROR 80 ENGINE LOGIC BOARD FAILURE 04 343 Switch printer power Off then On If the problem persists replace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 69 Error Chain Gode Eni Front Panel Message 81 04 358 ERROR 81 CONTROLLER TO ENGINE COMMUNICATIONS FAILURE Switch printer power Off Remove the Image Processor Board Image Processor Board Cover and the Image Processor Metal Cover and inspect the orange colored ribbon cable between the Relay Board and the Engine Control Board for proper connector seating If the problem persists replace the Image Processor Board RRP 39 on page 7 202 If the problem continues to persist replace the Electrical Chassis Assembly RRP 41 on page 7 204 If the problem continues replace the Engine Control Board RRP 42 on page 7 206 82 04 340 ERROR 82 ENGINE LOGIC BOARD RAM ROM FAILURE 04 342 1 Turn printer power Off then On 2 If the problem persists replace the Engine Controller Board RRP 42 on page 7 206 83 04 36
117. ed before an end of life or near end of life message Do not to extend the life of the assembly Doing so may cause premature failure of other internal printer components The printer prompts the user to reset the life counts if the assembly is replaced after receiving a Replace Belt Cleaner Assembly or Replace Belt Cleaner Assembly Soon message 1 From the Main Menu highlight Supplies Info Menu and press OK 2 Highlight Reset Belt Cleaner Life and press OK 3 Reset Cleaner Life NOW is displayed press OK to reset the Accumulator Belt life Resetting Transfer Roller Life Resetting the transfer roller life is to be performed only if the Transfer Roller Assembly was defective and or the assembly is replaced before an end of life or near end of life message Do not to extend the life of the assembly Doing so may cause premature failure of other internal printer components The printer prompts the user to reset the life counts if the assembly is replaced after receiving a Replace Transfer Roller or Replace Transfer Roller Soon message 1 From the Main Menu highlight Supplies Info Menu and press OK 2 Highlight Reset Transfer Roller Life and press OK 3 Reset Transfer Roller Life NOW is displayed press OK to reset the Accumulator Belt life 6 148 Phaser 7700 Color Laser Printer Service Manual Service Diagnostics NVRAM Resets PostScript NVRAM Reset Resetting the printer setup values resets the job defaults front panel lang
118. edaserdeeura eten 8 267 Phaser 7700 Color Laser Printer Service Manual xvii PL 8 20 Lift Components FRUS eervererrrvsvoreverrrrsvererervsreverenesvereveneresvenerenene 8 268 PL 8 21 Wiring FRUS soisissa ninaa a iie 8 270 PL 8 22 Auxiliary Feeder FRUS ccccccsccscscsescsssscsescseececsesecesscsescsesaceesens 8 272 PL 8 23 Lower Tray Deck LTD FRUS cccccccssscscscsececescsscsescseseceseeseseens 8 274 PL 8 24 Lower Tray Deck LTD FRUs cont d mmveenvrrvrrrrsverovrrrrrrvorerenrne 8 276 PL 8 25 High Capacity Feeder PRS 8 277 PL 8 26 High Capacity Feeder FRUS feontd 1 8 278 PL 8 27 High Capacity Feeder FRUS feontd 1 8 279 PL 8 28 High Capacity Feeder FRUS feontd 1 8 280 PL 8 29 High Capacity Feeder FRUS feontd 1 8 281 KE 8 282 Manual Packs amp Service Manual ccccccescsssecscscseecessssesesecsescseseceeesseseens 8 283 SOMMAR asa node Ae TENNER REE 8 284 Supplies and Accessories c ccccscsesesecscseseseseeececsesesececsesesesessescsuseseseeaeeeees 8 284 Recommended Service Tools cccccsesscscscsesesssscscscseeececsesecescsescsesacecseaes 8 285 Test Prints 9 287 Analyzing the fest dE 9 288 Print Color Test Heinescht im nitid ihesidikeieeieddid er 9 289 Diagnostics Mode rsrerrsnovrsveresverrsnernsnerssnersrnerssnerssnerverssserssversssersssersssenssnenne 9 291 Wiring Diagrams 10 295 Phaser 7700 Finisher 11 313 Finisher Overview 11 314 General Information seniai 11 315 Assemblies of
119. eder then swap the one from another tray and retest Also swap the Feeder Assembly with one from another tray and retest 4 If the Feed Lift Motor does not operate and another is available swap the Feeder Assembly and retest 5 Inspect the wiring harness for damage and continuity 6 Replace the Auxiliary Feeder Control Board RRP 60 on page 7 229 7 Replace the Engine Control Board RRP 42 on page 7 206 Tray 2 3 or 4 Will Not Lift In order for a paper tray to lift the 24 VDC interlock circuit through the LH Door of the Auxiliary Feeder must be complete one or both of the top two Paper Size Switches must be closed and the Tray Level Sensor must be deactuated 1 Determine if the Feed Lift Motor operates normally if the motor operates but does not sound right or if the motor does not operate 2 If the Feed Lift Motor operates normally check the paper tray for damage If it is a Universal Tray then swap the tray with one of the others and retest 3 Ensure that all packaging material has been removed 4 If the Feed Lift Motor operates but does not sound normal check the drive coupling for damage If it is a Universal Tray swap the tray with another and retest Also swap the Feeder Assembly with one from another tray and retest For HCF Tray 3 and 4 carefully inspect the gear drive mechanism for damage Swap the Feed Lift Motor with one from another tray 5 If the Feed Lift Motor does not operate swap the Feeder Assembly
120. elect Switch 3X E Universal Tray Assembly 7700 069 Figure 7 73 Paper Select Switches Removal 1 Remove the Paper Tray 2 Reaching inside the cabinet disconnect the wire harness LTD 3 places HCF 1 place 3 Reaching inside the cabinet remove the 1 screw that secures the Paper Select Switch LTD 3 places HCF 1 place Phaser 7700 Color Laser Printer Service Manual 7 231 RRP 63 Auxiliary Feeder Paper Feed Motor Assembly Paper Feed Motor Assembly e Trays 2 amp 3 HCF Trays 2 3 amp 4 LTA Chute to Lower s 87700 102 Figure 7 74 Paper Feed Motor Assembly and Chute LTA amp HCF Removal Remove the Left Hand Cover Open the Tray halfway Disconnect the wiring harness Remove the two screws holding the Tray 1 feeder assembly not the screws securing the lower tray bracket 5 Remove the Tray feeder assembly RON ch Note Some wiggling may be required to disengage the gears Removal of the Motor 1 Disconnect the wiring harness from the motor 2 Remove the two screws securing the motor to the feeder bracket 3 Lift the motor straight out of the bracket to clear the gear on the motor shaft Note When reinstalling the motor it may be necessary to manually rotate the gears to mesh them with the other gears 7 232 Phaser 7700 Color Laser Printer Service Manual RRP 64 Bracket Assembly Left Hand and Right Hand Gear HCF B
121. embly Item 2 7 2 H Transport Open Cover 3 116 1291 00 Magnetic Catch 4 Screw 5 Guide 6 116 1246 00 1 Roll 7 Plate Spring 8 Stopper 9 116 1289 00 Entrance Upper Cover Assembly Item 10 12 10 Entrance Upper Cover 11 Roll 12 Plate Spring 13 Screw 14 116 1259 00 1 H Transport Front Cover 15 116 1261 00 1 H Transport Upper Rear Cover 16 116 1263 00 1 H Transport Rear Cover 17 H Transport Exit Guide 18 Stopper 19 Support Phaser 7700 Color Laser Printer Service Manual 11 353 Horizontal Transport Assembly FRUs cont d Nasnsssensned 19 7700 299 Figure 11 31 Horizontal Transport Assembly FRUs cont d 11 354 Phaser 7700 Color Laser Printer Service Manual Table 11 7 Horizontal Transport Assembly FRUs List cont d No Part Number Qty Description 1 H Transport Roll IN 2 H Transport Roll OUT 3 116 1284 00 1 H Transport Belt REP 17 4 1 4 Roll 5 Support 6 Bearing Ball 7 Harness Guide 8 Cover 9 116 1644 00 1 H Transport Entrance Sensor REP 17 4 2 10 116 1285 00 1 Top Tray Full Sensor REP 17 4 2 11 116 1247 01 1 H Transport Exit Sensor 12 116 1286 00 1 Gate In Solenoid Assembly Item 13 18 13 Gate In Solenoid 14 Spring 15 Link 16 Cover 17 Bracket 18 Earth Wire 19 Wire Harness 20 Bearing 21 116 1281 00 1 Gear 37T 22 116 1282 00 1 Gear 30T 23 116 1283
122. eme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 1 and P600 3 see fig ure page 2 47 Does the resistance measure approximately 6 ohms for a 110 VAC Fuser or approximately 20 ohms for a 220 VAC Fuser Yes No Replace the Fuser Assembly Measure the resistance between the Fuser Assembly connector P600 7 see figure page 2 47 and P600 9 see figure page 2 47 Does the resistance measure between 20 ohms and 100 ohms Yes No Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 3 see figure page 2 46 and P404A 4 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K ohms and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser einstall the Fuser Switch printer power ON Does the Fuser get warm Yes No Replace the Chassis AC Power Assembly RRP 49 on page 7 214 eplace the Engine Control Board RRP 42 on page 7 206 2 64 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Link Front Panel Message 47 10 356 ERROR 47 FUSER SSR2 ON TIME FAILURE Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between
123. ems oerrnrrrorerenvsvsvoverrvrsverevevesvrverenenn 3 104 Macintosh Printing Problems 3 104 Phaser 7700 Color Laser Printer Service Manual xiii Windows Printing Problems soranenrorovrsvrnrnrrvrsrnrnnrsrrnrsrrnesrrnrsrrnrsrrsessrnennnn 3 104 Troubleshooting Network Problems 3 105 Media Jams and the Paper Path seersvrnrsvrsrsvrsrsvrsrsvrsverrsvenrsnenesnennsnenssnenssnennsnen 3 106 Media based Problems vanuunnarnsseanismasatsnsmmasieanaannie 3 106 Multiple sheet Pick de ssssdaunanuknanbkeann dennes 3 106 MUSH e 3 106 Skewed Mage vanskar sandra 3 106 Will 3 107 FSR JanS Neer eee eect 3 107 3 LET EE ints 3 107 Print Image Quality Problems oseoorrrrvorerervsvereresvsvsvaverenrsvsverenesveverenvsveverenesnnne 3 108 Light undertone Prints all Colors oorannonornronnnrrrnrnrnvrrrrennrrrnrsrnrrennnnrnnn 3 108 Blank Prints eege RE Ra here eee i Gate 3 108 One Color is Faded or Missing 3 109 Missing Band in Direction of Paper Travel esnervrnrrrrverrsverrrverrrverrrnernrnenne 3 110 Streaks in Direction of Paper Travel ccccccscscscssecscsessessssesesecssssseseaeaees 3 111 Streaks Parallel with the Leading Edge orenarevvsvovarenrsvsvaverevenvoveneresvovenerenn 3 112 Random Missing Spots cccccccscsescscsecscscsesecetscsescsesecececsesecesscsescsesecseeeses 3 113 Random Edel LEE 3 113 SUMO 228 COLON EE 3 113 Al Goosen EE 3 114 Repetitive Mark Appears on Each Prin
124. en the 2 screws that secure the power supply to the PS mounting bracket 3 Disconnect the wiring harness at P502 P505 and P2 from the 24 VDC power supply and the fan motor wiring harness P214 4 Remove the 1 screw at the top of the bracket and loosen the remaining four screws in slots 5 Remove the power supply and bracket assembly 7 212 Phaser 7700 Color Laser Printer Service Manual RRP 48 T2 High Voltage Power Supply per U ANN gt deal Figure 7 54 T2 High Voltage Power Supply Removal 1 Remove the 24 VDC Power Supply and Bracket RRP 11 on page 7 165 2 Disconnet the high voltage wires from the KCMY connectors 3 4 Remove the two screws that secure the 19 BTR assembly to the printer Disconnect the wiring harness from J575 and J576 frame Remove the T2 High Voltage Power Supply Phaser 7700 Color Laser Printer Service Manual 7 213 RRP 49 Chassis AC Power Assembly S7700 439 Figure 7 55 Chassis AC Power Assembly Removal Note AC power consists of the AC drive noise filter and GFI assemblies and mounting bracket Remove the T2 high voltage power supply RRP 48 on page 7 213 Remove T1 and T3 power supply assembly RRP 44 on page 7 208 Disconnect the wiring harnesses P15 and P16 the AC drive wiring harness P43 and the individual wires at J39 J40 J41 and J47 of the AC drive board Disconnect the AC wires from P15 and P16 on t
125. enly seated when reinstalling the Print Cartridge Plate Assembly There is a locating pin at the back of each developer housing assembly Lightly tug the wires to ensure that they are not pinched by the plate or developers while reinstalling Be very careful not to catch any of the wires on the left hand side of the plate while re installing There are two locating holes in the PCPA that corresponds to locating pins on the frame of the printer Failure to align the holes with the pins prior to tightening screws could result in bending the plate Center the connectors flat against the wire guide with the yellow developer connector further to the right Phaser 7700 Color Laser Printer Service Manual RRP 27 Developer Housing Assembly 87700 174 kb 7700 425 Figure 7 29 Developer Housing Assembly Removal Note Complete removal of the Print Cartridge Plate Assembly is not required for removal of the Developer s Tilt the Print Cartridge Plate Assembly forward enough to allow the Developer s to be removed Do not disconnect the Print Cartridge Plate harnesses 1 Partially remove the Print Cartridge Plate Assembly RRP 26 on page 7 182 2 Remove the desired Developer Housing Assembly RRP 27 on page 7 185 Note A locating pin is at the back of each Developer Housing Assembly that matches a hole in the frame when positioned and seated correctly A slight rotating back and forth of the assembly will help find the l
126. ents as Initialization Do the results indicate the test passed indicated in the procedure second panel data only until the test passes then to back to step 3 page 4 140 then repeat step 8 4 132 Phaser 7700 Color Laser Printer Service Manual RegiCon Flowchart Phaser 7700 Registration Control Adjustment DC685 RegiCon Adjustment Set DIP switch 2 down Run Belt Edge Learn Check Print Quality primary fill test prints OK Yes Correct print quality problem and reset Correct Fault Replace Accumulator Belt Run Coarse RegiCon Initialization and Adjust YMK lt 1mm from Cyan Rerun RegiCon 4 and Adjust mirrors for values greater than 5 to 5 All results 5 to 5 Troubleshoot repair and start over Move MOB Sensor to Center position Run RegiCon 3 Yes Restore MOB Sensor Set DIP Switch 2 UP Store NVRAM to HD Figure 4 5 RegiCon Flowchart Adjust mirrors for values greater than 5 or 5 Note 1 Do not make adjustments of 5 or fewer clicks Any adjustment of 5 or less is considered noise Note 2 Always record the results of each RegiCon procedure This provides a path by which the printer can be restored Note 3 After running a RegiCon test always wait 10 seconds after the printer reboots and comes to ready before interrupting power Phaser 7700 Color Laser Printer Service Manual 4 133 Step 1 Bel
127. eplacement ESDs Motion such as your clothes brushing together or lifting a foot from a carpeted floor can generate enough static electricity to damage an ESD a Handle ICs and EPROMs carefully to avoid bending a pin a Pay attention to the direction of parts when mounting or inserting them on a PCB X Phaser 7700 Color Printer Service Manual Contents User Safety Summary ccccscccsssscssscsssssssscssssessecsesssssessesssssssscessesesacseeesssasseaeeesases 1 iii Terms in EE 1 iii Terms on Produet 2uunern e E cence E S 1 iii Welle EE 1 iv Power Supply and Electrical Components n snsnnsnsnnsnsisnssnnesnssennsnesnsrenenenn 1 iv Mechanical Components iisi ariiraa 1 iv Laser Components ccccseccscsesssececsesesesssececsesesecscsesesesssesacsesesessesesesavasacsesaeeses 1 v TEE lu 1 v SG d se UC 1 v Ell 1 v SIGN dl 1 vi Gare of Product cc s s2sce2ecescntteccesesivecoeesdtededtasesehdhaep ae ai 1 vi Groundihe Give GE 1 vi Service Safety TTT 1 vii General Guidelines nooornvrrvrrererrrnonesrsvrvorerrsvsvovavesnsnsvenersnvsvereresesnenenesssnsvenene 1 vii REENERT WE lee EE 1 vii Federal Communication Commision Compliance seoronrnvorororvorererrsvoverenenn 1 viii Ganadian ill 1 ix Avisi Canadia M sagn ssdiaaskeoa seder ere 1 ix European Nolte soens gei onina unaa RAE ANEN E NE 1 ix all EE 1 ix ESD TTT 1 x Contents 2 xi List of Tables 2 Xxi List of Figures 1 xxiii Phaser 7700 Color Laser Printer
128. er m Clean dry lint free cloth m Black light protective bag Cleaning Caution Never apply alcohol to the fuser rollers Note Never use a damp cloth to clean up toner 1 Turn Off the printer 2 Remove the waste cartridge carefully keeping the waste cartridge from tipping 3 Vacuum out any loose toner from the interior of the printer with a Type Il toner vacuum only 4 Clean the laser window with the cleaning wand following the details labelled in the inside of the front door Open left side door and clean up any toner inside Remove and clean the paper trays Clean pick rollers with a dry lint free cloth NO oO Phaser 7700 Color Laser Printer Service Manual 5 143 5 144 Phaser 7700 Color Laser Printer Service Manual Resetting NVRAM Resetting NVRAM returns all the image processor s NVRAM stored parameters to their factory defaults except the print counts and the Adobe firmware serial number You can reset both the PostScript and engine NVRAM the PostScript Menu or the Service Diagnostics Menu PostScript NVRAM Resets Restore Factory Settings color You can reset settings for density and color balance to the factory default values From the Main Menu highlight Support and press OK Highlight Improve Print Quality and press OK Highlight Calibrate Colors Menu and press OK Highlight Restore Factory Settings and press OK Highlight Restore Factory Settings NOW and press the OK to reset t
129. er Cover RRP 68 on page 11 326 3 Remove the Entrance Sensor Cover pry up on the locking tab while pressing firmly towards the entrance end of the transport 4 Disconnect the wiring harness connector 5 Press down on the two locking tabs located at the top of the sensor press up on the two locking tabs at the bottom of the sensor and remove the sensor Top Tray Sensor 1 Disconnect the wiring harness 2 Remove one screw and remove the sensor bracket and sensor Replacement Note When replacing the sensor be sure the harness guide is engaged into the cover 11 328 Phaser 7700 Color Laser Printer Service Manual RRP 71 Gate In Solenoid Assembly 7700 375 Figure 11 13 H Transport Gate In Solenoid Removal 1 Remove the Rear Cover RRP 67 on page 11 325 2 Disconnect the ground wire from the solenoid housing 3 Remove the two screws and remove the Gate In Solenoid Assembly Phaser 7700 Color Laser Printer Service Manual 11 329 RRP 72 Finisher Covers Left Top Cover Rear Cover Front Cover Left Cover 7700 396 Figure 11 14 Finisher Covers 11 330 Phaser 7700 Color Laser Printer Service Manual Removal Remove the Horizontal Transport Assembly RRP 66 on page 11 324 Remove one screw from the Left Panel and remove Remove five screws from the Rear Cover Clear the gear at the top of the Rear Cover and remove the cover Open the Front Door Remove four screws secu
130. er Roller and replace if necessary RRP 17 on page 7 172 Inspect the Fuser to see whether paper is wrapped around the Fuser Replace the Fuser RRP 19 on page 7 174 ap oo mn ch Repetitive Mark Appears on Each Print 3041 48 An identical mark or image appears on each or every other printed image 1 From the front panel s Support Menu select Improve Print Quality then select Remove Print Smears This function passes several blank sheets of paper through the printer to clean the fuser rollers 2 From the front panel s Printable Pages Menu select Service Pages then select Repeating Defects page The Repeating Defects page contains rulers to help determine the source of the repeating defects 84 mm 3 3 in Fuser 94 mm 3 7 in Fuser mark in all colors or print cartridge mark in single color 88 mm 3 5 in Transfer roller 2nd bias 44 mm 1 7 in Print cartridge 28 3 mm 1 1 in Developer housing roller 3 114 Phaser 7700 Color Laser Printer Service Manual Background Contamination There is toner contamination on all or most of the page The contamination appears as a very light gray dusting The printer displays no error code 1 Ensure that the loaded media matches the front panel settings In some cases switching the paper type setting for example from Heavy Laser Paper to Thin Cover Index may improve print quality Run the Calibrate for Paper routine From the front panel
131. er Switch Cover Warning Turn Off the printer and disconnect the power cord Remove the Rear Cover RRP 1 on page 7 154 Open the Left Hand Door Loosen one screw from the Top Rear Cover There is a hidden captive tab on the front and side of this cover that resists the upward pull Place your finger on the front side of the cover to release the tab and pull towards you RON ch 7 158 Phaser 7700 Color Laser Printer Service Manual Removal cont d Cover Left Hand Rear Mid 5 Remove one screw from the Left Hand Rear Low Cover and remove the cover 6 Remove one screw from the Left Hand Rear Mid Cover 7 Lift the cover up to release captive hooks then toward you out of the printer Phaser 7700 Color Laser Printer Service Manual 7 159 RRP 6 Left Hand Lower Cover Assembly 57700 010 Figure 7 6 Left Hand Lower Cover Assembly Removal 1 Open the Left Hand Lower Cover Assembly 2 Disconnect the sensor in the door wiring harness plug at the rear and free the harness from the clamp near the rear pivot 3 With a flat tip screwdriver pry out the pivot pin then pry out the pivot pin expansion sleeve 4 Remove the Left Hand Lower Cover Assembly 7 160 Phaser 7700 Color Laser Printer Service Manual RRP 7 Front Cover Assembly 87700 028 Figure 7 7 Front Cover Assembly Removal 1 Open the Front Cover Assembly 2 Rotate the printer end of the strap 90 degrees and pu
132. er ma se et Seu S2408sr ma ve 1901 VSIONISI 82aoesr 42aoesr NYO Oc 1901 BNI NIEVAODLONS 9Q808s8r nie ee T90r VIONSULSLOV EE DEST 1d gc Lo0t WNLIOWSYLSLOV E anser rote aS ONL CET Saeed over I 458 1 SdAH YL9S ZL SdAH He ou ELGT Abet else OL 6 Eier NLHAPZ EE e e ELST 428 WA V OG Ler d L ELsSr 499 WMd V OV TLSTP d o ELST 499 WMd W 90 ezsr d 498 NMd W OY e R 498 WMd 9 OG d e ezsr 498 WMd 9 OV EEN e z ELGT 498 WMd Y 90 EEN d R ezsr 498 WMd 4 OV LSP L HSP d ELST X19 edger Keren anSv 1870 ezer HDD LLST S BLEr OWI z25 S LNOOAH r else uowg Zist gt S Jer uowy LEST Rart TSA ve slot RESCHT voorr KEZI OIATrZIZ IZOoL NLYAS V90PT dg vest AUD va e22z01 ASt voorr rest JIA va e2z0L MIO SdAH Vv90rr TOSdAH v90trr KIEREN NOW OL SdAH perth 13A ba z z0L YIST Tan ve eLeol SdAH OL NON AS YNS TINAL voorr SOC SOC NIUS V9O0 T Le DES mn I iB SZst 13A ve ele0r WMady 10ST S 5 lt 8887 TIA va ele0t WMdd TOST gt a 0 ofS 1aA ve ZLotr DER 7 oh 3787 13A va Ler NMdA OST og bei op pS SLSR TSA va slett ANDY FOST dg 4 eS S250 13A va eleOr NONM FOST gt kl EELER NONO OST og 0 83287 13A va eLeor ie lt SLS 13A be Ze0r U x
133. errupt the Stapler Front Corner Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Remove the Finisher Front Cover RRP 72 on page 11 330 Measure the voltage at the Front Corner Sensor pin 2 yellow and Finisher frame ground Once again manually move the Stapler Assembly so as to interrupt the Stapler Front Corner Sensor p Phaser 7700 Color Laser Printer Service Manual 2 77 Error Chain Gode bins Front Panel Message 118 12 256 FINISHER ERROR 118 STAPLER FRONT CORNER SENSOR ON FAILURE Continued 119 12 257 FINISHER ERROR 119 STAPLER FRONT CORNER SENSOR OFF FAILURE Continued A BC Does the voltage toggle between 5 VDC and 0 VDC Yes No Yes No Yes No Measure the voltage at Front Corner Sensor pin 1 gray Does the voltage measure 5 VDC Measure the voltage between the Finisher Control Board P850A 3 and Finisher frame ground Does the voltage measure 5 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Front Corner Sensor Measure the voltage at the Front Corner Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Measure the voltage between the Finisher Control Board P850A 1 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring
134. es or seal damage during disassembly and reassembly of the Developer This contamination prevents Developer beads from flowing on to the Magnetic Roller correctly 57700 566 Mottled prints can be a result of bead carryout Bead carryout is when most of the beads in the Developer are carried out of the Developer Assembly into the Waste Toner Cartridge s7700 567 Procedure 1 Replace the Developer beads of the effected color s In almost all cases replacing only the Developer beads RRP 28 on page 7 186 will resolve the problems It is not usually necessary to replace the Developer Assembly P N 116 1115 00 2 Thoroughly clean the Developer Assembly before installing the new Developer bead mix Rotate the Developer Drive backwards during cleaing to ensure no contamination remains under the Magnetic Roller When reinstalling the cover in step 4 of RRP 28 on page 7 186 be careful not to tear or dislodge any portion of the Foam Seal Phaser 7700 Color Laser Printer Service Manual 3 121 3 122 Phaser 7700 Color Laser Printer Service Manual Adjustments and Calibration The engine firmware has several built in diagnostic routines that perform various alignment and calibration procedures The RegiCon 685 Adjustment procedures should be used whenever the technician removes or replaces the Laser Unit the Print Cartridge Plate Assembly the Mark on Belt Assembly Developer Housing Assembly or where color registration is bad The
135. ess Phaser 7700 Color Laser Printer Service Manual 7 195 RRP 35 Accumulator Belt Assembly 57700 152 Figure 7 40 Accumulator Belt Assembly 7 196 Phaser 7700 Color Laser Printer Service Manual Removal 1 Open the right cover door 2 Open the front cover and lower the main lever 3 Lift the Accumulator Belt locking lever and pull the assembly out of the printer You need to hold the locking lever up until the white nylon handle is exposed Caution The Accumulator Belt assembly is heavy Use the white nylon handle when removing the assembly from the printer Do not get fingerprints on the belt Note Metal tabs allow the Accumulator Belt to be laid on a flat surface It can also be carried by the black handle located on the side Replacement Note When reinstalling the Accumulator Belt assembly the black handle faces the front of the printer Caution Ensure that the Accumulator Belt is fully inserted or severe printer damage will result NEVER FORCE THE MAIN LEVER Phaser 7700 Color Laser Printer Service Manual 7 197 RRP 36 Belt Cleaner Assembly 7700 022 Figure 7 41 Belt Cleaner Assembly Removal 1 Open the right cover door 2 Open the front cover and lower the main lever 3 Lift the Accumulator Belt locking lever and pull the assembly out a few inches 4 Using a 2 5 mm hex driver remove the two screws on the left side of the belt cleaner assembly 5 Remove the belt cleaner assembly
136. est Backup the new engine NVRAM values to the printers hard drive using the NVRAM Access menu s Store Engine NVRAM menu item Replacement ATC Sensors and the ATC Sensor on a replacement Developer Housing both include a tear off sticker with the Sensor s calibration value printed on it Apply the sticker near to the corresponding Developer behind the Waste Cartridge Next to the laser cleaning slot is good location Photo Mode Among other actions selecting Photo Mode causes the printer to perform a Developer bead agitation cycle between printing each page This allows the electrical charge applied to the toner in the Developer Housing to be evenly distributed to all the toner This ensures better more even toner transfer to the Accumulator Belt resulting in the colors of the last high coverage print looking the same as the colors in the first high coverage print 3 102 Phaser 7700 Color Laser Printer Service Manual Bead Carryout BCO The ATC Sensor magnetically measures the ratio of toner particles to developer carrier beads not the volume Under a combination of rare circumstances and component tolerances it is possible fo rthe carrier beads to be pulled from the Developer during printing this is called bead carryout or BCO The Engine Control Board will only auger in the amount of toner to achieve the desired ratio with the remaining carrier beads If beads are being carried out then less and less toner will be augered i
137. ew that secures the assembly to the frame and remove the shutter solenoid assembly Replacement Caution Itis very easy to miss positioning the lever back into the slot upon re assembly 1 Remove the Waste Toner Cartridge Remove the black Print Cartridge 3 While reinstalling the shutter solenoid assembly with a flashlight view where the Solenoid Lever engages the notch in the shutter plate 4 Tighten the mounting screw and reconnect the wiring harness N 7 176 Phaser 7700 Color Laser Printer Service Manual RRP 22 Tray 1 Feeder Assembly and Paper Lift Motor 7700 009 Figure 7 23 Tray 1 Feeder Assembly Removal 5 1 Remove the Left Hand Lower Cover Assembly RRP 6 on page 7 160 2 Open Tray 1 halfway 3 4 Remove the two screws holding the Tray 1 feeder assembly not the screws Disconnect the wiring harness securing the lower tray bracket Remove the Tray 1 feeder assembly Note Some wiggling may be required to disengage the gears Removal of the Motor 1 2 3 Disconnect the wiring harness from the motor Remove the two screws securing the motor to the feeder bracket Lift the motor straight out of the bracket to clear the gear on the motor shaft Note When reinstalling the motor it may be necessary to manually rotate the gears to mesh them with the other gears Phaser 7700 Color Laser Printer Service Manual 7 177 RRP 23 Waste Cartridge Sensor Holder
138. f YMK to adjust Select how many millimeters 1 5 to adjust Select which direction Left Right The next screen asks for confirmation Adjust lt color gt by lt n gt mm Yes No select Yes 6 Repeat steps 4 and 5 for the other colors You reprint the Grid 1 Dot pattern as outlined in step 3 or go to the Adjustments Calibrations menu RegiCon 685 Setup Cycle test If the 1 test fails print the Grid 1 Dot page to see if the vertical lines are all clustered within 1 mm of the Cyan line If not repeat It may be necessary to closely inspect the Color Solid Fill Prints to determine if the image quality is acceptable Phaser 7700 Color Laser Printer Service Manual 4 141 ATC Sensor Setup The Automatic Toner Calibration ATC sensor measures the amount of toner in each developer These sensors have an intrinsic gain and output value are stored in printer NVRAM New values must be entered when a new Developer Housing Housing is installed Incorrect values have color balance effects On the side of each new Developer Housing Assembly is a small white tag with a bold faced three digit number printed near the bottom The first digit is always 0 The other digits range between 0 and 99 There is a tear off section of the tag that should be placed on the chassis somewhere in plain view when the front door is open To set the new values Enter Service Diagnostics Highlight Adjustments Calibrations menu and press OK Highlight ATC
139. figuration is shown in Figure 7 36 57700 568 Figure 7 36 Reconfigured Inverter The parts that are NOT necessary for the Inverter Transport Assembly to work correctly in the Phaser 7700 are shown in Figure 7 37 Not The Roller shown in Figure 7 37 is NOT the Exit Roller Assembly P N 116 1759 00 7700 569 Figure 7 37 Parts No Longer Installed Phaser 7700 Color Laser Printer Service Manual 7 193 The Interlock Actuator and two 0 5 mm spacers are now being added to the Inverter Transport Assembly packaging as a separate item see Figure 7 38 If only the Interlock Actuator is broken it can now be replaced individually The 0 5 mm spacers should be placed between the Interlock Actuator and the Inverter Transport Assembly vo Spacers Interlock Actuator s7700 570 Figure 7 38 Interlock Actuator and Spacers 7 194 Phaser 7700 Color Laser Printer Service Manual RRP 34 Fuser Fan Assembly Locating Pin 7700 025 Figure 7 39 Fuser Fan Assembly Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the Top Cover RRP 3 on page 7 156 3 Remove Right Side Cover RRP 2 on page 7 155 Note Note the routing of the wiring harness Note It is easier to re install the wire harness if the Fuser Fan and plastic mounting bracket are removed from the printer 4 Remove the two screws that secure the Fuser Fan Assembly and remove the assembly 5 Disconnect the wiring harn
140. fore you plug the product into a power Source Care of Product Disconnect the power plug by pulling the plug not the cord Disconnect the power plug if the power cord or plug is frayed or otherwise damaged Or if any liquid or foreign material is spilled into the case Or if the printer is exposed to any excess moisture Or if the printer is dropped or damaged Or if you suspect that the product needs servicing or repair And whenever you clean the product Ground the Product Plug the three wire power cord with grounding prong into grounded AC outlets only If necessary contact a licensed electrician to install a properly grounded outlet vi Phaser 7700 Color Printer Service Manual Service Safety Summary General Guidelines For qualified service personnel only Refer also to the preceding Users Safety Summary Do not service alone Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present Use care when servicing with power on Dangerous voltages may exist at several points in this product To avoid personal injury do not touch exposed connections and components while power is On Disconnect power before removing the power supply shield soldering or replacing components Do not wear jewelry Remove jewelry prior to servicing Rings necklaces and other metallic objects could come into contact with dangerous voltages and cur
141. frame ground Again manually actuate the Stack Height Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at the Stack Height Sensor pin 2 yellow and Finisher frame ground Once again manually actuate the Stack Height Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at Stack Height Sensor pin 1 gray Does the voltage measure 5 VDC Yes No Measure the voltage between the Finisher Control Board P850B 6 see figure page 2 46 and Finisher frame ground Does the voltage measure 5 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 Repair or replace the wiring harness between the Finisher Control Board and the Stack Height Sensor NoteThere is an intermediate connector in this harness J870 behind the Front Cover Remove Front Door to repair replace the harness Phaser 7700 Color Laser Printer Service Manual 2 75 Error Chain Gode Link Front Panel Message 116 12 254 FINISHER ERROR 116 STACKER HEIGHT SENSOR OFF FAILURE Continued A B C D Measure the voltage at the Stack Height Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Yes No Measure the voltage between the Finisher Control Board P850B 4 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 Note There is an intermediate conne
142. front panel LED is On If the RAM tests fail the Image Processor Board health LED is turned Off and the front panel LED is red At 1 2 second intervals the health LED and the front panel LED toggle continuously Phaser 7700 Color Laser Printer Service Manual 2 33 POST Diagnostics Test Descriptions Table 2 1 POST Diagnostics Test Descriptions Test Fault Code Description SDRAM 1 Hard This test fails if the boot loader finds no RAM present or faulty RAM Boot loader posts the message RAM error to the front panel and blinks the front panel LED Front Panel 2 Hard Performed during the POST firmware initialization phase If the front panel is unplugged a hard fault is indicated by the heath LED I O ASIC 3 Hard This test determines if the I O chip is functioning properly Memory 4 Hard This test checks 64 bit reads and writes to memory EEPROM 10 Hard Addressing of the EEPROM part is tested Ethernet 11 Hard Checks the ethernet core CPU Interrupts 12 Hard This test checks that each interrupt source to the CPU is functioning USB 13 Hard Checks that the USB core is functioning properly Real Time Clock 7 Soft The real time clock is tested RAM DIMM 8 Soft This test examines bad or incompatible RAM Presence DIMMs RAM Limits 9 Soft Checks that there is at least 128 Mbytes installed and ignores more than 512 Mbytes IDE Disk 12 Soft Checks the disk controller c
143. ft section page 3 95 in Troubleshooting Phaser 7700 Color Laser Printer Service Manual 2 71 Error Chain Gode Link Front Panel Message 111 12 241 FINISHER ERROR 111 STAPLER MOVE SENSOR ON 112 12 242 FAILURE FINISHER ERROR 112 STAPLER MOVE SENSOR OFF FAILURE Open the Finisher Front Door Defeat the Front Door Interlock Switch Enter Service Diagnostics Mode Run the Stapler Move Front Move Rear and Reverse tests to verify the movement of the Stapler Carriage Assembly Does the Stapler Carriage Assembly move smoothly through its full range of travel Yes No Refer to the Finisher Troubleshooting Procedures to troubleshoot this problem Inspect the Stapler Move Sensor for damage and secure mounting Is the sensor in good condition and secure Yes No Repair or replace the sensor emove the Finisher Rear Cover RRP 42 on page 7 206 and the Board Cover RRP 42 on page 7 206 Measure the voltage between Finisher Board connector P852 7 see figure page 2 46 and Finisher frame ground while interrupting the Move Sensor Does the voltage toggle between 0 VDC and 5 VDC Yes No Measure the voltage at Finisher Board connector P852 8 see figure page 2 46 Does the voltage measure 5 VDC Yes No Replace the Finisher Control Board Measure the voltage at Finisher Board connector P852 6 see figure page 2 46 Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board eplace the
144. g the Cam Bracket Assembly the manipulate the Eject Assembly to ensure the gears follow one another from the back of the Cam Bracket Assembly Manually push the set clamps to engage the gears Phaser 7700 Color Laser Printer Service Manual 11 341 RRP 82 Staple Unit Assembly and Motor 57700 304 Figure 11 24 Staple Unit Assembly 11 342 Phaser 7700 Color Laser Printer Service Manual Removal Staple Unit Assembly 1 Remove the Front Cover RRP 72 on page 11 330 2 Remove the two connectors to the Staple Unit 3 Remove two screws note one screw has a ground wire 4 Pull the Staple Unit Assembly down tilt up and pull out towards the front Staple Motor 1 Remove the staple unit assembly 2 Remove the right cover 3 Disconnect the wiring harness 4 Remove two screws and remove the motor Phaser 7700 Color Laser Printer Service Manual 11 343 RRP 83 Compiler Tray H 87700 357 57700 359 Figure 11 25 Compiler Tray Removal Remove all covers RRP 72 on page 11 330 Remove the Finisher Control Board Shield RRP 77 on page 11 336 Disconnect P848 connector Remove Set clamp solenoid connector Remove the Staple Unit RRP 82 on page 11 342 Remove two screws from the bottom of the tamper assembly front and rear Push the wiring harness into the printer frame Tilt the carriage up and slide straight back letting the car
145. ge Processor Board ccescsesscseseeessseesseeesseeesseeecseeesseeessesaeseeas 1 16 Figure 1 13 Assemblies of the Print Engine 1 17 Figure 1 14 Assemblies of the Print Engine contd 1 1 18 Figure 1 15 Assemblies of the Print Engine contd 1 1 19 Figure 1 16 Auxiliary Feeder Assemblies nsrnrrvrvrrvrrnrvrsrrvrrrrnrrvererverrrverervenssnennr 1 20 Figure 1 17 Front Panel sstsistsiccsnnopieanciniairnen okee arn anneks 1 21 Figure 1 18 Printer Rear Connections cccsescsescsssecscsesesesssscsescsesececsesesececaees 1 23 Figure 1 19 Printer Clearances EEN 1 24 Figure 2 1 Voltage Measurement Point Locations osrsnsvrsnsvrsverrsverrsvererverssnene 2 46 Fig 2 2 Fuser Connector Pin Locations 2 47 Figure 3 1 Circuit Diagram ssrornvovorerverovesrvrsvererevesvevarenesnsvsvereresvsnenerenesvsnsvenenenne 3 91 Figure 3 2 Toner Cartridge Gear 3 97 Figure 3 3 Toner deu dr EE 3 98 Figure 3 4 Toner Dispense Assembly sssrinin 3 99 FIgur 3 5 TONer EE 3 100 Figure 3 6 Developer HOUSING ccccccecesescesseeesceecsetecsessesesseseseseeesesesnesseeeees 3 103 Figure 4 1 Coarse RegiCon Initialization oo ccc cccccssssesescsssececsesesscecscseseeessees 4 124 Figure 4 2 Coarse and Fine Skew Adjustments ccccccccccccsesscetsesescsetsesesesees 4 125 Figure 4 3 In Out Skew Adjustment ssrsrnrororrrrrvovorrsvsvenerrsverereresvsverenessnrsvenene 4 125 Figure 4 4 Center Skew Adjustment c ccccscscsescses
146. giCon when the customer has the PostScript startpage enabled Note The Service Menu functions are to be used only by Xerox service personnel and authorized service providers The printer can be damaged by the improper use of the built in service tests In all the service tests m The Back or Cancel button can be used to abort a test and return you to the menu from where the test began m The OK button either enters the next lower level menu or causes the highlighted test to execute m The Up and Down keys highlight test options or selection of an appropriate entry while executing a test If there is a numeric value that must be entered these keys are used to adjust that value m The Info button is used to post information or define a mnemonic Press the Info or OK button again to remove the text and restore the menu Phaser 7700 Color Laser Printer Service Manual 2 35 Service Diagnostics Test Menu Functions Table 2 2 Service Diagnostics Test Menu Functions Test Front Panel Display Test Operation Results and Function Definition Print Service Menu Map Prints the service diagnostics menu page General Status Provides current print engine status Engine ROM Version Engine Version is 3 60 Video ASIC Version 1 15 Prints Current engine status Configuration STM or HCF if present Duplexer Finisher if present Displays optional components 3TM LTD Ambient Temperature is X
147. haser 7700 Color Laser Printer Service Manual Y RADC Target 400 Ave RADC Trans 367 may be different and may change Ideal LD Ill 251 may be different and may change VBias 862 VBCR 0 M RADC Target 400 Ave RADC Trans 450 may be different and may change Ideal LD Illl 281 may be different and may change VBias 862 VBCR 0 C RADC Target 338 Ave RADC Trans 325 may be different and may change Ideal LD Ill 293 may be different and may change VBias 862 VBCR 0 K RADC Target 380 Ave RADC Trans 397 may be different and may change Ideal LD Ill 297 may be different and may change VBias 862 VBCR 0 If the adjusting screws reach their maximum adjustment range either Clockwise or Counter Clockwise center the adjusting position of the screws and restart the RegiCon procedure The adjusting screws have 18 complete turns from fully CW to fully CCW To adjust the screws to the center position turn the screw to either limit and then turn it back 9 complete turns 1 Fine Skew Adjustment Procedure this process examines the fine RegiCon image on the belt and reports the skew adjustments needed to be made page 4 137 2 is an IN OUT Skew Procedure this process calibrates the end points of the scan line for magnification adjustment There may be manual skew screw adjustments recommended by this test page 4 138 3 is a CENTER Skew procedure this process requires moving the Mark On Belt MOB sensor from the edge of the Ac
148. haser 7700 Color Laser Printer Service Manual 8 241 PL 8 6 Cover FRUs cont d DEE TEE rg i EG 87700 039 Figure 8 6 Cover FRUs cont d Table 8 6 Cover FRUs cont d List Parts Part Number Qty Name and Description vendor description 1 116 1181 00 LH Lower Cover Assembly Cov Assembly LH Low LH Lower Cover Earth Plate Magnet Pinch Roll Assembly Bracket Spring Pinch Roller Bearing Bearing Bearing Tray 1 Feed Out Sensor Wire Harness 029E31600 Rivet compatible with Phaser 7760 8 242 Phaser 7700 Color Laser Printer Service Manual PL 8 7 Cover FRUs cont d 57700 060 Figure 8 7 Cover FRUs cont d 8 243 Phaser 7700 Color Laser Printer Service Manual Table 8 7 Covers FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1179 00 1 Rear Cover Assembly Cover Assembly Rear 1 Blind Cover 2 116 1190 00 1 Cover Top Rear ps Cover Top Rear 3 116 1189 00 1 Cover LH Rear Mid 4 116 1193 00 1 Cover LH Front Low 5 116 1191 00 1 Cover LH Rear Low 6 116 1188 00 1 Tray Module Connector Cover Cover Blind TM 7 116 1194 00 1 Fuser Front Cover 8 116 1319 00 1 Top Cover 9 116 0001 02 1 Front Panel Control Panel 10 116 0002 00 1 Control Panel Wiring Harness Top Cover Stopper s N as Print Cartridge Plate Cover 8 244 Phaser 7700 Color Laser Printe
149. hat run along the page from leading edge to trailing edge in the direction of paper travel B size print shown The printer displays no error code Note A size prints are processed through the printer with the short edge of the print parallel to the direction of the paper path making print artifacts parallel to the short edge of the print 1 Clean the laser windows with the cleaning wand located in the front door 2 Print the solid fill test pages From the front panel s Printable Leading Edge 3041 40 Pages Menu select Service Pages then select Print Solid Fill Pages 3 If the missing bands only occur in a single primary color swap the print cartridge ap 3 110 Phaser 7700 Color Laser Printer Service Manual Replace the Developer Housing Assembly RRP 27 on page 7 185 Replace the Laser Unit RRP 38 on page 7 200 Streaks in Direction of Paper Travel There are dark lines running along Leading Edge the page in the direction of paper travel from the leading edge to the trailing edge B size print shown The printer displays no error code Note A size prints are processed 3 through the printer with the short edge of the print parallel to the direction of the paper path making horizontal print artifacts parallel to the shot edge of the print B size prints are processed through the printer with the long edge of the print parallel to the paper path making
150. he color settings to factory defaults ORON Restore Previous Settings color You can return the color settings to the ones that existed before you saved the last color balance adjustments From the Main Menu highlight Support and press OK Highlight Improve Print Quality and press OK Highlight Calibrate Colors Menu and press OK Highlight Restore Factory Settings and press OK Highlight Restore Previous Settings and press OK to restore the previous color settings ORON Phaser 7700 Color Laser Printer Service Manual 6 145 Restore Factory Settings margins You can reset margin settings to the factory default values Caution Use caution when resetting your margins to the factory default settings Changing these settings back to factory defaults may not be the last saved settings if you have previously calibrated your margins From the Main Menu highlight Support and press OK Highlight Improve print quality and press OK Highlight Calibrate Colors Menu and press OK Highlight Restore Factory Settings and press OK Highlight Restore Factory Settings and press OK to reset the margin settings TROND ch Reset Calibrations color margins paper Note Resetting calibrations resets the color margin and paper settings From the Main Menu highlight Support and press OK Highlight Improve print quality and press OK Highlight Reset Calibrations and press OK Highlight Reset Calib
151. he Noise Filter board Clear the wiring harnesses from their retaining clips Remove the seven screws securing the Chassis Assembly to the printer frame 7 Remove the complete assembly from the printer frame aon ch ou E 7 214 Phaser 7700 Color Laser Printer Service Manual RRP 50 Main Drive Assembly Do NOT remove these 5 screws 87700 002 Figure 7 56 Main Drive Assembly Removal 1 Remove the Fuser RRP 18 on page 7 173 1 Remove the Multi Purpose Tray RRP 12 on page 7 166 2 Remove the T2 high voltage power supply RRP 48 on page 7 213 3 Disconnect the wiring harness Note There are 5 brass screws that hold the main drive assembly together DO NOT remove these screws 4 Remove the five black screws that secure the complete main drive assembly to the printer frame 5 Lift the complete main drive assembly up and out of the printer Note When reinstalling rotate the main drive to ensure the gears move freely Remove the Fuser unit to give better visiblility Phaser 7700 Color Laser Printer Service Manual 7 215 Note As the main drive assembly is being installed into position make sure the gears are meshed with the mating gears by slightly rotating the main motor until the main motor bracket seats without stress and flat against the frame Rotate the main drive after installing the assembly to ensure it rotates freely and ensure it is FLAT against the frame It is easy to pin
152. he Service Diagnostics menu highlight Adjustments Calibration menu and press OK 7 Select Regi Con 685 Setup Cycle and press OK 8 At the prompt Which DC685 procedure select RegiCon 3 Center Skew Setup and press OK The front panel now displays lt PostScript will do 685 3 gt 9 The printer now reboots and runs the test Wait for approximately 10 seconds after the motors turn off then cycle power and enter Service Diagnostics To display the results or continue you must re enter Service Diagnostics Mode 10 Enter Adjustments Calibration gt Regi Con 685 Results and press OK 11 Wait until the test results are displayed as follows DC685 3 Passed A Center Blocks 24 B Center Blocks 4 lt Press Ok for more Data gt Note If the block counts are not the same number as presented here the printer has a print quality problem Please refer to section Streaks in Direction of Paper Travel on page 3 111 to resolve the print quality problems before proceeding further with RegiCon 12 Using the back of the Laser Cleaning Tool hook the loop of the MOB Sensor just pushed back in step 3 above and pull it all the way to the front Continue holding the MOB Sensor in position while reinserting the securing screw removed in step 2 above and tightening When DC685 3 Fails This is probably due to the Mark On Belt sensor not being positioned properly assuming that RegiCon 1 and 2 tests have already passed The sen
153. he shaft Phaser 7700 Color Laser Printer Service Manual 11 335 RRP 77 Finisher Control Board Bracket and Shield Figure 11 19 Finisher Control Board Bracket and Shield Phaser 7700 Color Laser Printer Service Manual 11 336 Removal 1 Remove the Rear Cover RRP 72 on page 11 330 2 Remove eight screws and loosen the two bottom screws 3 Remove Finisher Control Board Shield 4 Undo all the connectors 5 Remove two screws on the left 6 Loosen one screw on the right 7 Undo one connector 1 Loosen the outer screws located at the bottom of the Finisher Control Board cover 2 Remove the eight remaining cover screws 3 Remove the Finisher Control Board cover 4 Remove the four wiring connectors 5 Remove six screws from the control board remove Note When reinstalling the cover do not insert screws into the second or fourth holes at the bottom of the cover as these are used to secure the outer cover Phaser 7700 Color Laser Printer Service Manual 11 337 RRP 78 Stacker Motor Assembly 7700 361 Figure 11 20 Stacker Motor Assembly Removal 1 Remove the Finisher Control Board Bracket and Shield RRP 77 on page 11 336 2 Remove one connector 3 Remove three screws and remove the Stacker Motor Assembly Note When reinstalling ensure the gear is engaged and the sensor for the stacker is tripped 11 338 Phaser 7700 Color Laser Printer Service Manual RRP 79 Pa
154. heck the fault list to ensure that no other errors are present 1 Check the Tray Level Sensor actuator for damage and freedom of movement Check the Paper Size Switches for damage 2 Enter Service Diagnostics Mode and run the sensor test Check the Level Sensor operation by removing and reinserting the paper tray while observing the display If available swap the Feeder Assembly with one from another tray Does not apply to HCF Tray 4 Verify continuity of the wiring between the No Paper Sensor and the Control Board If the problem is with Tray 2 3 or 4 replace the Auxiliary Feeder Control Board RRP 60 on page 7 229 Replace the Engine Control Board RRP 42 on page 7 206 O a RK Ww 3 94 Phaser 7700 Color Laser Printer Service Manual Tray 1 Will Not Lift In order for Tray 1 to lift the 24 VDC interlock circuit through the LH RH and Front Doors must be complete one or both of the top two Paper Size Switches must be closed and the Tray Level Sensor must be deactuated 1 Determine if the Feed Lift Motor operates normally if the motor operates but does not sound right or if the motor does not operate at all 2 If the Feed Lift Motor operates normally check the paper tray for damage If the printer has an Auxiliary feeder then swap the Universal Tray with another and retest 3 If the Feed Lift Motor operates but does not sound normal check the drive coupling for damage If the printer has an Auxiliary fe
155. heet of newspaper or something similar available to place the removed assemblies on Note The dispense assemblies overlap and must be removed in the following order Y M C K then reinstalled K C M Y 1 Open the Front Door 2 Remove the print cartridges as necessary Note Cover the exposed opening with a wide piece of tape to avoid spillage Do not overlap the tape to the base plate located behind the opening 3 Remove the print cartridge plate cover RRP 24 on page 7 179 4 Leave the main lever down 7 180 Phaser 7700 Color Laser Printer Service Manual 5 Pull the shut off gate of each toner cartridge toward you approximately 3 4 or 20mm to shut off the toner supply for each toner tube see Figure 7 26 Dispense Assembly on page 7 180 Caution Be careful when moving the stops They are easily broken and may come out completely 6 Remove the screw holding each dispense assembly to the printer 7 Remove the dispense assembly by pulling both the top and bottom sections evenly away from the printer Note The flexible tubing is not secure and can come apart during removal and replacement causing toner spillage Phaser 7700 Color Laser Printer Service Manual 7 181 RRP 26 Print Cartridge Plate Assembly Removal Caution The Print Cartridges are very light sensitive Store the Print Cartridge away from light Do not touch the surface of the Print Cartridges 1 Remove the Print Cartridges 2 Leave
156. hole 4 Disconnect the three wiring harnesses and slip the wiring harnesses through the access hole one connector at a time 7 168 Phaser 7700 Color Laser Printer Service Manual 5 Remove the retaining clip off the restraint post 6 Support the Left Hand Door and then remove the restraining bracket from the door 7 While supporting the left side door carefully lower it to 75 90 then remove the door by lifting it up off the pivot points Replacement 1 Reverse the above steps to install the Left Hand Cover Assembly Left Hand Door Caution When reinstalling the Left Hand Door reach underneath the door and hold the black plastic duplex chute up to avoid breaking the chute while closing the left hand door 2 The damper at right hand pivot of Left Hand Door should be set as illustrated below Caution Align the marks on the damper whenever the Left Hand Cover is removed or replaced to ensure the teeth are not damaged When reassembling align the marks e on the friction damper Figure 7 15 Damper Teeth Alignment Phaser 7700 Color Laser Printer Service Manual 7 169 RRP 15 Duplex Chute 7700 430 Figure 7 16 Duplex Chute Removal 1 Partially remove the Left Hand Cover Assembly Left Door RRP 14 on page 7 168 2 Rotate the Duplex Chute downward until the keyed pivot shaft can be removed from the pivot bracket 3 Remove the Duplex Chute 7 170 Phaser 7700 Color Laser Pr
157. horizontal artifacts parallel to the long axis of the print 3041 42 Check the end of life for each of the consumables by printing the supplies usage page From the front panel s Printable Pages Menu select Print Supplies Page Run the solid fill test pages From the front panel s Printable Pages Menu select Service Pages then select Print Solid Fill Pages If the missing bands only occur in a single primary color replace the print cartridge of the affected color Swap print cartridges and run another test print Note Under some circumstances streaking may occur in the NOD ap margin of SRA3 size paper This is due to the edges of the paper extending beyond the end of the imaging components print quality in the margins of SRA3 paper is not guaranteed Inspect the Accumulator Belt cleaner replace the cleaner if necessary Run the Remove Print Smears routine From the front panel s Support Menu select Improve Print Quality then select Remove Print Smears Replace the Developer Housing Assembly RRP 27 on page 7 185 Remove the print cartridge and with a flashlight check for debris along the edge of the developer housing Phaser 7700 Color Laser Printer Service Manual 3 111 Streaks Parallel with the Leading Edge There are dark lines running Leading Edge parallel with the leading edge of the print perpendicular to direction of paper travel B size print shown The prin
158. hotographic Components FRUs List Parts Part Number Name and Description vendor description 1 116 1110 00 Laser Unit ROS Assembly 2 116 1197 00 Print cartridge Plate Assembly 3 116 1118 00 Toner Dispense Base Assembly Dispenser Base Assembly Dispenser Base Gear Toner Dispense Motor Y Toner Dispense Motor M Toner Dispense Motor C Toner Dispense Motor K Shaft 8 258 Phaser 7700 Color Laser Printer Service Manual PL 8 15 Electrophotographic Components FRUs cont d 87700 057 Figure 8 15 Electrophotographic Components FRUs cont d Phaser 7700 Color Laser Printer Service Manual 8 259 Table 8 15 Electrophotographic Components FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1115 00 1 Developer Housing Assembly Hsg Assembly Deve 1 Developer Housing 1 ATC Sensor 1 Seal Note requires one of the following 116 1111 00 Developer Black Pkg Assembly DV K 116 1112 00 Developer Yellow Pkg Assembly DV Y 116 1113 00 Developer Magenta Pkg Assembly DV M 116 1114 00 Developer Cyan Pkg Assembly DV C 2 116 1121 00 1 Yellow dispense assembly Disp Assembly Y 3 116 1122 00 1 Magenta Dispense Assembly Disp Assembly M 4 116 1119 00 1 Cyan Dispense Assembly Disp Assembly C 5 116 1120 00 1 Black Dispense Assembly Disp Assembly K 8 260 Phaser 7700 Color Laser Printer Service Manual PL 8 16
159. ically Sensitive Devices ESDs examples include integrated circuits ICs Large Scale Integrated circuits LSIs some field effect transistors and semiconductor chip components The following techniques reduce the occurrence of component damage caused by static electricity CAUTION Be sure the power is Off to the chassis or circuit board and observe all other safety precautions a Immediately before handling any semiconductor components assemblies drain the electrostatic charge from your body by touching a known earth ground Alternatively wear a discharging wrist strap device Be sure to remove the strap before applying power to the unit under test to avoid potential shock a After removing an ESD equipped assembly place it on a conductive surface such as aluminum foil or the static bag to prevent accumulation of an electrostatic charge Do not use freon propelled chemicals These can generate electrical charges sufficient to damage ESDs Do not remove a replacement ESD from its protective package until you are ready to install it Most replacement ESDs are packaged with leads that are electrically shorted together by conductive foam aluminum foil or other conductive materials Immediately before removing the protective material from the leads of a replacement ESD touch the protective material to the chassis or circuit assembly into which the device is to be installed Minimize body motions when handling unpackaged r
160. ies The printer features two slots which accept 64 128 and 256 Mbytes of SDRAM All combinations are allowed for configurations of 128 192 256 320 384 and 512 Mbytes m 144 pin SODIMM m Serial presence detect m 3 3 volt m 100 MHz PC100 or 133 MHz PC133 The Startup Page and the Configuration Page list the amount of RAM installed in the printer If memory does not meet the above specifications it will be ignored by the printer With more memory the printer gains the capabilities of printing without having to use image compression which trades less installed RAM for longer image processing time and dual frame buffers for printing one image while processing a second image which gives greater printing throughput The printer features two slots each which can contain a 64 128 or 256 Mbyte SDRAM Any slot may be used for any size memory module SDRAM memory totalling beyond 512 Mbytes will be ignored For acceptable memory see Supplies and Accessories on page 8 284 1 4 Phaser 7700 Color Laser Printer Service Manual CRC Life Counter Behavior Internal counters track Customer Replaceable Consumables CRC life usage and store the values in NVRAM The Image Processor Board monitors these counters in order to display the near end of life and end of use messages Table 1 1 CRC Life Accessory Shelf Life from Manufacturer Print Cartridge 15 Months 24k color mode K in B amp W mode 31 2k B amp W
161. ight Reset Job Defaults NOW and press OK to reset the job defaults Resetting Network Setup Values to Default Resetting the network setup values resets the TCP IP address TCP IP address menu settings gateway broadcast etc CentreWare IS EtherTalk Netware set IPX frame type IPP and Ethernet speed to their default values 1 From the Main Menu highlight Network Setup Menu and press OK 2 Highlight Reset Network Setup and press OK 3 Reset Network Setup NOW is displayed press OK Resetting Accumulator Belt Life Resetting the Accumulator Belt life is to be performed only if the Accumulator Belt Assembly was defective and or the assembly is replaced before an end of life or near end of life message Do not to extend the life of the assembly Doing so may cause premature failure of other internal printer components The printer prompts the user to reset the life counts if the assembly is replaced after receiving a Replace Accumulator Belt Assembly or Replace Accumulator Belt Assembly Soon message 1 From the Main Menu highlight Supplies Info Menu and press OK 2 Highlight Reset Accumulator Belt Life and press OK 3 Reset Accumulator Belt Life NOW is displayed press OK to reset the Accumulator Belt life Phaser 7700 Color Laser Printer Service Manual 6 147 Resetting Belt Cleaner Assembly Life Resetting the belt cleaner life is to be performed only if the Belt Cleaner Assembly was defective and or the assembly is replac
162. igure 7712 MPT ASSembly 00 et sites 7 166 Figure 7 13 Multi Purpose Tray Pick Rollers mesrrvrnvrrrrverrrvrrrvrrrrrrrsrrensrnennrnn 7 167 Figure 7 14 Left Hand Cover Assembly Left Hand Door ccceseeseeee 7 168 Figure 7 15 Damper Teeth Alignment sicsniscecin amikini eaan 7 169 Figure 7 16 Duplex Chute resnim a E a 7 170 Figure 7 17 Duplex Unit Assembly oo edsin enrii 7 171 Figure 7 18 Transfer Roller Assembly 2nd BIR 7 172 Figure 7 19 Inverter Transport Assembly ou ce eceeccsseecsseeceeeceeeseteseeesaseeeaees 7 173 Figure 7 20 Fuser UM ia cheater RA a nae the 7 174 Figure 7 21 Registration Transport Assembly msnrnrsvrnrsvrnrrvenrrvrnrrnrnsrnrnsrnennrnr 7 175 Figure 7 22 Shutter Solenoid Assembly cccsesesesessescscseecetscsesseesecseseeeseeess 7 176 Figure 7 23 Tray 1 Feeder Assembly ou ccceccsecscsseeceseecseeecseeecsesscesseeesaeesaees 7 177 Figure 7 24 Waste Cartridge Waste Cartridge Cover and Waste Cartridge Sensor Holder 7 178 Figure 7 25 Print Cartridge Plate Cover plastic orerrrsrnrororerrsvorereresvorsvenenn 7 179 Figure 7 26 Dispense Assembly eroice nre einin rn haearn aan ri 7 180 Figure 7 27 Print Cartridge Plate Assembly ooarrrsrorerrrvsvovovererrsverereresversvennne 7 182 Figure 7 28 Print Cartridge Plate Assembly cont d ersnevovorerrrvorereresvorsvenenn 7 183 Figure 7 29 Developer Housing Assembly sennrnrsnrnrrvrnrrvenrrvenrrvennrrrrsrrennrsernenn
163. inienenene 3 93 Front Panel Continually Displays the Xerox Phaser 7700 Splash Screen 3 93 Front Panel Continually Displays warming up please wait Message 3 93 Front Panel displays Fatal Fault Encountered message ccccceeceeseeeeeees 3 94 Troubleshooting Printer Comes to a Ready State mmenerevrovorovorerrrrrrerarrsesvener 3 94 False LH Door RH Door or Front Door Open Messages cccccecccceecsenees 3 94 False Load Paper in Tray 1 2 3 4 Message rsrsnrsnrnrrnrnrrnrsrrnrrrrvesrrnessrnennnnr 3 94 False Tray 1 2 3 4 Missing Message 3 94 Tray KUUTECh d 3 95 Tray 2 3 or 4 Will Not Lift revererrnrororonrsversvonerrnvovereresvsvenevesnsnsvenerenvsnenarssssnenen 3 95 Tray 2 3 and 4 Will Not Lift or Printer Will Not Recognize the Auxiliary Feeder msossersrorrrrrverrrverrrvrnrrsensrnennnne 3 96 Printer Will Not Recognize the Finisher nsssnnnsnnsnensnsnsnnnnnnnnensesnsnsnrnrnrnnneenens 3 96 Troubleshooting the Toner Dispense Auger Developer System 3 97 Checking the Toner Cartridge c ccccccscccsesescscsscscscsesecetscsesesscscsesecessesesesaeass 3 97 Checking the Toner Auger System ssvenevrsnsvoreresnsvsvenerenvrvereresnsvenenesssnsvenene 3 98 Checking the Developer ATC Sensor c ccccccscsssscscscsesesstscsescsesecesseseseceeaees 3 101 Checking the Developer ENEE 3 102 RIVE 3 102 Operation System and Application Probl
164. inisher The Finisher s Requirements power supply provides all required DC voltages throughout the Finisher Option The Phaser 7700 Light Finisher shall meet FCC part 15 subpart B Class A CISPR22 Class A Dimensions Height Width Weight 7700 376 Figure 11 2 Dimensions of the Finisher Phaser 7700 Color Laser Printer Service Manual 11 315 Table 11 1 Finisher Specifications cont d Category Specification Media Types Long Edge Feed LEF Short Edge Feed SEF B5A3 A4A4 LetterB4 8 x 10 Letter US Folio Legal Tabloid Media Weight 64 105 g m Thick Thin paper Stacker 1000 non stapled sheets 20 Ib paper letter A4 or smaller Capacity 500 unstapled sheets 20 Ib paper over size Letter A4 300 unstapled sheets Mix Stack loading large on small 50 stapled sets Staple 5000 staples Cartridge Capacity 11 316 Phaser 7700 Color Laser Printer Service Manual Assemblies of the Finisher Staple Finisher Gate Unit Horizontal Transport Stacker 7700 445 Figure 11 3 Assemblies of the Finisher Phaser 7700 Color Laser Printer Service Manual 11 317 Internal Assemblies of the Finisher Exit Assembly Cam Bracket Assembly Main Motor Finisher Control Board Decurler Stacker Motor Assembly Combpiler Tray 7700 372 Staple Assembly Track Staple Unit Figure 11 4 Internal Asse
165. int quality problems before proceeding further with RegiCon 7 If the display indicates lt DC685 2 READJUST Passed gt press OK to see the second panel data If an adjustment is needed adjust by the amounts displayed on the front panel Be sure to tap the screw that was adjusted with a heavy screwdriver to ensure the adjustment remains true Skew Corr Y 7 clicks CCW Skew Corr M 7 clicks CW Skew Corr C 5 clicks CCW Skew Corr K 12 clicks CCW When DC685 1 or DC 685 2 Fails The horizontal alignment error is excessive and a manual adjustment is required before the diagnostics test routines for fine skew can pass For details of the Coarse RegiCon Init procedure see Coarse RegiCon Initialization on page 4 140 4 138 Phaser 7700 Color Laser Printer Service Manual Step 5 RegiCon 3 Center Skew Adjustment This test adjusts magnification balance There are no manual adjustments required after completing the test Note To perform this test move the Mark On Belt sensor to the CENTER position After the test has been run the Mark On Belt must be moved back to the home position 1 Remove the Waste Cartridge 2 Remove the screw that holds the Mark On Belt MOB sensor to the front of the printer 3 Using the laser mirror cleaning tool backward push the sensor all the way to the CENTER position until it hits the stop 4 Reinstall the Waste Cartridge 5 Close the door and run the test 6 From t
166. inter Service Manual Error Chain code Pink Front Panel Message 78 09 358 ERROR 78 WASTE TONER CARTRIDGE FULL DETECTION SENSOR FAILURE Remove the Waste Cartridge Sensor Holder without disconnecting the harnesses RRP 23 on page 7 178 Measure the voltage between the yellow wire to the Waste Cartridge Full Sensor and frame ground and alternately interrupt the Waste Cartridge Full Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage between the gray wire to the Waste Cartridge Full Sensor and frame ground Does the voltage measure 5 VDC Yes No Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P406A 3 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Inspect the wiring harness between the Engine Board and the Waste Cartridge Full Sensor Repair or replace the harness as necessary Measure the voltage between the violet wire to the Waste Cartridge Full Sensor and frame ground Does the voltage measure 0 VDC Yes No Inspect the wiring harness between the Engine Board and the Waste Cartridge Full Sensor Repair or replace the harness as necessary eplace the Waste Cartridge Full Sensor Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P406A 2 Voltage M
167. inter Service Manual RRP 16 Duplex Unit Assembly CLIP Duplex Unit Cover 7700 094 Figure 7 17 Duplex Unit Assembly Removal 1 Release the clip securing the Duplex Unit Cover and remove the cover 2 Loosen the two captive screws securing the Duplex Unit Assembly to the Left Hand Cover Assembly and remove Phaser 7700 Color Laser Printer Service Manual 7 171 RRP 17 Transfer Roller Assembly 2nd BTR 57700 458 Figure 7 18 Transfer Roller Assembly 2nd BTR Special Tool required 2 5 mm hex driver Removal 1 Open the Left Hand Cover Assembly Left Door 2 Using a 2 5 mm hex driver remove the four captive screws from the mounting brackets 2 at each end of the Transfer Roller Assembly 3 Remove the assembly Replacement Note Make sure the mounting brackets are seated on the locating pins as the screws are installed 7 172 Phaser 7700 Color Laser Printer Service Manual RRP 18 Duplex Transport Assembly N N w Zz 4 o lt Ax o UE i 9 d 7700 030 Figure 7 19 Inverter Transport Assembly Removal 1 Partially remove the Left Hand Cover Assembly Left Door RRP 14 on page 7 168 2 Remove the e clip and remove the shaft 3 Remove the two screws that secure the Inverter Transport Assembly to the Left Hand Door and remove the Inverter transport assembly Phaser 7700 Color Laser Printer Service Manual 7 173 RRP 19 Fuser Unit
168. ions s s snsnssnnisnsnnnnennnnnnnna 2 36 Table 8 1 Accumulator Belt FRUS List serrsnrrrsnerrsvrnrrverrrvrnrrrenrrnrnnrnrnrnrnsrnrrnrnn 8 236 Table 8 2 Left Hand Door FRUS ei 8 238 Table 8 3 Media Trays FRUS List rnrrnvrnrnvrrrnvrnrsvrsrsvrrrsvrsvenrsvenrsvenrsvennsnennsnennsnnn 8 239 Table 8 4 Duplex Unit FRUS et 8 240 Table 8 6 Coven FRUS LIS eis cscesescssescsoa denges REENEN 8 241 Table 8 6 Cover FRUs cont d Uert 8 242 Table 8 7 Covers FRUs List cont d ceeceeceseceseeeeeeeeeeeeeeeeeeeeeeteteeeeeeeteteeeees 8 244 Table 8 8 Switch and Sensor FRUS Uer 8 246 Table 8 9 Switch and Sensor FRUs List econtd 8 248 Table 8 10 Circuit Board FRUS Uert 8 250 Table 8 11 Power Supplies FRUS et 8 252 Table 8 12 Power Supplies FRUs List eontd 1 8 254 Table 8 13 Motors Drivers FRUS ist 8 256 Table 8 14 Electrophotographic Components FRUS Uert 8 258 Table 8 15 Electrophotographic Components FRUs List cont d 0 0 8 260 Table 8 16 Multi Purpose Tray MPT FRUS Uert 8 262 Table 8 17 Paper Feed FRUS List 8 264 Table 8 18 Paper Feed FRUs List eontd 1 8 266 Table 8 19 Fans FRUS List siisccccccccescaencesctccctetetendacehducetiacchecndedenducchdvietededsevaceetede 8 267 Table 8 20 Lift Components FRUS et 8 269 Table 8 21 Wiring FRUS List us sdssenernesa Seed dE 8 271 Table 8 22 Auxiliary Feeders FRUS si 8 273 Table 8 23 Lower Tray Deck LTD FRUS List nrorrrorrrorsvorovorerrrvsvoreresvsvererenn 8
169. ition to reestablish electrical connections to the belt Open the RH Door and defeat the interlock switch Look for rotation of the Accumulator Belt during the following test Run the Belt Edge Learn test Did the Accumulator Belt rotate Yes No Remove the Accumulator Belt Assembly RRP 35 on page 7 196 CautionRemoving the Accumulator Belt Assembly allows ambient light into the print cartridge area Avoid exposing the print cartridge drums to light Manually rotate the gear that drives the Accumulator Belt Does it move freely Yes No Inspect the Accumulator Belt Cleaner Waste Auger for packed toner Is the area inside the auger relatively clear of toner Yes No Note It is easy to spill toner in the next step Remove the Waste Toner Cartridge Run the Agitator Motor Test Does the Waste Toner Agitator Motor rotate Yes No Measure the voltage at the Engine Control Board J404B 3 see figure page 2 46 Does the voltage measure 24 VDC Yes No Measure the voltage at the Engine Control Board J408 7 see figure page 2 46 Does the voltage measure 24 VDC Yes No Check for 24 VDC at the supply using the Troubleshooting 24 VDC LVPS procedure in the Troubleshooting Section Troubleshooting the 24 VDC LVPS on page 3 90 eplace the Engine Control Board RRP 42 on page 7 206 Repeat the Agitator Motor test while measuring the voltage at the Engine Control Board J404B 4 Does the voltage
170. kColor and Walk Up are trademarks of Xerox Corporation in the United States and or other countries Adobe Reader Adobe Type Manager ATM and PostScript are trademarks of Adobe Systems Incorporated in the United States and or other countries Apple AppleTalk EtherTalk LaserWriter LocalTalk Macintosh Mac OS and TrueType are trademarks of Apple Computer Inc in the United States and or other countries HP GL HP UX and PCL are trademarks of Hewlett Packard Corporation in the United States and or other countries Windows and Windows Server 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 M 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 UNIXO is a registered trademark in the US and other countries licensed exclusively through X Open Company Limited PANTONE Colors generated may not match PANTONE identified standards Consult current PANTONE Publications for accurate color PANTONE and other Pantone Inc trademarks are the property of Pantone Inc O Pantone Inc 2000 ii Phaser 7700 Color Printer Service Manual User Safety Summa
171. l RRP 55 Main Lever Assembly Right and Left Hand Jacks 57700 455 Figure 7 61 Main Lever Right Hand and Left Hand Jacks Removal Main Lever Assembly 1 Remove the Accumulator Belt Assembly RRP 35 on page 7 196 2 Remove the Print Cartridges and protect from the light 3 Remove Fuser Front Cover RRP 8 on page 7 162 4 Remove the Left Hand Cover Assembly RRP 14 on page 7 168 5 6 7 8 Lower the Main Lever Assembly to fully horizontal Remove the e clip and remove the RH Handle Pivot Pin Remove the screw and washer and remove the RH Handle Pivot Pin Remove the Main Lever Assembly Removal RH Jack Assembly Caution Ensure that the Lift Frame Assembly is fully lifted and the N wech BAARD RH and LH Lift Jack Assembly racks are even Hold the Main Lever in a horizontal position Slide the Main Lever gears under the Lift Jack Assembly racks and lift into position Insert the clevis pins Remove RH Cover Assembly RRP 2 on page 7 155 Remove the Main Lever Remove the e clips and washers from the RH Lift Jack Assembly roller guides Remove the four screws that hold the RH Lift Jack Bracket and remove the bracket Phaser 7700 Color Laser Printer Service Manual 7 221 8 Remove the two screws holding the Waste Auger Assembly 9 Remove the four screws holding the RH Lift Jack Bracket and remove from the printer Note When reinstalling the RH Lift Jack Asse
172. lamp Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Measure the voltage at Eject Clamp Home Sensor pin 1 gray Does the voltage measure 5 VDC Measure the voltage between the Finisher Control Board P849 6 see figure page 2 46 and Finisher frame ground Does the voltage measure 5 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Eject Clamp Home Sensor Phaser 7700 Color Laser Printer Service Manual 2 79 Error Chain Gode Link Front Panel Message 120 12 260 FINISHER ERROR 120 EJECT CLAMP HOME SENSOR ON FAILURE 121 12 262 FINISHER ERROR 121 EJECT CLAMP HOME SENSOR OFF FAILURE A B C D Yes No Measure the voltage at the Eject Clamp Home Sensor pin 3 violet and Finisher frame ground Does the voltage measure 0 VDC Measure the voltage between the Finisher Control Board P849 4 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the Finisher Control Board and the Eject Clamp Home Sensor Replace the Eject Clamp Home Sensor RRP 76 on page 11 335 Repair or replace the wiring harness between the Finisher Control Board and the Eject Clamp Home Sensor Replace the Finisher Control Board RRP 77 on page 11 336 Replace the Fini
173. ll it straight out of the printer both sides 3 Remove the screws that secure the hinges and slide the hinges off the locating pin both sides and remove the hinge 4 Remove the Front Cover Assembly Phaser 7700 Color Laser Printer Service Manual 7 161 RRP 8 Fuser Front Cover 7700 029 Figure 7 8 Fuser Front Cover Removal 1 Remove the Front Cover Assembly RRP 7 on page 7 161 2 Remove two screws from the Fuser Front Cover and push upward and remove the cover 7 162 Phaser 7700 Color Laser Printer Service Manual RRP 9 Rear Shield Te 57700 423 Figure 7 9 Rear Shield Removal Warning Turn Off the power and disconnect the power cord 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the seven screws securing the Rear Shield to the printer 3 Remove the shield Phaser 7700 Color Laser Printer Service Manual 7 163 RRP 10 Rear Shield Bracket 87700 422 Figure 7 10 Rear Shield Bracket Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the Rear Shield RRP 9 on page 7 163 3 Remove the three screws securing the Rear Shield Bracket to the printer 4 Remove the Rear Shield Bracket 7 164 Phaser 7700 Color Laser Printer Service Manual RRP 11 24 VDC Power Supply Shield a Ee 87700 424 Figure 7 11 24 VDC Power Supply Shield Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the Rear Shield RRP 9 on page 7
174. m Examine the ATC values for the color you are testing As toner is consumed but no fresh toner is augered into the Developer Housing the toner concentration will fall In a properly working Developer Housing the values Ave ATC and ATC Vol should rise about 20 points to reflect this concentration change A change of about 30 points should trigger a Replace Toner Cartridge message ATC Control and ATC Corr should remain unchanged 10 If the ATC values do not change as expected as toner is consumed in the Developer replace the ATC Sensor Note For ATC Sensor errors 12 13 14 and 15 be sure to clear the Tech Rep Faults 09 380 to 09 383 using the Service Diagnostic s NVRAM Access Clear Tech Rep Fault Phaser 7700 Color Laser Printer Service Manual 3 101 Checking the Developer If after these checks the problem still exists 1 Inspect the wiring harnesses leading to the Developer for nicks pinched wiring or poor connections 2 If the wiring harnesses are OK replace the Developer RRP 27 on page 7 185 3 After installing a new Developer print 25 100 Solid Fill A size pages to ensure it prints correctly If the problem still exists replace the Engine Control Board RRP 42 on page 7 206 Tips ATC Sensor Setup When you replace an ATC Sensor or a Developer make sure to program the ATC Sensor s calibration value into the printers engine s NVRAM Use the Adjustment Calibrations menu s ATC Sensor Setup T
175. m Repeating spots m Any one weak color may indicate a faulty developer print unit or first transfer m Weak colors may also be caused by a defective high voltage power supply m lf all colors are weak this could indicate a problem with the ADC or second transfer systems m Worm tracks or wrinkles may be caused by the fuser 9 290 Phaser 7700 Color Laser Printer Service Manual Diagnostics Mode 7700 290 i S i 7700 292 Laser Check This is a gray print with all four colors turned on at about 25 fill Things to look for A hue shift that indicates one of the primary CMYK colors is missing A missing primary indicates that the laser is faulty Halftones This test prints 6 pages of 100 solid fill of Yellow Magenta Cyan Black Red and Green This print sequence is very useful in determining if there is any streaking of usually yellow or cyan that has interfered with RegiCon registration control When you get DC685 1 results showing A Patch IN OUT block counts of less than 24 or B Patch IN OUT block counts of less than 4 use these prints to decide if attention needs to be focussed on the toner delivery mechanisms Until toner is evenly deposited on the developer roller RegiCon cannot pass Things to look for A mottled color especially on the red and green pages Phaser 7
176. manually rotate the gear that drives the Accumulator Belt Does it move freely now Yes No Replace the Accumulator Belt Drive Assembly RRP 51 on page 7 217 Replace the Waste Auger Assembly RRP 37 on page 7 199 Run the Accumulator Belt Motor test Does the Accumulator Belt Motor rotate Yes No Inspect P530 see figure page 2 46 on the Engine Control Interface Board for proper seating If the problem persists replace the Accumulator Belt Drive Assembly RRP 51 on page 7 217 If the problem continues to persist Replace the Engine Control Board RRP 42 on page 7 206 eplace the Accumulator Belt Assembly RRP 51 on page 7 217 Replace the Accumulator Belt Assembly RRP 51 on page 7 217 Cautionif the Accumulator Belt is damaged determine the cause of the damage before installing a new Accumulator Belt Assembly Visually inspect the Accumulator Belt area inside the printer and inside the LH door for foreign object or damage parts Inspect the belt steering mechanism to determine if it is operable It may be necessary to query the user for additional information as to likely causes If the problem persists replace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 55 Error Chain Code Link Front Panel Message 31 04 347 ERROR 31 Accumulator Belt HOME POSITION FAILURE Lower the Main Release Lever and return to the upright pos
177. mblies of the Finisher 11 318 Phaser 7700 Color Laser Printer Service Manual Horizontal Transport Sensor Interlock and Switch Locator Map Gate In Solenoid H Transport Entrance Sensor H Transport Interlock Sensor IOT Face Down Tray Full Sensor H Transport Exit Sensor 7700 4457 Figure 11 5 Horizontal Transport Sensor Interlock and Switch Locator Map Phaser 7700 Color Laser Printer Service Manual 11 319 Finisher Sensor Interlock and Switch Locator Map Stack Height Sensor Eject Clamp Home Sensor Decurler Cam Home Sensor Docking Interlock Sensor 7700 449 Figure 11 6 Finisher Sensor Interlock and Switch Locator Map 11 320 Phaser 7700 Color Laser Printer Service Manual Finisher Sensor Interlock and Switch Locator Map Rear Tamper Tamper Unit Home Sensor Top Cover Interlock Switch Stacker Upper Limit Switch Staple Move Sensor PAN Front Cover Stack A Sensor Interlock Switch Stack B Sensor Staple Front Corner Sensor 7700 448 Figure 11 7 Finisher Sensor Interlock and Switch Locator Phaser 7700 Color Laser Printer Service Manual 11 321 Blank Page 11 322 Phaser 7700 Color Laser Printer Service Manual Removal and Replacement Procedures This section details the removal and replacement procedures for the main assemblies of the Phaser 7700 Light Finisher When replacing sensors actuators interlocks and or switches m Refer to the appropria
178. mbly 7 232 RRP 64 Bracket Assembly Left Hand and Right Hand Gear HCF 7 233 Phaser 7700 Color Laser Printer Service Manual 7 153 RRP 1 Rear Cover Assembly Lower Tray Assembly Connector Cover 87700 202 Figure 7 1 Rear Cover Assembly Removal Warning Turn Off the printer and disconnect the power cord 1 If an Auxiliary Feeder has been installed open the Auxiliary Feeder Connection Cover and disconnect the Auxiliary Feeder wiring harness 2 Remove the four screws that secure the Rear Cover Assembly to the printer 3 Pull the top edge of the Rear Cover Assembly about one inch away from the printer and push down to release the cover 7 154 Phaser 7700 Color Laser Printer Service Manual RRP 2 Right Side Cover Assembly Right Hand Door Tabs 4x Finisher J800 7700 033 Figure 7 2 Right Side Cover Assembly Removal 1 Open the Front Cover 2 Remove the three screws that secure the Right Side Cover to the printer One screw is located behind the Right Hand door 3 Lightly press downward to release the four hidden tabs that are behind the right side cover then pull the cover away from the printer Phaser 7700 Color Laser Printer Service Manual 7 155 RRP 3 Top Cover Assembly 700 078 Figure 7 3 Top Cover Assembly Removal 1 Remove the Right Side Cover Assembly RRP 2 on page 7 155 2 Remove the two screws visible on the right side of
179. mbly install the screws as follows Upper Left Upper Right then the lower screws Note When reinstalling the RH Lift Jack Assembly ensure that the Jack racks protrude evenly before returning the Main Lift Lever to its upright position Removal LH Lift Jack Assembly 1 Remove the Accumulator Belt Assembly RRP 35 on page 7 196 2 Remove the Print Cartridges and protect from the light 3 Remove the Main Lever Assembly only on the LH side RRP 55 on page 7 221 Remove the LH Lever Hinge Use a stubby screwdriver Remove the Transport Registration Assembly RRP 20 on page 7 175 Remove the Mark On Belt MOB Sensor Assembly RRP 32 on page 7 191 Reach inside the LH cover cavity and remove the black print cartridge rail by pushing on the rail slot while pulling on the rail NO E CO Caution Cover the developers with multiple sheets of stiff paper or cardboard to prevent damage to the developer rollers and to catch e clips and washers loosened in the next step 9 Remove the Fuser Assembly then remove the catch tray mounted on the Accumulator Belt Assembly 10 Remove the e clips and washers from the LH Lift Jack Assembly roller guides 11 Remove the four screws that hold the LH Lift Jack Bracket and remove the bracket 12 Remove the four screws holding the LH Lift Jack Bracket and remove from the printer Note When reinstalling the LH Lift Jack Assembly install the screws as follows Upper Front U
180. mbly to the finisher 3 Remove two screws from the bottom of the assembly 4 5 Press down on the two locking tabs located at the top of the sensor press Remove one screw on the sensor bracket up on the two locking tabs at the bottom of the sensor and remove the sensor Remove the connector from the sensor Phaser 7700 Color Laser Printer Service Manual 11 333 RRP 75 Set Clamp Clutch and Gear Figure 11 17 Set Clamp Clutch and Gear Removal 1 Remove the Rear Cover RRP 72 on page 11 330 2 Remove the set clamp actuator 3 Remove one screw from the set clamp actuator retainer and remove 4 Remove the clutch collar and clutch 5 Remove the gear Replacement Note When replacing after installing the clutch collar you need to depress the clutch solenoid and rotate the set clamp shaft 1 4 revolution Counter Clockwise then install the set clamp actuator Rotate the clutch until the solenoid snaps into position 11 334 Phaser 7700 Color Laser Printer Service Manual RRP 76 Eject Roll Assembly 7700 333 Figure 11 18 Eject Roll Removal 1 Remove the Rear and Left Covers RRP 72 on page 11 330 2 Remove Stack Paper Sensor Assembly RRP 73 on page 11 332 3 Undo the intermediate connector 4 Remove the Right Cover 5 Remove the Set Clamp Clutch and Gear RRP 75 on page 11 334 6 Remove both KL clips from the Set Clamp Shaft 7 Push the bearings out of the frame assembly and remove t
181. me ground Does the voltage measure 0 VDC Yes No Test the wiring harness and the Finisher Control Board for continuity to Finisher frame ground Replace the Finisher Control Board eplace the Stapler Unit Assembly Replace the Finisher Control Board Perform the Stapler Ready sensor test Phaser 7700 Color Laser Printer Service Manual 2 73 Error Chain Gode pinks Front Panel Message 113 12 244 FINISHER ERROR 113 STAPLER FAILURE Continued Does the sensor indicate the Stapler is ready Yes No Remove the Finisher Front Cover RRP 72 on page 11 330 Measure the voltage between Stapler Unit Assembly connector J886 3 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Replace the Stapler Unit Assembly emove the Finisher Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between Finisher Board connector P852 3 see figure page 2 46 and Finisher frame ground Does the voltage measure 0 VDC Yes No Repair or replace the wiring between the Stapler Unit Assembly and the Finisher Control Board eplace the Finisher Control Board Replace the Finisher Control Board If the problem persists replace printer Engine Control Board RRP 42 on page 7 206 If the problem continues to persist verify the ground continuity between Finisher frame ground and Printer frame ground 114 12 252 FINISHER ERROR 114 FRONT TAMPER FAILURE 115 12
182. measure 0 VDC when the test is run and 24 VDC when the test is not run Yes No Replace the Engine Control Board RRP 42 on page 7 206 Replace the Waste Toner Agitator Motor RRP 31 on page 7 190 2 56 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Link Front Panel Message 31 04 347 ERROR 31 Accumulator Belt HOME POSITION FAILURE Continued A B C D Run the Yes No Using a Type II toner vacuum cleaner vacuum out the Waste Auger Assembly Replace the Waste Toner Cartridge Recheck the gear that drives the Accumulator Belt for freedom of rotation Does it move freely now Yes No Replace the Waste Auger Assembly RRP 37 on page 7 199 einstall all parts and assemblies and verify printer operation If problem persists resume this procedure at next line below Remove the e clip and remove any one of the Waste Auger Drive Gears Again manually rotate the gear that drives the Accumulator Belt Does it move freely now Yes No Replace the Accumulator Belt Drive Assembly RRP 51 on page 7 217 Replace the Waste Auger Assembly RRP 37 on page 7 199 Accumulator Belt Motor test Does the Accumulator Belt Motor rotate Inspect P530 see figure page 2 46 on the Engine Control Interface Board for proper seating If the problem persists replace the Accumulator Belt Drive Assembly RRP 51 on page 7 217 If the problem continues to persist
183. n Problems m Macintosh printing problems m Windows printing problems Media Jams and the Paper Path m Media based problems m Multiple sheet picks m Mis picks m Skewed images m Damaged prints m Fuser Jams a Exit Jams Print Image Quality Problems m Light undertones prints all colors Blank Prints One color is faded Missing bands in direction of paper travel Streaks in direction of paper travel Banding Streaks parallel with the leading edge Random missing spots Random spotting Repetitive mark appears on each print Background contamination Infused image or image rubs off easily Toner on back of print Image is mis registered on paper Residual image or ghosting 3 88 Phaser 7700 Color Laser Printer Service Manual Troubleshooting Power Supplies and Interlocks Troubleshooting AC Power 1 Verify that the AC Input Voltage is present and within specifications 2 Verify that the Reset button on the GFI is depressed 3 Reconnect AC power If the GFI trips immediately with the Power switch Off disconnect AC power remove the rear cover and metal shields Check for shorts in the AC Circuit from the GFI to the Noise Filter the AC Driver Board and up to the Power Switch 4 Switch the printer on If the GFI trips unplug the printer remove the fuser then retest Disconnect AC power remove the rear cover and metal shields Check for shorts in the AC Circuit from the Power Switch back to the AC Driver Board and to the bot
184. nect P400 see figure page 2 46 and P401 see figure page 2 46 on the Engine Con trol Board Inspect both connectors to determine they are fully engaged as a unit Re engage if neces sary Note The two connectors can NOT properly seat into their socket s unless they are both engaged as a unit Ensure there is no separation Carefully reinsert the plugs into their joint socket and FIRMLY seat them Replace the Laser Unit RRP 38 on page 7 200 Note Whenever the mounting screws for the Laser Unit have been loosened it is necessary to recalibrate the unit by performing the RegiCon Adjustment Procedure beginning on page 4 124 If the problem persists replace the Engine Control Board RRP 42 on page 7 206 11 06 372 ERROR 11 LASER UNIT POLYGON MOTOR FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Remove Rear Cover RRP 1 on page 7 154 Disconnect P400 see figure page 2 46 and P401 see figure page 2 46 on the Engine Con trol Board Inspect both connectors to determine they are fully engaged as a unit Re engage if neces sary Note The two connectors can NOT properly seat into their socket s unless they are both engaged as a unit Ensure there is no separation Carefully reinsert the plugs into their joint socket and FIRMLY seat them Replace the Laser Unit RRP 38
185. nisher Covers FRUS mmsrrveverevvrvereresvsvsvovererrsverersvesveneresrsvener 11 347 Figure 11 28 Finisher Stand FRUS ccececesecescsececeseeeeceneeeeeeeeeeeetenseseeeeeeeenees 11 348 Figure 11 29 Gate Unit FRUS nesiaha a a 11 350 Figure 11 30 Horizontal Transport Assembly FRUS msnrnrsnrrrsvrrrsverrsnrrrrvernrnennr 11 352 Figure 11 31 Horizontal Transport Assembly FRUS cont d mmrrnrnrenrnrrvrnrrnn 11 354 Figure 11 32 Top Cover and Eject Roll FRUS ssrorrvororrrvovoreresvsvarsvesnersvenesvrner 11 356 Figure 11 33 Paper Transport Assembly ERUN 11 358 Figure 11 34 Paper Transport Assembly FRUS cont d eseese 11 360 Figure 11 35 Staple Unit Assembly FRUS erernvrnrrrnroverororvsverenrsverersvesnersvenesvrner 11 362 Figure 11 36 Compiler Tray Assembly ERUN 11 364 Figure 11 37 Stacker Elevator Assembly FRUS ns ssnssssssssnssesseesnssnenesnssresrenrsnnnne 11 366 Figure 11 38 Exit Assembly FRUS 11 368 XXVi Phaser 7700 Color Laser Printer Service Manual Figure 11 39 Electrical FRUS isro dorno ienr Ar enke ated A Figure 12 1 Block diagram of the Finisher seosesrsvrsnrnrrnrnrrsrnrrvenrrvenernrnrrnennene Figure 12 2 Wiring diagram of the Pnteher Phaser 7700 Color Laser Printer Service Manual xxvii xxviii Phaser 7700 Color Laser Printer Service Manual General Information The Phaser 7700 Color Laser Printer Service Manual is the primary document used for repairing and maintaining the Xerox Pha
186. nitialization Reprint the Grid 1 Dot print from procedure Diagnostics page 4 140 Go d to step 1 Do all the colors align correctly Se 4 130 Phaser 7700 Color Laser Printer Service Manual Table 1 RegiCon Procedure cont d Step Actions and Questions Yes No 3 Note Turn Netware Off before running any RegiCon procedures Perform the RegiCon 1 Fine Skew Adjustment page 4 137 To view the results you must re enter Service Diagnostics by turning Off the printer pressing the Back and Info buttons simultaneously and switching the printer On Do the results indicate the test passed Scroll down using Go to step 8 the Down arrow button to view the results and perform skew correction adjustments as indicated in the second panel data until less than 5 clicks are required for each color then go to step 4 Sometimes large numbers of clicks are displayed If this occurs center the adjusting position of the screws and restart the RegiCon procedure The adjusting screws have 18 complete turns from fully CW to fully CCW To adjust the screws to the center position turn the screw to either limit and then turn it bak 9 complete turns and re test Perform the RegiCon 2 In Out Skew Adjustment procedure page 4 138 To view the results you must re enter Service Diagnostics by turning Off the printer pressing the Back and Info buttons simultaneously and switching the p
187. nt Cart Cyan is H Print Cart Black is H Engineering use only Finisher Sensors Interlocks Left Hand Cover is L Top Cover is L Docking is H Horiz Transport is L Horizontal Transport Entry is L Exit is L IOT Full is H Compiler Tray Exit is L Paper is L Cover Safety Switch is L Stacker No Paper is L Height is H Upper Limit is L Stack Ais L Stack B is L Tamper Rear Home is L Front Home is H Stapler Head Home is L Low is L Ready is L Move is L Front Corner is H Miscellaneous IOT Reg Clutch is H Eject Home is L Set Clamp Home is L Decurler Cam Position L Optional only if Finisher is installed H Open actuated or paper present L Closed deactuated or no paper present Engineering use only Engineering use only Engineering use only Engineering use only Motors Fans Tests Tests the operation of motors by running one or more motor tests at a time Main Motor Main Motor is On This test produces gear hopping Turn Motor Off noise unless you perform the 2nd All Motors Off BTR retract motor test 2 40 Phaser 7700 Color Laser Printer Service Manual Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Steering Motor To avoid damaging the Accumulator Belt remove Do you wish to continue Yes No Motor On Motor Off Please cycle power to the printer now Cauti
188. nt Engine cont d 1 18 Assemblies of the Print Engine cont d s es 1 19 Auxiliary Feeder Assemblies mnerrvrnvrsnrvrrrsvrrnrvrrvererverrsveresverrsnenssnerssnenssnenns 1 20 Front Panel DESenption seiors knusende 1 21 RS RRE 1 21 Front Panel Shortouts diissii an danene 1 22 earkanglt A E N A E E A EE E 1 23 RE TC 1 23 Printer Specifications 1 24 Physical Dimensions and Clearances ccccccccscccscsessssssesescsesseecscsesecetscsesenes 1 24 Supported Paper Weights Page Sizes and Print Area rmeerssvsvsvovrrrvrrverene 1 27 Diagnostics Error Codes and Messages 2 31 Error Messages 2 31 Troubleshooting Error Codes 2 31 Ghain Leeder Eeer 2 31 Where do they come from sa ssnsssseokasseeeansnnasn eninie 2 31 Why are they EE 2 31 System Boot Sequence EE 2 32 Power On Self Test POST eerste dende anda den 2 32 POST Rau lt Lunnan ie 2 33 Fault Reporting Devices nescire ernn E E EEE 2 33 LED Blink Patterns vieirai iaiia 2 33 POST Diagnostics Test Descriptions semeverevervorovorererrsrereresesversveresvererenn 2 34 Service DiaGnOStiCS 2 0 ee EES cients hte aaa aids 2 35 xii Phaser 7700 Color Laser Printer Service Manual Entering Service Diagnostics Mode 2 35 Service Diagnostics Test Menu FUNCTIONS sororrvorerrrvsvororervrrsvorerenvsnerereservene 2 36 Error Codes and Messages Troubleshooting cccccscsscscsesessescscseecesseseteeeeeees 2 46 Voltage Measurements avatar et 2 46 Fuser
189. nter Service Manual Troubleshooting For Error Codes and Messages refer to Diagnostics Error Codes and Messages on page 2 31 The Phaser 7700 Printer has built in diagnostics to aid in troubleshooting problems with the printer The Service Diagnostics Menu provides a means to test sensors motors and solenoids Diagnostics also contains built in test prints and calibration and cleaning procedures For details on error codes messages and service diagnostics Diagnostics Error Codes and Messages on page 2 31 Note Before troubleshooting power supply problems disconnect the Auxiliary Feeder or Finisher if installed and restart the printer Verify the problem is still present or refer to the appropriate Option troubleshooting section This section is ordered as follows Troubleshooting Power Supplies and Interlocks m AC Power m Low voltage Power Supplies LVPS m 3 3 VDC and 5 VDC LVPS m 24VDCLVPS m 24 VDC Interlock Circuit m 5 VDC Interlock Circuit System problems where the printer will not come to Ready m Printer does nothing when power is turned On Fanon Front Panel LED never On m Fanon Front Panel LED on no Front Panel message m Front Panel continually displays Xerox Phaser 7700 splash screen m Front Panel continually displays WARMING UP m Front Panel displays FATAL FAULT ENCOUNTERED Phaser 7700 Color Laser Printer Service Manual 3 87 Troubleshooting Network Problems Operating System and Applicatio
190. nter printing within its environmental specifications 2 3 Ensure that the loaded media matches the front panel settings 4 Is the jam caused by a heavy stiff paper being used for two sided printing In such cases a lighter grade of paper should be used or face up mode to the side output tray should be used 5 Clean all the eject rollers with a clean dry lint free wipe if debris is visible 6 Does the exit sensor flag properly actuate its sensor Test the sensor using Service Diagnostics 7 Replace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 3 107 Print Image Quality Problems Light undertone Prints all colors The overall image density is too light a PON 7 8 Ensure that the correct color correction was set in the driver Is the correct paper being used in the printer Ensure that the loaded media matches the front panel settings Verify the Bias Transfer Roller is not reaching its end of life by printing the Supplies Usage Page Run the Calibrate for Paper routine From the Front Panel s Support Menu select Improve Print Quality then select Calibrate for Paper Menu and press OK Cycle the power which causes an Auto Density Control Cycle to take place Replace the Bias Transfer Roller RRP 17 on page 7 172 Replace the High voltage Power Supply RRP 44 on page 7 208 Blank Prints The entire image area is blank ap on
191. nto the Developer Housing no error message will necessarily be displayed Printing of that primary color will get progressively lighter and lighter In such a case the Developer Housing must be replaced Opened Developer Housing The Developer Toner mix should fill the Developer about to the shafts of the two Augers Developer Toner should adhere to the Magnetic Roller Figure 3 6 Developer Housing Print Cartridges The four Print Cartridges in the printer are rarely the cause of any print quality problems A Print Cartridge is a fairly simple component there is very little that can go wrong with it Realistically the only reason a Print Cartridge should be replaced is for a repeating defect to the cartridge s photoconductive drum Phaser 7700 Color Laser Printer Service Manual 3 103 Operation System and Application Problems Macintosh Printing Problems Image Never Prints Printer acts as if it is receiving data but nothing comes out of printer or it goes back to Ready mode without printing image 1 Power cycle the printer and print again 2 Make sure that the correct Phaser 7700 printer icon was selected in the Chooser Try printing the job again 3 In the Chooser or the print dialog switch background printing to Off Try printing the job again 4 Ensure that the printer can print by printing an internal front panel test print Image Prints in Black and White 1 In the print driver dialog box m
192. nuous Printing 220 to 600 watts average Peak warming up to 1100 watts Phaser 7700 Color Laser Printer Service Manual 1 25 Table 1 9 Environmental Specifications Characteristic Specification Temperature Operating 10 to 32 C Storage 20 to 50 C Humidly Operating 10 to 85 relative humidity Storage 30 to 85 relative humidity Altitude 0 to 2500 m 8000 ft at 25 C Acoustic Noise Idle 38 3 db Printing 54 8 db with impulse noise of 63 3 db 1 26 Phaser 7700 Color Laser Printer Service Manual Supported Paper Weights Page Sizes and Print Area Supported Paper Sizes The table identifies the paper weights that can be placed in each tray Laser Paper with the following weights 60 90 g m 16 24 Ib bond 40 60 Ib book Heavy Laser Paper with the following weights 91 105 g m 25 28 Ib bond 61 71 Ib book Thin Cover Index with the following weights 106 169 g m 50 60 Ib cover 65 90 Ib index 32 40 Ib bond and Thick Cover Index with the following weights 170 220 g m 65 80 Ib cover 100 110 Ib Index Paper Size Universal Universal Multi High capa Tray 1 Trays Purpose city Trays 2 4 Tray 3 4 Statement 5 5 x 8 5 in Executive 7 25 x 10 5 in 8 x 10 in UK Foolscap 8 x 13 in A Letter 8 5 x 11 in US Folio 8 5 x 13 in Legal 8 5 x 14 in B Tabloid 11 x 17 in Tabloid Extra 12 x 18 in A6 105 x 148 mm A5 148 x 210 mm A4 210 x 297 mm A3 297
193. nvovererrsvovarenesvensvenevesvsverevssssverenesesvsnener 4 127 Registration Control Procedures 4 130 RegiCon Flowchart siirre ianiai a 4 133 Step 1 Belt Edge Learn eosessesrsrsrorrsersororrrrsrsnosonrsrnrssonsrsnnsrnnssnnssensssnnn 4 134 xiv Phaser 7700 Color Laser Printer Service Manual Step 2 RegiCon 4 Coarse Skew Adjustment snsnnsnnnnsnsisnesnnnseneneenenn Step 3 RegiCon 1 Fine Skew Adjustment srorororrrrrrrvoreronvrrereresvsvsvovenerenne Step 4 RegiCon 2 In Out Skew Adjustment ooorrrrrrorororrvererervsvsvovenerrnne Step 5 RegiCon 3 Center Skew Adjustment nososnrrrororrrrrrererervsvsvovenerrnne Coarse RegiCon Initialization 0 0 cc cescsescsssscecscsesecessesesesecsesesecessesesesecececseneenss ATG SENSOF SELUP EE Additional Information 0 ceccsesesceseeeesesseseesseeeseseesseeseseeseseessseeseseeseeeeeets Cleaning and Maintenance 5 143 Service Preventive Maintenance Procedure Recommended Tools iv nine hasene istidene RT EE Resetting NVRAM 6 145 PostScript NVRAM Resets cccccccccsssecscsesescsssscscsecesscsesesscsesssesssesecsessesacsesenees Restore Factory Settings Color eesecececsseeeceseeeseeeeeeeeeeeeeeeeeeeeseeeeeeteeees Restore Previous Settings color csscccceeseseeeseceeceeeeeeeeceteteeeetetetneneeees Restore Factory Settings margins smerrvrsrrrrvonrrrnvrreverervsverevererrveneresnsnener Reset Calibrations color margins paper
194. o Measure the voltage at the Engine Control Board J404B 3 see figure page 2 46 Does the voltage measure 24 VDC Yes No Measure the voltage at the Engine Control Board J408 7 see figure page 2 46 Does the voltage measure 24 VDC Yes No Check for 24 VDC at the supply Troubleshooting the 24 VDC LVPS on page 3 90 eplace the Engine Control Board RRP 42 on page 7 206 2 54 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Link Front Panel Message 30 04 346 ERROR 30 Accumulator Belt HOME POSITION TOOK TOO LONG Continued A B C D E Repeat the Agitator Motor test while measuring the voltage at the Engine Control Board J404B 4 see figure page 2 46 RRP 42 on page 7 206 Does the voltage measure 0 VDC when the test is run and 24 VDC when the test is not run Yes No Replace the Engine Control Board RRP 42 on page 7 206 Replace the Waste Toner Agitator Motor RRP 31 on page 7 190 Using a Type II toner vacuum cleaner vacuum out the Waste Auger Assembly Replace the Waste Toner Cartridge Recheck the gear that drives the Accumulator Belt for freedom of rotation Does it move freely now Yes No Replace the Waste Auger Assembly RRP 37 on page 7 199 Reinstall all parts and assemblies and verify printer operation If problem persists resume this procedure at next line below Remove the e clip and remove any one of the Waste Auger Drive Gears Again
195. o d Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 1 see figure page 2 46 and P404A 2 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser einstall the Fuser Switch printer power ON Does the Fuser get warm Yes No Replace the Chassis AC Power Assembly RRP 49 on page 7 214 eplace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 61 Error Chain code Link Front Panel Message 43 10 353 ERROR 43 FUSER SSR1 ON TIME FAILURE Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 1 see figure page 2 47 and P600 3 see figure page 2 47 Does the resistance measure approximately 6 ohms for a 110 VAC Fuser or approximately 20 ohms for a 220 VAC Fuser Yes No Replace the Fuser Assembly Measure the resistance between the Fuser Assembly connector P600 4 see figure page 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly einstall Fuser
196. o ADC Output check under adjustments and calibration Toner Waste Cartridge Waste Cartridge presence is H Waste Cartridge full is H All door switches must be closed H Present or full L Not present or not full Tray Sensors Tray 1 Do you want auto media lift Yes No Tray 1 SW1 4 HHHL lt Letter gt Level H NoPaper L Tray 2 lt same as tray 1 gt Tray 3 lt no data available if HCF is installed gt Tray 4 lt same as tray 3 gt The four switch pattern indicates the media size L Tray not lifted H Tray lifted H Paper not present L Paper present Note Level 6 entries for Trays 2 4 follow the same pattern as for Tray 1 MPT Sensors MPT No Paper is L engineering use only MPT size is XXX MPT Multi Purpose Tray Range 0 1000 i e Letter LEF approx 180 i e Letter SEF approx 460 HCF Sensors No HCF Attached or HCF Path 1 is L HCF Path 2 is L High Capacity Feeder Engineering use only ATC Sensor ATC 1 is nnn ATC 2 is nnn ATC 3 is nnn ATC 4 is nnn ATC Automatic Toner Calibration Value range 0 1000 Engineering use only Phaser 7700 Color Laser Printer Service Manual 2 39 Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Print Cartridge Print Cart Yellow is H H Cartridge present Sensors Print Cart Magenta is H L No cartridge present Pri
197. o far out of adjustment that a manual adjustment is required before the diagnostics test routines for fine skew can pass Other possible problems a Mark On Belt Sensor failure Developer Developer Bias Voltage Print Cartridge or Engine Control Board Failure m Perform the Coarse RegiCon Initialization procedure on page 4 140 This adjusts the horizontal alignment closer and allows RegiCon 4 to pass m After Coarse RegiCon Initialization is complete perform RegiCon 4 Coarse Skew Adjustment again Make the required adjustments Note Adjustments should be made only if the skew correction indicated is greater than five clicks A positive number indicates clockwise CW adjustment is needed A negative number indicates a counter clockwise CCW adjustment is needed Adjustment screws are located behind the Waste Cartridge which must be removed for access From left to right the adjustment screws are K C M and Y 4 136 Phaser 7700 Color Laser Printer Service Manual Step 3 RegiCon 1 Fine Skew Adjustment This process uses sensors to examine the RegiCon image on the belt and report what skew adjustments need to be made A side effect of this test is that horizontal and vertical alignments are automatically done if the test passed The data output presents the skew screw adjustment values some number of clicks of the screw either CW or CCW direction Values less than 5 or so are noise and should not need adjusted
198. ocating pin hole in the printer frame Phaser 7700 Color Laser Printer Service Manual 7 185 RRP 28 New Developer Housing Assembly Charging Release Tabs ryg 7700 179 Figure 7 30 Developer Housing Assembly Recharge Recharging a Developer Housing Assembly Caution If replacing a Developer Housing Assembly write down the new ATC tag number Remove the tear off ATC tag number label and adhere it to the appropriate print cartridge connector on the print cartridge plate assembly then perform the procedure See ATC Sensor Setup on page 4 142 Note It is easy to spill toner in this procedure Use only a type II toner vacuum to clean up any spilled toner 1 Place the Developer Housing Assembly new or used to be recharged on large piece of newspaper or cloth 7 186 Phaser 7700 Color Laser Printer Service Manual Caution During this procedure the Developer Housing Assembly must be kept in a level position at all times It is recommended the Developer Housing Assembly be fully supported level by laying it on something like a large piece of cloth paper towels or styrofoam hollowed out for the Developer Housing Assembly to lie on The reason for supporting the Developer Housing Assembly in a level position is to prevent spilling toner If new remove the protective cover over the magnetic roller Do not touch the magnetic roller Note The wires are routed under and behind the right snap tab 2 Release the snap tabs
199. ome people have noticed that there seem to be only 7 distinct bands Maybe one of the bands is 0 fill Things to look for Within a bar any ringing that indicates the laser is not capable of making a solid bar of the same halftone 7700 294 Phaser 7700 Color Laser Printer Service Manual 9 293 9 294 Phaser 7700 Color Laser Printer Service Manual S6c 01 enue 32114985 JAJUL JASE 10 09 0022 1 S2Yd GOv 00ZZS Aejay Ob J8M0d C1 SAUG OV 069d 90td OL MS ul DV 149 49H JOAOD H H asion erd MS SJ OH youms abueyn JaMOd 4 A0D HA selg OL ms v 400q U014 MS Joo s puueg SdAH S Lead SEM elr EL Seier n A Wno EE el lea ord e La TE er sJejjoy 1 Tr I E 29d W wna OAM selg SdAT SdAT SdAT 8 HC Jedojeneg GST JOJO oL 08Sd yorjeq Ave AG AEE saline S TON am WW 89g 06Sd OL ov Sir a EI p LL base EN Hd oa AN ZCHd y UDO 9 Jang o seig puz e gl ej Zk GR 1040y 1409 15 a AH a 8 mes 008d 9ESd OL gt yoejeq EE 809d z 4 0H 1 SULIL DE Hd vieL SIS eeer R J SN4 OL to 4 a EI SdAH E J
200. on To avoid damaging the Accumulator Belt it is recommended that you leave the belt installed and perform the Belt Edge Learn test instead Step 1 Belt Edge Learn on page 4 134 Bypass the right hand door interlock switch and observe the steering motor as the test is performed Print Cartridge To avoid damaging the Caution Only run this test Motor Accumulator Belt remove Fl oe power cycle i i o avoid excessive Do you wish to continue toner forced inside the Yes developer and No destroying it Motor On Motor Off Please cycle power to printer now Accum Belt To avoid damaging the Caution To avoid damaging the Motor Accumulator Belt remove Sel Belt it is recommended that you Do you wish to continue leave the belt installed Yes and perform the Belt No Edge Learn test Motor On instead Step 1 Belt Motor Off Edge Learn on page 4 134 Please cycle power to printer now 2nd BTR 2nd BTR Motor is Retract Note This test needs to be Motor run twice to return the This test toggles between the two values of Retract and Contact Motor Off motor to a retracted position Duplex Motor Duplex motor is On Turn Motor On Low Speed Turn Motor On High Speed All Motors Off Press Up Down to change setting Paper Feed Feed Motor 1 Running this test causes a static jam Motors 2 Clear paper path after running this 3 test 4 Paper Lift Lift Motor 1 Press Up Down to change setting Motors 2 3 4
201. on Initialization Note Cyan is the reference color to which all other colors are aligned 4 124 Phaser 7700 Color Laser Printer Service Manual Coarse and Fine Skew Adjustments Skew error is the mislevel of one or more of the four scan lines C M Y amp K During the RegiCon 4 Coarse and RegiCon 1 Fine adjustments the left side of each line is adjusted to be level with the right end Figure 2 Skew Adjustment ame eg 57700 461 Figure 4 2 Coarse and Fine Skew Adjustments In Out Skew Adjustment The In Out Skew Adjustment Magnification ensures that all four scan lines are the same length During RegiCon 2 the printer measures then adjusts the four scan lines to the proper length Figure 3 Magnification gt l 57700 462 Figure 4 3 In Out Skew Adjustment Phaser 7700 Color Laser Printer Service Manual 4 125 Center Skew Adjustment The Center Skew Adjustment Magnification Balance adjusts the linearity of the scan lines During RegiCon 8 the printer measures a specific midpoint of each scan line and adjusts it to a horizontal reference midpoint Figure 4 Magnification Balance 57700 463 Figure 4 4 Center Skew Adjustment 4 126 Phaser 7700 Color Laser Printer Service Manual Processes of the RegiCon Adjustment RegiCon is an engine resident algorithm that aligns the Magenta Yellow and Black lasers to the Cyan laser Normally the RegiCon pro
202. ontinue Yes No Motor On Motor Off Please cycle power to the printer now Caution To avoid damaging the Accumulator Belt it is recommended that you leave the belt installed and perform the Belt Edge Learn test instead Step 1 Belt Edge Learn on page 4 134 Clean Tray 1 Rollers Clean Tray 2 Rollers Clean Tray 3 Rollers Clean Tray 4 Rollers Clean MPT Tray Rollers 2 44 Phaser 7700 Color Laser Printer Service Manual Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition NVRAM Access You can read or reset selected NVRAM address locations For all NVRAM access tests Service Diagnostics NVRAM Resets on page 6 149 PostScript NVRAM Reset Refer to Service Diagnostics NVRAM Resets on page 6 149 Clear Tech Rep Faults Clear lt 4 346 gt Clear lt 9 380 9 383 gt Clear lt 9 654 gt Clear lt 9 910 913 gt Clear lt 10 348 amp 10 350 gt Error Code 30 Error Codes 12 13 14 amp 15 Engineering Use Only Engineering Use Only Error Codes 40 and 44 CRU Life Counters Engineering Use Only Reset Engine NVRAM Writes data to Eng NVM from Hard Drive Are you sure Yes No Refer to Reset Engine NVRAM on page 6 150 Store Engine Writes data to Hard Drive from Refer to Store Engine NVRAM NVRAM Eng NVM on page 6 150 Are you sure Yes No
203. or Assembly FRUs 7700 306 Figure 11 37 Stacker Elevator Assembly FRUs Phaser 7700 Color Laser Printer Service Manual 11 366 Table 11 13 Stacker Elevator Assembly FRUs List No Part Number Qty Description 1 116 1287 00 1 Stacker Motor Assembly 2 116 1276 00 1 Bracket Assembly Belt 3 Clamp 4 Bearing 5 116 1274 00 1 Gear Rear 6 Actuator 7 116 1275 00 1 Gear Front 8 Stacker Tray Bracket Assembly 9 116 1273 00 1 Rack 10 Tray Guide 11 116 1270 00 1 Stack Paper Assembly Item 12 16 12 116 1253 00 1 Stack Paper Sensor 13 Actuator 14 Bracket 15 Spring 16 Cover 17 Bracket 18 116 1253 00 Upper Limit Stack A Stack B Sensor 19 Bracket 20 Pin 21 Bearing 22 Shaft Phaser 7700 Color Laser Printer Service Manual 11 367 Exit Assembly FRUs 7700 307 Figure 11 38 Exit Assembly FRUs 11 368 Phaser 7700 Color Laser Printer Service Manual Table 11 14 Exit Assembly FRUs List 2 Oo Part Number Qty Description Gear 482 Bearing 116 1243 00 Exit Shaft Collar Gear 322 18T Bearing 116 1304 00 Paddle Gear Shaft REP 17 12 1 CO Ji o ol A Gol M i Paddle Bearing o Lower Exit Chute CH 116 1302 00 Pinch Roll Exit 1 k Pinch
204. ore and runs a DIAGNOSE command on the hard drive Note If the fault code indicates 12 you must check the front panel to see if the test name is CPU Interrupts or IDE Disk before beginning troubleshooting 2 34 Phaser 7700 Color Laser Printer Service Manual Service Diagnostics Service diagnostics are to be executed by the service technician through the front panel The DIP switches should be set to Service Mode while performing functions of the Service Diagnostics menu Entering Service Diagnostics Mode 1 To enter Diagnostics mode the printer must be turned Off 2 Hold down the Back and Information keys simultaneously and turn the printer back on Continue to hold the keys until the following message is displayed on the front panel Service Diagnostics V3 60 Initializing and then release Next the front panel displays the Service Diagnostics Menu gt ww You can print a service Diagnostics menu map by highlighting Print Service Menu Map using the arrow key and pressing OK Dip Switches Four DIP switches allow you to reset the printer or place the printer in different operating modes You must set the switches before the printer is switched On to enter the selected mode Note When performing the Registration Control Procedures Processes of the RegiCon Adjustment on page 4 127 you must set the switches to Service Mode refer to Rear Panel on page 1 23 This avoids a problem with Re
205. ore than 240 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector Refer to a qualified service technician for changes to the cord or connector WARNING If the product loses the ground connection usage of controls and other conductive parts can cause an electrical shock Power Supply and Electrical Components Before starting any service procedure switch off the printer power and unplug the power cord from the wall outlet If you must service the printer with power applied be aware of the potential for electrical shock Do not touch any electrical component unless you are instructed to do so by a service procedure Mechanical Components Manually rotate drive assemblies to inspect and gears Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running iv Phaser 7700 Color Printer Service Manual Laser Components WARNING This printer generates a laser beam as part of the printing process The laser beam in this printer is invisible Direct eye exposure to the laser beam may cause eye injury or blindness To avoid permanent eye damage follow these directions a Before starting any service procedure switch off the printer power and unplug the power cord from the AC wall outlet Do not disassemble the Laser Scanner Assembly a Use caution when you are working around the Laser Scanner Assembly or
206. orizontal Transport Assembly 11 324 Figure 11 9 H Transport Top Open Front and Rear Covers mmmeeeeeesveeverns 11 325 Figure 11 10 Horizontal Transport Entrance Upper Cover cccccccseeceeeees 11 326 Figure 11 11 Horizontal Transport Belts soseseersnrvrrverrrverrrvrrrrversrnrrnrsrrnenenne 11 327 Figure 11 12 H Tra Entrance and Top Tray Full Sensor ereeesversvonrrrvovenrsvrnrn 11 328 Figure 11 13 H Transport Gate In Solenoid reeorovorerrrvovoreresvovsvenerervsnevesrrne 11 329 Figure 11 14 Finisher GOVersi nn eeg uer Eeer ee 11 330 Figure 11 15 Stack Height Sensor Assembly c ceecccesscstseseteetseesecseeeceeseees 11 332 Figure 11 16 Stacker Paper Sensor Assembly c ccsececcesesesesetececscseeecetsesesenes 11 333 Figure 11 17 Set Clamp Clutch and Gear 11 334 Figure 11 18 Eject Roeien a al 11 335 Figure 11 19 Finisher Control Board Bracket and Shield 11 336 Figure 11 20 Stacker Motor Assembly cccceceseeececeseeeeeeeseseeeeteneeseseeeeteeees 11 338 Figure 11 21 Paddle Shatt eerst au 11 339 Figure 11 22 Paper Transport Motor serores siie en han nais 11 340 Figure 11 23 Cam Bracket Assembly srsrararrsnorsvonrvrnrovererrsnsverevesrsrsveversnrsvener 11 341 Figure 11 24 Staple Unit Assembly ou ccescsesceseecscsesecetscsesececesseeesesesesenes 11 342 Figure 11 25 Compiler Dray assistanse 11 344 Figure 11 26 Finisher Unit Main Assemblies FRUS n se 11 345 Figure 11 27 Fi
207. per and envelopes can be fed The printer also supports manual feeding using the Multi Purpose Tray The Lower Tray Assembly is available with three additional 500 sheet universal media trays A High Capacity Feeder is also available which features two high capacity A A4 size trays and one 500 sheet universal tray An optional 1000 sheet high capacity stapler stacker is available with the Lower Tray Deck or High Capacity Feeder The printer is marketed in three versions m The Phaser 7700 DN Printer comes standard with 128 Mbytes of RAM m The Phaser 7700 GX Printer features 256 MB of RAM a three tray Lower Tray Deck and PhaserMatch 7700 ICC Color Matching Software m The Phaser 7700 DX Printer features 256 MB of RAM a High Capacity Feeder and Finisher RAM memory in the printers can be supplemented with one additional 64 128 or 256 Mbyte RAM SODIMMs the maximum usable capacity is 512 MB in the printers two memory slots After being idle for the selected amount of time the printer switches into its ENERGY STAR mode where it consumes less than 45 watts of power It awakens upon receiving data at any of its ports 1 2 Phaser 7700 Color Laser Printer Service Manual Proof Jobs A proof job is a specific case of a multiple copy job With a proof job the customer assigns a password and copy account at the client workstation before printing The first set of prints are printed immediately The original number of requested se
208. per Menu 3041 53 Note Verify the settings be sure the setting is not at 4 value before running Calibrate for Paper The MPT must be have the right setting to run calibrate for paper 3 118 Phaser 7700 Color Laser Printer Service Manual Image Mis registered on Paper The image area is not centered on the page or the image is bleeding off of the page The printer displays no error code 1 Run the configuration or Startup Page to verify the hard drive application and driver settings From the front panel s Printable Pages Menu select Print Configuration Pages or Print Startup Page Is the correct weight paper loaded in the tray or multi purpose tray Ensure that the paper guides are set to the correct position for the paper loaded in the tray Try printing from the other trays If the problem only occurs from one tray clean the rollers in that tray Run the Calibrate for Margins 3041 54 routine From the front panel s Support Menu select Improve Print Quality then select Calibrate Margins Menu Phaser 7700 Color Laser Printer Service Manual 3 119 Residual Image or Ghosting There are faint ghostly images appearing on the page The images may be either from a previous page or from the page currently being printed The printer displays no error code 1 Make sure that the paper you are using is the correct type for the printer and is correctly loaded in the
209. pper Rear then the lower screws Note When reinstalling the RH Lift Jack Assembly ensure that the Jack racks protrude evenly before returning the Main Lift Lever to its upright position 7 222 Phaser 7700 Color Laser Printer Service Manual Aligning Lift Jack Assembly Gears Visually examine both ends of the Accumulator Belt Assembly or Belt Lift Frame Assembly while operating the Lift Handle to determine if the left or right end is out of alignment Then follow the applicable procedure in Main Lever Assembly Right and Left Hand Jacks on page 7 221 to remove the affected Lift Jack Assembly Once the assembly is removed check the alignment of the Lift Pins as shown in Figure xyz The center of both Pins should be the same distance from the bottom of the assembly E s7700 561 Figure 7 62 Lift Pin Alignment If the Lift Pins are misaligned follow this procedure to realign the individual Gears with the Rack 1 Remove the 8 cover screws from the Lift Jack Assembly s7700 562 Figure 7 63 Cover Screw Location Phaser 7700 Color Laser Printer Service Manual 7 223 2 Flip open the Cover Plate 57700 563 Figure 7 64 Cover Removed 3 Remove the tension spring
210. pplies FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1146 00 1 High Voltage Power Supply T1 PSHVT1 1 T1 Control Board 2 116 1147 00 1 High Voltage Power Supply T2 PSHVT2 3 116 1148 00 1 High Voltage Power Supply T3 PSHVT3 4 116 1149 00 1 Low Voltage Power Supply 3V 110V PSLV LF308 5 116 1150 00 1 Low Voltage Power Supply 3V 220V PSLV LF308 6 116 1151 00 1 Low Voltage Power Supply 5 VDC 110V PSLV LF506Q 7 116 1152 00 1 Low Voltage Power Supply 5 VDC 220V PSLV LF506Q 8 116 1153 00 1 Low Voltage Power Supply 24 VDC 110V PSLV OP2C 9 116 1154 00 1 Low Voltage Power Supply 24 VDC 220V PSLV OPR2C 10 116 1320 00 1 LD Power Relay 11 116 1143 00 1 Engine Control Interface Board Assembly PWB IF MCU 8 252 Phaser 7700 Color Laser Printer Service Manual PL 8 12 Power Supplies FRUs cont d 2 g ge e gt gt Noise filer bd 7700 054 Figure 8 12 Power Supplies FRUs cont d Phaser 7700 Color Laser Printer Service Manual 8 253 Table 8 12 Power Supplies FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1155 00 Chassis Assembly AC Power 110V Bracket AC Drive Board Clamp Noise filter GFI Breaker Wire harness Wire harness Wire harness Wire harness Screw Wire Harness 2 116 1156 00 Chassis assembly AC Power 2
211. pressing OK on page 2 35 Refer to Troubleshooting the Low voltage Power Supplies on page 89 Replace the Front Panel Cable RRP 4 on page 7 157 Replace the Front Panel RRP 4 on page 7 157 Replace the Internal Hard Drive RRP 40 on page 7 203 Replace the Image Processor Board RRP 39 on page 7 202 Fans On Front Panel LED is Red No Front Panel message Replace the Front Panel Cable RRP 4 on page 7 157 Replace the Front Panel RRP 4 on page 7 157 Replace the Internal Hard Drive RRP 40 on page 7 203 Replace the Image Processor Board RRP 39 on page 7 202 Front Panel Continually Displays the Xerox Phaser 7700 Splash Screen Enter Service Diagnostics Mode Refer to Entering Service Diagnostics Mode on page 2 35 Watch the Front Panel during the initializing period for messages indicating any printer faults View the Fault List for indications of any printer faults Replace the Engine Control Board RRP 42 on page 7 206 Replace the Engine Control Interface Board RRP 43 on page 7 207 Replace the Hard Disk RRP 40 on page 7 203 Replace the Image Processor Board RRP 39 on page 7 202 Front Panel Continually Displays WARMING UP PLEASE WAIT Message See the procedure for Error 86 High voltage Power Supply Failure on page 2 70 Phaser 7700 Color Laser Printer Service Manual 3 93 Front Panel displays Fatal Fault Encountered message See procedure for Error 81 Controller to Engin
212. printer From the front panel s Printable Pages Menu select Print Paper Tips Page 2 Make sure that the paper loaded in the tray matches the paper type selected on the printer s front panel 3 If the problem continues set the paper type in the front panel to the next heaviest type of paper than what you are using Below is 3041 49 a list of paper types from the heaviest weight to the lightest Thick Cover Index Thin Cover Index Heavy Laser Paper Laser Paper 4 If the colors are offset by only a small amount 10 mm maximum then calibration of the laser may be needed This is mis registration not ghosting Go to Mis registration on page 3 119 5 If the ghost is offset by more than 84 mm run the Print Smears routine to clean the fuser From the front panel s Support Menu select Improve Print Quality then select Remove Print Smears 6 Inspect and replace the Fuser if necessary RRP 19 on page 7 174 Note Some ghosting may appear on transparency film printing and is a limitation of the printer 3 120 Phaser 7700 Color Laser Printer Service Manual Light Bands Dark Bands or Mottled Prints An image void dark bank or mottle in a primary CMYK color or a visible area on the Developer Roller where toner is missing Cause Narrow image voids or a dark band in the process direction can be caused by contamination in the Developer Assembly These contaminants have been attributed to vendor manufacturing process
213. ptible to ESD damage Observe proper ESD procedures Disconnect all communication cables Remove the four screws and remove the image processor board Remove the Internal Hard Drive RRP 40 on page 7 203 Remove the socketed NVRAM chip located near the parallel port connector from the board just removed and use it to replace the one on the new board to preserve the customer s network and setup values RON ch Note Remove the image processor top cover and the metal plate to inspect that the image processor board is fully seated when reinstalling 7 202 Phaser 7700 Color Laser Printer Service Manual RRP 40 Internal Hard Drive Fig 1 57700 434 Figure 7 46 Internal Hard Drive Caution The Internal Hard Drive is susceptible to ESD damage Observe proper ESD procedures 1 Remove the Image Processor Board See RRP 39 on page 7 202 2 Using a T 10 torx bit remove four screws on the bottom side of the Image Processor Board holding the Internal Hard Drive 3 Slide the Internal Hard Drive away from the connector Note It is possible to mis align the pins when seating the new Internal Hard Drive Caution If you replace the Internal Hard Drive you must enter Service Diagnostics Mode and run the Store NVRAM test Phaser 7700 Color Laser Printer Service Manual 7 203 RRP 41 Electrical Chassis Card Cage Assembly 7700 205 Figure 7 47 Electrical Chassis Assembly Removal
214. r 7 158 Left Hand Lower Cover Assembly rernvrnnvrnvrvorerrsveverenrsvensvenerrsverenenene 7 160 Front Cover Assembly sssini oasen a ai a 7 161 Fuser Front COVED EE 7 162 R ar Shell eer eegent de Eeer 7 163 Rear Shield Bracket cccccscsescsssscscscsececscsesecssscsescsesecessesesecessesesesaeass 7 164 24 VDC Power Supply Shield ererorerovrrrorrvorrrrsvorereresvsveneveserrsvererennne 7 165 Multi Purpose Tray MPT Assembly errnrnrrnrnrrnrnrrnrnrrnrrsrnrrsrnrrsrnrrnene 7 166 Multi Purpose Tray Paper Pick Rollers 7 167 Left Hand Cover Assembly Left Hand Door seseeeeeeeeeteeeee 7 168 WIEL 7 170 Duplex Unit ASSembly nrrsnsvrsrsvrsrnvrrerrsvenrrrnrsrenrsrenrsrenssrenrsrrsesenennnne 7 171 Transfer Roller Assembly 2nd BIR 7 172 Duplex Transport ASSembly ou eceesesseseeeesscececeesececseceeesseeessesaeeeaees 7 173 FUSer UNN usteet tele Eeer une uken 7 174 Registration Transport Assembly ccceccececeeeeceececsseeceeecseeecsesaeesaees 7 175 Shutter Solenoid Assembly smovennvrnrnvorerrrvsversvenevrnvoverevreneneserrsvenerennne 7 176 Tray 1 Feeder Assembly and Paper Lift Motor ssssssssssesensnsnrneseneeenen 7 177 Waste Cartridge Sensor Holder c ccceseccscscsesecseseesesecsescsesecesseseseens 7 178 Print Cartridge Plate Cover c ccscccsecccscsesecetscsescsesecesscsesecessesssenaeass 7 179 DISPENSE ASSEMDNY uensennes ermene 7 180 Print Cartridge Plate As
215. r Motor Assembly c cccccccescccscseecscseseseesscecseseeecessesesetasseseees 11 338 Paddle Shaft sonene bet egeege deeg deeg ee et 11 339 Paper Transport Motor Motor Assembly Main rorrnvrnrnvrrrnvrrrnrrnrnnr 11 340 Cam Bracket Assembly n ssarronsnsrovorrvrsvorerevrsvovarenesenrsvonavenssnererenssrsnen 11 341 Staple Unit Assembly and Motor eeerensversnsvsvorerrsvsveveresvsvsvenerenvsvener 11 342 Compiler May vuvssuamusinesssmasostnersatagsresetaenanet 11 344 Finisher FRU Parts List 11 345 Finisher Wiring Diagrams 12 371 Phaser 7700 Color Laser Printer Service Manual XIX XX Phaser 7700 Color Laser Printer Service Manual List of Tables Table TT CRC LIG Linns fiende hasene 1 5 Table 1 2 Front Panel Key Descriptions sosvevorvrrrrvrrrrvrrrsvernrvrrnernrnersrnernrnersnnn 1 21 Table 1 3 Front Panel Ghortcuts 1 22 Table 1 4 Rear Panel DIP Switch Gettinges 1 23 Table 1 5 Physical Dimensions of the Printer oorerrerrorerrorverrenresvernenrernrnnnrnren 1 24 Table 1 6 Physical Dimensions of Lower Tray Feeder 1 24 Table 1 7 Functional Gpnechflcatons 1 25 Table 1 8 Electrical Gpechtlcations 1 25 Table 1 9 Environmental Specifications ccccccescscsscccscsescstscsescesscecscseeeceeaees 1 26 Table 1 10 Specialty EE 1 28 Table 1 11 Paint E E E E if 1 28 Table 2 1 POST Diagnostics Test Descriptions ssarovrsvorovrnrvrsvorererrsrsverenervernnr 2 34 Table 2 2 Service Diagnostics Test Menu Funct
216. r Service Manual 11 361 Staple Unit Assembly FRUs 7700 304 Figure 11 35 Staple Unit Assembly FRUs 11 362 Phaser 7700 Color Laser Printer Service Manual Table 11 11 Staple Unit Assembly FRUs List 2 Oo Part Number Qty Description 116 1255 00 1 Carriage Assembly Item 2 6 Bracket Assembly 116 1256 00 Motor Assembly Stepping Gear Staple Remover Roll 116 1259 00 Staple Front Corner Sensor COIN o ol A wo N Plate 9 116 1254 00 Rail REP 17 9 1 10 116 1257 00 Staple Assembly Item 11 12 REP 17 9 2 Staple Cartridge Bracket Phaser 7700 Color Laser Printer Service Manual 11 363 Compiler Tray Assembly FRUs 7700 305 Figure 11 36 Compiler Tray Assembly FRUs Phaser 7700 Color Laser Printer Service Manual 11 364 Table 11 12 Compiler Tray Assembly FRUs List No Part Number Qty Description 1 116 1251 00 1 Compiler Tray Assembly Item 2 15 2 116 1252 00 1 Motor Assembly Tamper 3 Plate 4 116 1253 00 1 Front Rear Tamper Home Sensor 5 Rack 6 Actuator 7 Tamper Assembly 8 Finger 9 Spring 10 116 1234 00 1 Compiler Paper Sensor 11 Actuator 12 Paper Guide 13 116 1269 00 1 Spring 14 Wire Harness 15 End Guide Phaser 7700 Color Laser Printer Service Manual 11 365 Stacker Elevat
217. r Service Manual PL 8 8 Switch and Sensor FRUs K N see D a 57700 407 Figure 8 8 Switch and Sensor FRUs Phaser 7700 Color Laser Printer Service Manual 8 245 Table 8 8 Switch and Sensor FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1299 00 1 Waste Cartridge Full Sensor part of Sensor Kit 2 116 1124 00 1 Mark On Belt MOB Sensor Assembly 3 116 1299 00 1 Automatic Toner Cal ATC Sensor Assembly part of Sensor Kit 4 116 1126 00 1 Paper Select Switch Assembly Switch Assembly PS Tray 110K12990 2 3 Paper Size Switch also 4 5 on LTA Phaser 7760 compatible 5 116 1299 00 1 Transport Exit Sensor Assembly part of Sensor Kit 6 116 1299 00 1 Belt Edge A Sensor Assembly part of Sensor Kit 7 116 1138 00 1 Waste Cartridge Sensor Holder Holder Assembly Sensor 1 Lever 1 Waste Cartridge Interlock Switch 1 Holder 8 116 1545 00 1 Sensor Left Door Open 9 116 1545 00 1 Sensor Right Door Open 8 246 Phaser 7700 Color Laser Printer Service Manual PL 8 9 Switch and Sensor FRUs cont d 2 87700 415 Figure 8 9 Switch and Sensor FRUs cont d Phaser 7700 Color Laser Printer Service Manual 8 247 Table 8 9 Switch and Sensor FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1210 00 1 Paper Detect Flag MPT part of Sensor Flag
218. r cover and 24 VDC PS metal shield Connect AC Power and turn the printer On Check for proper AC Voltage at the connector at the bottom of the LVPS If not present go to the Troubleshooting AC Power section Check for the 5 VDC enable signal at P505 4 grey wire If not check the same signal at the Engine Interface Board P537 6 If not present replace the Engine Control Board RRP 42 on page 7 206 then the Engine Interface Board RRP 43 on page 7 207 5 Check for 24 VDC at any of the orange wires of connector P502 at the top of the LVPS Unplug the connector and retest If still no voltage replace the LVPS link If the voltage returns check the 24 VDC circuit for shorts to frame ground in the wiring harness Engine Board Relay Board and Interlock Circuit Ja on 3 90 Phaser 7700 Color Laser Printer Service Manual Interlock Circuit Diagram PRINT CARTRIDGE CRUM CONNECTORS GRY 1 ES Verse EE J631 GRY m 5V INTERFACE LVPS SE WASTE CARTRIDGE BOARD INTLK SW o gt gt GRY 24V LVPS GRY LETRE E gt gt ID POWER RELAY p H g GRY 7 POE 5 GRY T d SS I ORN s ORN al ORN liy ORN FRONT COVER INTLK SW R H COVER INTLK SW LH COVER INTLK SW 87700 432 Figure 3 1 Circuit Diagram The 24 VDC Interlock Circuit The 24
219. racket N Assembly Gear LH HCF Ki Bracket Assembly Gear RH HCF 57700 421 Figure 7 75 Bracket Assembly Gear RH amp Gear LH HCF Removal 1 Remove the Rear Cover RRP 1 on page 7 154 2 Remove the two screws securing the Bracket Assembly Gear RH or Gear LH to the frame 3 Remove the Bracket Assembly Replacement Note There are locating pins for each Bracket Phaser 7700 Color Laser Printer Service Manual 7 233 7 234 Phaser 7700 Color Laser Printer Service Manual FRU Parts List This topic provides a list of Field Replaceable Units FRUs for the Phaser 7700 Color Laser Printer Changes to Xerox products are made to accommodate improved components as they become available It is important when ordering parts to include the following information m Component s part number m Product type or model number m Serial number of the printer Serial Numbering Particular fields in the serial number indicate the modification level of the printer the date of its manufacture and the sequence number of the printer produced on that day The serial number is coded as follows JLxxDMY J indicates the headquarter country of the manufacturing company Japan L indicates the modification level of the printer ranging alpha numerically from Oto Z Xx alpha numerically indicates the sequence of the printer among the printers produce on that day of manufacture ranging from 01 to ZZ representing 1 to 1155 the
220. rations NOW and press OK to reset the color margins and paper transfer settings to factory defaults Resetting All Printer Default Settings NVRAM Resetting the NVRAM resets all printer values including network printer setup job defaults color margin and paper calibrations Za GA Mich From the Main Menu highlight Support and press OK Highlight Service Tools Menu and press OK Reset NVRAM is displayed press OK Highlight Reset NVRAM and Reset Printer NOW and press OK to reset all the settings to default Resetting Engine NVRAM Resetting restoring the engine NVRAM values resets the RegiCon color margin and A4 B5 selection paper settings to default This is NOT the diagnostics reset To restore data stored on the hard drive to NVRAM see Reset Engine NVRAM on page 6 150 RON ch 1 From the Main Menu highlight Support and press OK 2 Highlight Service Tools Menu and press OK 3 Reset NVRAM is displayed 4 Highlight Reset Engine NVRAM NOW and press OK 6 146 Phaser 7700 Color Laser Printer Service Manual Resetting Job Defaults Resetting the job defaults resets the paper source paper destination job offset stapling options print quality mode 2 sided printing image smoothing and tekcolor corrections to their default values 1 From the Main Menu highlight Print Setup Menu and press OK 2 Highlight Job Defaults Menu and press OK 3 Reset Job Defaults is displayed press OK 4 Highl
221. refer to the Federal Communications Commission s booklet How to Identify and Resolve Radio TV Interference Problems This booklet is available from the U S Government Printing Office Washington D C 20402 Stock No 004 000 00345 4 viii Phaser 7700 Color Printer Service Manual Canadian Notice This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as described in the radio interference regulations of the Canadian Department of Communications Note Installation of the Finisher and or the Token Ring Interface results in a classification change to Class A Avis Canadien Cet appareil numerique est conforme aux limites mission de bruits radio lectriques pour les appareils de classe B stipul s das le r glement sur le brouillage radio letrique du Minist re des Communcations du Canada European Notice This equipment was tested and is determined to be compliant with VDE requirements for a Class B device Hinweis Hiermit wird bescheinigt dass der Babe Laserdrucker in bereinstimmung mit den Betimmunngen der Vfg 104B 984 funkenst rt ist Der Deutschen Bundespost wurde das Inverkehrbringen dieses Gert es anggeigt und die Berechtigung zur berprufung der Serie auf Einhaltung der Bestimmungen eingeraumt Phaser 7700 Color Printer Service Manual ix ESD Precautions Some semiconductor devices are easily damaged from static electricity These components are Electrostat
222. rents Power Source This product is intended to operate from a power source that does not apply more than 127 or 240 volts AC RMS depending on printer model between the supply conductors or between either supply conductor and ground A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation Class 1 Laser Product The Phaser 7700 Color Printer is certified to comply with Laser Product Performance Standards set by the U S Department of Health and Human Services as a Class 1 Laser Product This means that this is a class of laser product that does not emit hazardous laser radiation this is possible only because the laser beam is totally enclosed during all modes of customer operation The laser and output of the laser scanner unit produces a beam that if looked into could cause eye damage Service procedures must be followed exactly as written without change When servicing the machine or laser module follow the procedures specified in the manual to avoid any hazards from the laser Laser FDA Any laser label visible to service must be reproduced in the service manual with location shown or indicated Safe working procedures and clear warnings concerning precautions to avoid possible exposure must also be included Phaser 7700 Color Printer Service Manual vii Federal Communication Commision Compliance This equipment has been tested and found to comply with the limits se
223. rervsvereveserrsvenene 7 220 Figure 7 61 Main Lever Right Hand and Left Hand Jacks msesnerrsnrrrsverrrversrnr 7 221 Figure 7 62 Lift Pin Alignment oiana i a A EE 7 223 Figure 7 63 Cover Screw Location cccccccscssscsescsssscscscsesececsesseecesseseeesecsesesees 7 223 Figure 7 64 Cover Removed ccccsscccscsscsssecssscsscscssessscsssesssssssscsssseecacsseesecares 7 224 Figure 7 65 Tension Spring Location ou cesesescsseseseecetsesescsssecessesesesecsenaeees 7 224 Figure 7 66 Front and Rear Gears Aligned eeseerensvoreresvsvsvorerrnrsvereresesversvesesvnne 7 224 Figure 7 67 Auxiliary Feeder GOVers c ccccccssscsescssssesesecessesescseecessesecesecsesesees 7 225 Figure 7 68 High Capacity Feeder HCF Cover Assembly nsovarrvrrrororenrsversn 7 226 Figure 7 69 High Capacity Feeder HCF Tray 3 7 227 Figure 7 70 High Capacity Feeder HCF Tray 4 and Paper Transpor 7 228 Figure 7 71 LTD Control or HCF Control Board seaveverevrrvorerrrrsvererrrvsversvenvrrnne 7 229 Figure 7 72 Transport Motor ASSEM Biyo eissira pns 7 230 Figure 7 73 Paper Select Switches ccccccsescsssecscscsesecesscsescsscecessesecesecseeenees 7 231 Figure 7 74 Paper Feed Motor Assembly and Chute LTA amp HCF eee 7 232 Figure 7 75 Bracket Assembly Gear RH amp Gear LH HCF eeeeeeeeeeeeeeeeee 7 233 Figure 8 1 Accumulator Belt FRUS 8 236 Figure 8 2 Left Hand Door FRUS rssrsnsvor
224. riage drop down in the frame then slide straight out the stapler cavity On OO P GO M ch on 11 344 Phaser 7700 Color Laser Printer Service Manual Finisher FRU Parts List Finisher Unit Main Assemblies FRUs 1 PL17 2 4 1 2Pcs 5 PL17 14 57700 369 Figure 11 26 Finisher Unit Main Assemblies FRUs Phaser 7700 Color Laser Printer Service Manual 11 345 Table 11 2 Finisher Unit Main Assemblies FRUs List No Part Number Qty Description 1 116 1292 00 1 Gate Unit 2 116 1280 01 1 H Transport Assembly 3 Staple Finisher 4 Screw 5 Rack Assembly 6 116 1244 00 1 Right Cover 7 116 1278 00 1 Stacker Tray 8 116 1279 00 1 Thumb Screw 9 Bracket 11 346 Phaser 7700 Color Laser Printer Service Manual Finisher Covers FRUs 7700 300 Figure 11 27 Finisher Covers FRUs Table 11 3 Finisher Covers FRUs List Description y t Q Part Number 116 1238 00 116 1239 00 116 1236 00 116 1237 00 116 1245 00 No 7 2 Front Cover Rear Cover Top Cover i 3 i i 3 4 5 Left Cover Front Door Left Panel Hinge Magnet 11 347 Phaser 7700 Color Laser Printer Service Manual Finisher Stand FRUs N wee zm em e zm e pm meme meme mem meme eee eee 2 e 3 E R E Ei Figure 11 28 Finisher Stand FRUs Phaser 7700 Color Laser Prin
225. ring the front cover and remove Remove two screws from the Left Cover and lift up and out to remove Loosen the four screws securing the Top Cover Remove the left portion of the top cover assembly Open the top door and remove the front and back screws 10 Pop off both straps tilt the cover up and remove OONDOARPWON Note When installing the rear cover be sure that the two cables exiting the rear cover are properly aligned around the plastic tab in the exit way If not the cables fall to the bottom of the exit way and the cable to the horizontal transport cannot reach the cable connector on the transport Phaser 7700 Color Laser Printer Service Manual 11 331 RRP 73 Stack Height Sensor Assembly Sensor Flag 87700 328 Connector Figure 11 15 Stack Height Sensor Assembly Removal 1 Remove the Horizontal Transport Assembly RRP 66 on page 11 324 2 Remove the Top Cover RRP 72 on page 11 330 3 Remove one screw from the Stack Height Sensor bracket 4 Press down on the two locking tabs located at the top of the sensor press up on the two locking tabs at the bottom of the sensor and remove the sensor 11 332 Phaser 7700 Color Laser Printer Service Manual RRP 74 Stacker Paper Sensor Assembly 7700 329 7700 374 Figure 11 16 Stacker Paper Sensor Assembly Removal 1 2 Loosen the thumb screw and remove the Stacker Tray Remove the four screws securing the Stacker Paper Sensor Asse
226. rinter On Do the results indicate the test passed Scroll down using the Down arrow button to view the results and perform skew correction adjustments as indicated until less 5 clicks are required for each color then go to step 5 Go to step 8 Phaser 7700 Color Laser Printer Service Manual 4 131 Table 1 RegiCon Procedure cont d Step Actions and Questions Yes No 5 Perform the RegiCon 3 Center Skew Verify the MOB Adjustment procedure page 4 139 To Sensor is view the results you must re enter Service correctly Diagnostics by turning Off the printer positioned in the pressing the Back and Info buttons center then simultaneously and switching the printer repeat the test on If the Sensor was Do the results indicate the test passed centered Note Be sure to move the MOB Sensor to diagnose ang it t ition bef i a this test repair the MOB its center position before running this test Sensor 6 Print the Grid 1 Dot print from Diagnostics Complete follow Go to step 7 Do all the colors align the Store Engine NVRAM procedure page 6 150 Reconnect all cables and turn Netware back on before call completion 7 Do the Print Halftone test prints exhibit any Correct the Complete print quality defects print quality defect and return to step 3 8 Perform the RegiCon 4 Coarse Skew Perform the skew Perform the Adjustment procedure page 4 135 correction Coarse RegiCon ven adjustm
227. roperly connected to the printer From the Front Panel check to see if the Finisher is recognized by the printer Remove the Rear Cover and Board Cover from the Finisher Check for presence of 24 VDC between the Finisher Board P844 2 and Finisher frame ground Turn the power Off and check the continuity of the serial data link circuit by verifying continuity between P531B 9 through 16 on the Engine Control Board and P843 1 through 8 on the Finisher Board Replace the Finisher Board RRP 77 on page 11 336 Replace the Engine Control Board RRP 42 on page 7 206 N oa RA NOD 3 96 Phaser 7700 Color Laser Printer Service Manual Troubleshooting the Toner Dispense Auger Developer System Failures relating to Toner Dispense Toner Auger and Developer System include m False Replace Toner Cartridge message m ATC Sensor errors 12 13 14 and 15 m Faded or missing primary colors Checking the Toner Cartridge 1 Ensure the Toner Cartridge is correctly installed and rotated into its opened position 2 Remove the Toner Cartridge in question 3 4 5 Inspect the cartridge s cap to ensure it is securely taped in placed Tilt the cartridge back and forth to ensure it contains toner Rotate the Gear at the rear of the cartridge You should hear the Auger Coil move inside the Toner Cartridge If the Auger Coil and Gear rotate correctly the cartridge is good Toner Cartridge Gear s7700 5
228. rrvrnrrvenrrvennrrensrrensrnennenn 7 202 Figure 7 46 Internal Hard Drive 0 0 0 ccccssssesscsesececsecessececsececaeeeseeceseecesaeeesaees 7 203 Figure 7 47 Electrical Chassis Assembly nmsnnvorarrrnsvoraresvsvsvovererrsverererrsvenerenenn 7 204 Figure 7 48 Engine Control Board eersverevrsvsvorovornsvoreresvsvsvovererrsvererenssvenenenene 7 206 Figure 7 49 Engine Control Interface Board ccccccccsssccscsesecsescseeeesscseseeeaees 7 207 Figure 7 50 T1 and T3 High voltage Power Supplies svrrrororovrrrrnvavesvorsvenenn 7 208 XXIV Phaser 7700 Color Laser Printer Service Manual Figure 7 51 3 3 VDC and 5 VDC Low Voltage Power Supplies 7 210 Figure 7 52 LD Power Rely aivc u2 Acca ce adkin ivhadtien EN 7 211 Figure 7 53 Low voltage Power Supply Fan and Bracket cccccsssssseseeeees 7 212 Figure 7 54 T2 High Voltage Power Supply c cccccsccssssesescsssececsesesseecscseseeessees 7 213 Figure 7 55 Chassis AC Power Assembly c cccsccccsescscsesecssscsescetscecscseseeecsees 7 214 Figure 7 56 Main Drive ASsembly operirani E 7 215 Figure 7 57 Accumulator Belt Drive Assembly rnrnrnrnvrrnrvrrrrverrrnrrnrvrrnrnersnnnr 7 217 Figure 7 58 Developer Drive Assembly 0 c eeceeseseecesesecseeeeseeeeseeeseneeeteesseseeees 7 218 Figure 7 59 Print Cartridge Drive Assembly ccccccececsesesescsseecesseseceeeesesenees 7 219 Figure 7 60 Tray 1 Paper Select Switches m mmmeerensversvorrrvere
229. ry Terms in Manual Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action Be aware of all symbols and terms when they are used and always read NOTE CAUTION and WARNING messages NOTE CAUTION WARNING A NOTE may indicate an operating or maintenance procedure practice or condition that is necessary to efficiently accomplish a task A NOTE may also provide additional information related to a specific subject or add a comment on the results achieved through a previous action A CAUTION indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment A WARNING indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in injury or loss of life Terms on Product CAUTION DANGER A personal injury hazard exists that may not be apparent For example a panel may cover the hazardous area A personal injury hazard exists in the area where you see the sign Phaser 7700 Color Printer Service Manual iii Power Source For 110 VAC printers DO NOT apply more than 127 volts RMS between the supply conductors or between either supply conductor and ground Use only the specified power cord and connector For 220 VAC printers do not apply m
230. s Measure the resistance between the Fuser Assembly connector P600 4 see figure page 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 1 see figure page 2 46 and P404A 2 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No d Repair or replace the wiring harness between the Engine Control Board and the Fuser eplace the Engine Control Board RRP 42 on page 7 206 2 60 Phaser 7700 Color Laser Printer Service Manual Error Chain Code Pa Front Panel Message 42 10 352 ERROR 42 FUSER STS FRONT WARM TIME FAILURE Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 1 see figure page 2 47 and P600 3 see figure page 2 47 Does the resistance measure approximately 6 ohms for a 110 VAC Fuser or approximately 20 ohms for a 220 VAC Fuser Yes No Replace the Fuser Assembly Measure the resistance between the Fuser Assembly connector P600 4 see figure page 2 47 and P600 6 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes N
231. s 6 Remove the one black screw and remove the Mark On Belt assembly Note If the Mark On Belt adjustment procedure RegiCon DC685 3 is being performed then proceed to the following steps Reverse these steps to install the Mark On Belt assembly or pull the MOB sensor back into the original position if the CD685 3 procedure was performed Store the plunger back in the front cover Phaser 7700 Color Laser Printer Service Manual 7 191 RRP 33 Exit Transport Assembly 87700 084 Figure 7 35 Exit Transport Assembly Removal Remove the Rear Cover RRP 1 on page 7 154 Remove Left Hand Top Power Switch Cover RRP 5 on page 7 158 Remove the Fuser Front Cover RRP 8 on page 7 162 Open left hand cover Remove the one screw securing the Transport Assembly Cover and remove the cover Disconnect the harnesses to the Transport Assembly and the left hand cover interlock connector 7 Remove the three screws securing the Transport Assembly and remove TRKON ch kd 7 192 Phaser 7700 Color Laser Printer Service Manual When replacing the Inverter Transport Assembly do not transfer any parts from the original assembly to the replacement asssembly The replacement assembly will work correctly in the Phaser 7700 printer Parts required for the Side Exit Exit Assembly an option not available on the Phaser 7700 are no longer installed on the Inverter Transport Assembly P N 116 1161 00 The revised con
232. scecscsesecesscsesesesscecsesssecessens 4 126 Figure 4 5 RegiCon Flowchart osevesvrvorerosvsvorovererrsvererenrsrererenvsvereresesnensvenesvsne 4 133 Figure 4 6 Grid 1 Dot Pattern Orientation for A size Paper rmserevrsvoverenrsvens 4 140 Figure 4 7 Grid 1 Dot pattern annotations eeeeveserrsrorsvorererrsvereresesverevenrsnnne 4 141 Figure 7 1 Rear Cover Assembly ENEE ENEE 7 154 Figure 7 2 Right Side Cover Assembly cccscsescssssescscsesecetscsesesesscecscseseeecsees 7 155 Figure 7 3 Top Cover Assembly sseossvssenrsrsvasonrsrnrssorerrnvsnnnornnrsensonnnrsnnssnnnrsennn 7 156 Figure 7 4 Control Panel Assembly ssesnavovorerrrvsvoreresnsvsvenerervsvereresesnensvenesrnne 7 157 Figure 7 5 Top Rear Power Switch Cover and Left Hand Rear Mid Cover 7 158 Phaser 7700 Color Laser Printer Service Manual xxiii Figure 7 6 Left Hand Lower Cover Assembly cccccccceseccscsesecsescseecececseseeesaees 7 160 Figure 7 7 Front Cover Assembly msmennvernsrvavererrrvsveveresvsvsvoverevrsnerevevesssnsvenenn 7 161 Figure 7 8 Fuser Front Cover c ccccsccsssccscsesesessssescsesssececsesesescsesseesecseseeenavass 7 162 Figure 7 9 Rear Shield 428 unjsdeseeke El Meats ee dukens 7 163 Figure 7 10 Rear Shield Bracket sssroorrrrrrererrrrsversvenerrsvsreveresnsveneveserrsvevenenene 7 164 Figure 7 11 24 VDC Power Supply Shield soerovrrrvrnrorororesvovererrsvorerevesvsrsvenenn 7 165 F
233. sembly sssnorrvrrrvrnvrvorerrsrovarenvsvensvenerrrvenevennnn 7 182 Developer HOUSING ASSembly sisirin 7 185 New Developer Housing Assembly Charging seeerrvorevrrrsvorevrrvorerenrne 7 186 Toner Dispense Motor Assembly 7 188 Steering Drive Assembly cccsescsescsstecscsesesecessesesesssececseseecessesesesaeass 7 189 Waste Toner Agitator Motor Assembly rornsvrnrnvrnrsvrsnsvrsrsvrsnsvrsnsvennrnnn 7 190 Mark On Belt MOB Sensor scessceceseeeeeeeeeceeeteeeeeeeetetteteeestenetees 7 191 Exit Transport ASsembly gesood concn anaa N AREN 7 192 Fuser Fan ASSembly seess geed ege RE sated cotta eegend EE 7 195 Accumulator Belt ASsembly sssini anaana 7 196 Belt Cleaner Assembly roravrararvonerrnvvererervsverevenevesveverevrsssverenesssnsvenere 7 198 Waste Augen Assembly sscscisessictssseuserctseurereurertucnsieecvecstivensnzucaicteensueeieetes 7 199 Laser Uni susasasdraedaabamusehesguasmdgumdn akse 7 200 Image Processor Board Assembly srsnrnrsvernrverrrnerrrnerrrnerssnersrnensrnenne 7 202 Internal Hard UE 7 203 Electrical Chassis Card Cage Assembly oornnnrnrnnvnrnnrnrnrsrsrnrnrnrnnnnnnn 7 204 Engine Control Board 7 206 Engine Control Interface Board esnersvesvvrnvovorenrsrevarenrsversveneresverenenene 7 207 Phaser 7700 Color Laser Printer Service Manual T1 and T3 High voltage Power Supplies srarrvorerrrvsvoreresvsvsvoverevrsvenenne 7 208 3 3 VDC and 5 VDC Low Voltag
234. ser 7700 Color Laser Printer Certification for servicing of this product requires completion of the Phaser 7700 printer service training 57700 433 Figure 1 1 The Phaser 7700 Color Laser Printer shown with the High Capacity Feeder Phaser 7700 Color Laser Printer Service Manual 1 1 Phaser 7700 Printer Overview The Phaser 7700 Color Printer combines a single pass tandem design color laser continuous tone print engine with an image processor supporting Adobe s PostScript 3 description language The image processor features a bi directional parallel interface a USB port and a 100baseT Ethernet port for host communication The PCLS5C printer language is also supported The 7700 printer prints at a standard resolution of 600 x 1200 dots per inch with bi level dots and at a high resolution of 600 x 600 dots per inch with variable dot sizing The printer can print up to 22 A A4 size pages per minute All printers feature an Internal Hard Drive for font storage storing print files print collation support and a check print before proceeding mode The hard drive also contains printer documentation accessible via a web browser The printer contains 136 standard built in fonts All printers feature a built in duplex unit which supports printing on both sides of a sheet of paper The printer features a built in 100 sheet multi purpose tray from which specialty media card stock larger format pa
235. ser 7700 Color Laser Printer Service Manual PL 8 25 High Capacity Feeder FRUs 57700 412 Figure 8 25 High Capacity Feeder FRUs Table 8 25 High Capacity Feeder FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1100 00 1 Aux Feeder Motor Assembly Motor Assembly 3TM 2 116 1220 00 1 HCF Control Board PWB Assembly TTM 3 116 1206 00 2 Caster Locking 4 116 1221 00 2 Caster 5 116 1099 00 1 Transport Motor Assembly Motor Assembly TTM Phaser 7700 Color Laser Printer Service Manual 8 277 PL 8 26 High Capacity Feeder FRUs cont d 7700 074 Figure 8 26 High Capacity Feeder FRUs cont d Table 8 26 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1168 00 1 Chute to Lower Chute F O Lower 2 116 1169 00 1 Chute to Upper Chute F O Upper 3 116 1218 00 1 HFC tray 4 Feed out Sensor Reflect Sensor GP2A25 4 116 1172 00 1 Gg Feeder Assembly HCF Tray 4 Feeder Assembly 8 278 Phaser 7700 Color Laser Printer Service Manual PL 8 27 High Capacity Feeder FRUs cont d 7700 075 Figure 8 27 High Capacity Feeder FRUs cont d Table 8 27 High Capacity Feeder FRUs List cont d Parts Part Number Qty Name and Description vendor description 1 116 1160 00 2 Paper Feeder Assembly Feeder Assembly 2 116 1173 00 1 Chute Assembly
236. ser 7700 Service Quick Reference Guide Phaser 7700 Color Laser Printer Service Manual 8 283 Software Table 8 32 Software Part Number Qty Name and Description 063 3405 00 1 CD Drivers amp Utilities English 063 3406 00 1 CD Drivers amp Utilities Traditional English 063 3407 00 1 CD Printer Management 063 3404 00 1 PhaserMatch Software Supplies and Accessories When the control panel notifies you that a supply is low or needs to be replaced make certain you have replacements on hand To order supplies and accessories contact your local dealer or visit the Xerox website www xerox com officeprinting supplies Table 8 33 Supplies PartNumber Supply Item Qty Name Description 016 1886 00 Customer Replaceable Consumable CRC 1 Print cartridge 016 1883 00 Customer Replaceable Consumable CRC 4 Print cartridge Kit 016 1890 00 Customer Replaceable Unit 1 Transfer roller 116 1094 00 Maintenance Item 1 Belt cleaner assembly 116 1889 00 Maintenance Item 1 Accumulator Belt 016 1882 00 Standard Toner Cartridge CRC 1 Black 016 1879 00 Standard Toner Cartridge CRC 1 Cyan 016 1880 00 Standard Toner Cartridge CRC 1 Magenta 016 1881 00 Standard Toner Cartridge CRC 1 Yellow 016 1947 00 Hi capacity Toner Cartridge CRC 1 Black 016 1944 00 Hi capacity Toner Cartridge CRC 1 Cyan 016 1945 00 Hi capacity Toner Cartridge CRC 1 Magenta 016
237. sher Control Board RRP 77 on page 11 336 2 80 Phaser 7700 Color Laser Printer Service Manual Error Chain Gode Link Front Panel Message 122 12 267 FINISHER ERROR 122 DECURLER FAILURE Remove the Finisher Rear Cover RRP 72 on page 11 330 Enter Service Diagnostics Mode From the Main Menu select Sensor Tests Finisher Sensors Miscellaneous Manually rotate the Decurler Cam Shaft such that the photo interrupter toggles the Decurler Cam Home Sensor Does the display indicate the Decurler Cam Home Sensor toggling between H amp L Yes No Remove the Rear Cover and the Board Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P849 2 see figure page 2 46 and Finisher frame ground Again manually rotate the Decurler Cam Shaft such that the photo interrupter toggles the Decurler Cam Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at the Decurler Cam Home Sensor pin 2 yellow and Finisher frame ground Once again manually rotate the Decurler Cam Shaft such that the photo interrupter toggles the Decurler Cam Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at Decurler Cam Home Sensor pin 1 gray Does the voltage measure 5 VDC Yes No Measure the voltage between the Finisher Control Board P849 3 see figure page 2 46 and Finisher frame ground Does the voltage measure 5
238. sis Card Cage Assembly n n nnn nanna nnana 7 204 7 152 Phaser 7700 Color Laser Printer Service Manual RRP 42 Engine Control Boa 7 206 RRP 43 Engine Control Interface Doan 7 207 RRP 44 T1 and T3 High voltage Power Supplies 7 208 RRP 45 3 3 VDC and 5 VDC Low Voltage Power Supplies and Bracket 7 210 RRP 46 LD Power Bel 7 211 RRP 47 24 VDC Low voltage Power Supply Fan and Bracket 7 212 RRP 48 T2 High Voltage Power Supp 7 213 RRP 49 Chassis AC Power Assembly 2 000 cece cece eee e eens 7 214 RRP 50 Main Drive Assembly 0 0 ccc cece eee ens 7 215 RRP 51 Accumulator Belt Drive Assembly 0 00 c cece eee 7 217 RRP 52 Developer Drive Assembly 0 00 0c ccc eee eens 7 218 RRP 53 Print Cartridge Drive Assembly 0 0 0 e cee cece eee 7 219 RRP 54 Tray 1 Paper Select Switches 00 ccc cece eee eee 7 220 RRP 55 Main Lever Assembly Right and Left Hand Jacks 7 221 RRP 56 Auxiliary Feeder Covers 0 cc ccc cece ee ees 7 225 RRP 57 Auxiliary Feeder Cover Aesembhy c cece ee eens 7 226 RRP 58 High Capacity Feeder HCF Tray 3 7 227 RRP 59 High Capacity Feeder HCF Tray 4 and Paper Transport 7 228 RRP 60 Auxiliary Feeder Control Boards 0 ccc cece eee 7 229 RRP 61 Auxiliary Feeders Motor Assemblies 7 230 RRP 62 Auxiliary Feeder Paper Select Switches cee 7 231 RRP 63 Auxiliary Feeder Paper Feed Motor Asse
239. sistance between P404A 3 see figure page 2 46 and P404A 4 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No 4 Repair or replace the wiring harness between the Engine Control Board and the Fuser eplace the Engine Control Board RRP 42 on page 7 206 45 10 351 ERROR 45 FUSER STS REAR FAILURE Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extreme caution to prevent burns Measure the resistance between the Fuser Assembly connector P600 see figure page 2 47 7 and P600 9 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No d Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 3 see figure page 2 46 and P404A 4 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser eplace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 63 Error Chain pode Link Front Panel Message 46 10 354 ERROR 46 FUSER STS REAR WARM TIME FAILURE Switch printer power OFF Remove the Fuser Assembly Warning Fuser may be very hot Use extr
240. sor has a wedge fit when in position for the number 3 center position If the Mark On Belt sensor not correctly positiond it can cause the test to fail Recheck the MOB sensor position and run the test again Phaser 7700 Color Laser Printer Service Manual 4 139 Coarse RegiCon Initialization The Coarse RegiCon Initialization procedure is needed when either RegiCon 1 or 4 fail If any one of the above conditions exist perform a manual adjustment of the horizontal alignment 1 Run the Belt Edge Learn test page 4 134 2 From the Adjustments Calibrations menu select Coarse RegiCon Init test After some NVRAM values are read the test asks Set Factory Defaults Yes No then select Yes This sets the horizontal and vertical alignment to centered values At this time it should not be necessary to reset the magnification or magnification balance values so select No to Reset Mag Bal Values Yes No Note In all the following steps Cyan is the reference line and cannot be adjusted so you need to adjust all the other lines towards the Cyan line 3 From the Built in Test Prints menu select Print Grid 1 Dot This print shows the relative error between the CMYK scan lines Always indicate which edge of the print comes out of the printer first to be certain which way is Left Right or Up Down see Figure 4 6 Grid 1 Dot Pattern Orientation for A size Paper Measure the distance in millimeters between the vertical lines with the
241. spense Assembly Phaser 7700 Color Laser Printer Service Manual 3 99 6 Print 2 to 3 Solid Fill prints using the primary color in question The toner level at the port should drop as toner is augered into the Developer Toner Port with Lowered Toner Level Not Yet Refilled s7700 559 Figure 3 5 Toner Port 7 If the Drive Shaft rotates but the toner level at the port does not drop replace the Toner Dispense Assembly RRP 25 on page 7 180 3 100 Phaser 7700 Color Laser Printer Service Manual Checking the Developer ATC Sensor 1 2 oo N DIR Power up the printer in Service Diagnostics mode Scroll to the Adjustment Calibration Tone Up Down menu item Press OK The test displays information regarding the Developer ATC Sensors Press OK to read the values for each Developer Examine the ATC values for primary color Developer you are troubleshooting For a properly operating ATC Sensor you should look at the values yellow shown here similar to these lt Tone Up Down gt Y SensWarn 0 Pages 34 ATC Control 470 ATC Corr 459 Ave ATC 472 ATC Vol 214 Record the ATC values and then exit Service Diagnostics Remove the Toner Cartridge of the color you are troubleshooting Print 15 A size pages of 100 Solid Fills of the primary color you are troubleshooting Turn Off the printer and then power up the printer in Service Diagnostics mode Re run the Adjustment Calibration Tone Up Down menu ite
242. stments Preparation for RegiCon 1 Use the Front Panel connection setup menu to disable Netware 2 Flip the Dip Switch 2 on the printer s rear panel Down this disables the Startup Page and enables the printer to write test results to the print engine NVRAM 3 Disconnect any parallel or network cables from the rear panel of the printer 4 If a Finisher is installed disconnect the two cables to the printer and slide the Finisher away from the printer Note Remember to wait until the printer displays Ready to Print plus 10 seconds after each of the 685 x tests are run before power cycling printer to display results in diagnostics Failure to wait long enough will result in a No Results message Phaser 7700 Color Laser Printer Service Manual 4 127 If any RegiCon routine appears to run correctly but does not return any results 1 You did not wait 10 seconds after the display indicated Ready to Print before re booting the printer 2 Netware was not disabled 3 If the printer is running version 4 02 Postcript code and Netware is enabled RegiCon will not initialize properly typicaly will result in an error 80 condition Disable Netware before performing any RegiCon procedure in diagnostics 4 The Hard Disk Drive has the MFGstartjob snippet in the sys start file Download the usrstart_del ps snippet to the printer This snippet can be found on the Xerox website m http cpidserv opbu xerox com pro
243. suy VLH Po See Soe eee ey 6S8rc Josuag wn Aes dop JOSUSS pesojo ER 48A0D VIH quiessy Odsue1y E9UOZUOH sserc JOSUSS XI WI 40JOWN BAU Joysluly 088r Gan yano weg l 2 Jeunoed 100 19963 8v8r d ret JOSUSS WOH duer jee JOSUSS SUWOH weg Jeune JOSUSS WOH duer pafa JOSUAS WOH Jedwuey Jeoy JOON Jadwey Jeoy JOSUSS WOH Jadwey 1UOJH JOJO Jadwey quod Josuas Jeded Jejidwuon plous og alpped due 195 youms woust J AOD 1UOIH ERR V RIS Josuas Josuas 4OUJOD 1UOJIH NW 9jdes Jeddn Ler JOSUSS e JOSUAS yoo sayu Jaded Buoog 7 yS ozer C Uu ERT 19109 dop JOSUSS S0UEJJUJ Jedwon JOSU9SS DE REG EZE GI vb 00ZZS enue SOA JOJUL JOSE 10 09 0022 J8S8Yd z NED va ezO VIONI FEN 2 13A ve 22001 Som CELI Ed KINO l HOLON 1 H ELE OMTIND W WOO LOWS TSP E e TE Fo ezo TINT A NODION DEED SA 40H l H34SNYHL 49H 3 e DEC
244. t ssoeeserververrrverrrverrrvrrrrrersrrrrserersenn 3 114 Background Contamination eersverevrrvvrereresvrvsvonerenrsverereresveverenesvsvsverenesner 3 115 Unfused Image or Image Easily Rubs Off of Page revrvrrrrrererrrrsvorenesvrvrvennr 3 116 Toner on Back of Print esnenrsnonrsnenrrrerrrvrnrsnenrvennsnrsrsnrsrsnrsrsnesrrnssrrsrrrsrsnrnnne 3 117 Print 15 MOtled EE 3 118 Image Mis registered on Paper rmsnsnrsnsvrsnsvrrrsvrnenrsvenesvenesvennsnennsnenssnenesnen 3 119 Residual Image or Ghosting soverevervorovorervrrrvererervsvenovesesvsvoverenssseveresessener 3 120 Light Bands Dark Bands or Mottled Prints rsrererrorrenrenrervrrnenrerrrnnrnvernnn 3 121 Adjustments and Calibration 4 123 Internal Hard Drive 4 123 Registration Control RegiCon Adjustment Overview c ccccsecsesececscseeeees 4 124 Coarse RegiCon Initialization ccscsescsssscecscsssececseseseecscsesecessesssesaeaes 4 124 Coarse and Fine Skew Adjustments sovrrrrrorerervsvororererrsverererrsreverenesesvsnener 4 125 In Out Skew Adjustment 0 ccc eececsscsescscsececscsesecesscsescsesesessesesececsesesenasass 4 125 Center Skew Adjustment enererrrvsvovovonrvenvorerereserrsvsverenesvsnsvenerssvsseveresesnener 4 126 Processes of the RegiCon Adjustment cccccscscscssesescseececsssesecetscsescseseessees 4 127 GheckPrint quality 24 0asmidsedunsbmusannmeiaedutn bi 4 127 Preparation for RegiGon esranenrvonrvr
245. t Front Panel Display Test Operation Results and Function Definition Clutch Tests Tests functionality of clutches by activating one clutch at a time Take Away Clutch On All tests are activated by pressing Clutch Clutch Off OK Developer Clutch On Listen for the clutch Clutch Clutch Off Test times out after 1 second Registration Clutch On Clutch Clutch Off Duplex Clutch Which Direction CCW CW Clutch On Clutch Off MPT Feed Clutch Finisher Clutches Decurler Cam Clutch Clutch On Clutch Off Solenoid Tests Tests functionality of the solenoids by activation one solenoid at a time Exit Gate Solenoid Solenoid On Engineering use only Solenoid Off Duplex Gate Solenoid On Engineering use only Solenoid Solenoid Off Shutter Solenoid Solenoid On Press OK to run test Solenoid Off ADC Shutter Open Solenoid On ADC Automatic Density Correction Solenoid Off Press OK to run test ADC Shutter Close Solenoid On ADC Automatic Density Correction Solenoid Off Press OK to run test MPT Feed Solenoid Solenoid On MPT Multi Purpose Tray Solenoid Off Press OK to run test Finisher Solenoids Set Clamp Paddle Press OK to run test HTrans Gate In Open HTrans Gate In Close Adjustments Calibrations Performs adjustments calibrations and operations essential to the performance of the printer For details on performing the RegiCon procedures Registration Control Procedures on
246. t Edge Learn Before doing skew adjustments it is necessary to align the Accumulator Belt positioning system A belt steering cam engages an arm on the Accumulator Belt cleaner to steer the belt A belt edge sensor provides the real time feedback to steer the belt Caution The Accumulator Belt must NOT be run without the Belt Cleaner in place The belt WILL walk off the rollers and be permanently damaged 1 From the Service Diagnostics Menu highlight the Adjustments Calibrations menu and press OK 2 Highlight Belt Edge Learn and press OK The display now reads lt Belt Edge Learn gt lt Press back or cancel to abort gt The following result must be displayed after the test completes Any other result means that the procedure failed lt Belt Edge Learn gt Belt Edge Learn Result OK Belt Edge Learn Walk Control lt Press back or cancel to abort gt Press Back to return to the menu If the Belt Edge Learn procedure fails The Accumulator Belt must be replaced 4 134 Phaser 7700 Color Laser Printer Service Manual Step 2 RegiCon 4 Coarse Skew Adjustment 1 From the Service Diagnostics menu highlight the Adjustments Calibration menu and press OK 2 Highlight Regi Con 685 Setup Cycle and press OK At the prompt Which DC685 procedure select 4 Coarse Skew Setup and press OK At the prompt Do DC685 4 Coarse Cycle highlight Yes and press OK The front panel now displays lt
247. t Prints to Locate a Feed or Paper Transport Problem You can use test prints to locate a problem with paper feed or with paper transportation along the paper path Note This procedure presumes you have investigated any displayed error code or message pertaining to paper feed or transport problems If not please do so now 1 Enter Printer Diagnostics and generate a test print 2 Follow the paper along the paper path to locate the cause of the problem 9 288 Phaser 7700 Color Laser Printer Service Manual Print Color Test Prints This color test print produces 6 prints CMYK 4 on 4 off a solid fill red and 4 on 4 off bars Interpreting Print Color Test Prints CYMK 4 on 4 off Yellow 7700 291 Phaser 7700 Color Laser Printer Service Manual 9 289 8 e e 7700 289 Interpreting Solid Fill Test Prints Non uniformity in any one color may indicate a problem with the developer or print units Light streaks in one color indicate developer or debris blocking the laser Dark streaks in one color indicate a problem with the developer or print units Repeating spots in one color indicate a problem with the print unit Non repeating spots in all colors indicate problems with the transfer belt Things to look for m Uniformity in each color m Streaks m Spots
248. t for a Class B digital device as stated in Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a commercial installation This equipment generates uses and may radiate radio frequency energy If not installed and used in accordance with the instructions provided this equipment may cause disruptive interference to nearby radio and television communications Even if the equipment is installed according to the instructions there is no guarantee of no interference in a particular installation If this equipment does cause disruptive interference to nearby radio and television reception switch the equipment off to determine if it is the true cause of the interference If the equipment is the cause of the interference the user should try to minimize the interference by taking one or more of the following courses of action Note Installation of the Finisher and or the Token Ring Interface results in an FCC classification change to Class A Either re orient or relocate the radio television receiving antenna a Increase the separation between the equipment and the radio television receiver a Connect the equipment to an AC outlet that is not on the same circuit as the radio television receiver a If the previous solutions fail to bring results you should consult either your equipment dealer or an experienced radio television technician For more information on interference
249. t secure the Toner Dispense Motor Assembly to the printer frame Disconnect the wiring harness from each motor Remove the Toner Dispense Motor Assembly 7 188 Phaser 7700 Color Laser Printer Service Manual RRP 30 Steering Drive Assembly oe 700 012 Figure 7 32 Steering Drive Assembly Removal 1 Remove the Print Cartridges and Print Cartridge Plate Cover RRP 24 on page 7 179 2 Disconnect the wiring harness 3 Remove the three screws and remove the Steering Drive Assembly Note You may have to rotate the CAM gear to reinstall the Steering Drive Assembly Phaser 7700 Color Laser Printer Service Manual 7 189 RRP 31 Waste Toner Agitator Motor Assembly 7700 016 Figure 7 33 Waste Toner Agitator Motor Assembly Removal 1 Remove the Print Cartridge Plate Cover RRP 24 on page 7 179 2 Remove the Waste Cartridge Assemblies RRP 23 on page 7 178 3 Disconnect the wiring harness to the motor 4 Remove the two screws that secure the Agitator Motor Assembly to the printer frame 7 190 Phaser 7700 Color Laser Printer Service Manual RRP 32 Mark On Belt MOB Sensor 7700 120 7700 121 Figure 7 34 Mark On Belt Sensor Removal 1 Remove the Waste Cartridge Assembly RRP 23 on page 7 178 2 Remove the Waste Toner Agitator Motor RRP 31 on page 7 190 3 Remove left hand inner cover 4 Disconnect the purple harness 5 Remove the wiring harness from three clip
250. t the media guides are set correctly and verify that the proper media is being used 3 Feed paper from the multi purpose tray Is the paper damaged when fed out of multi purpose tray Inspect the multi purpose tray for debris or obviously broken components that could be damaging the paper as it feeds out of the assembly and into the printer 4 Inspect the paper feeder for debris or broken components The following components are associated with this specific problem One or more of these components may have failed partially or completely If you can not isolate the problem replace each component listed below one at a time until the problem disappears m Fuser m Accumulator Belt usually appears with toner in creases or wrinkles Fuser Jams Is the paper in good condition and appropriate for a laser printer Is Xerox Series 7700 transparency film being used Is the printer printing within its environmental specifications Ensure that the loaded media matches the front panel settings Check the fuser area for debris Visually inspect the fuser baffle for burrs 1 2 3 4 5 Are the margins on the page greater than 3 mm 6 7 8 Test the fuser motor using Service Diagnostics 9 Replace the Fuser RRP 19 on page 7 174 1 0 Replace the Engine Control Board RRP 42 on page 7 206 Exit Jams 1 Is the paper in good condition and appropriate for a laser printer Is the paper curling Is the pri
251. t wiring harness up to the engine control board 4 Remove the two screws securing the laser unit in the printer Caution The laser unit is heavy 5 Pull the Laser Unit out of the printer Replacement You must perform the RegiCon adjustment procedures after replacing the Laser Unit Registration Control Procedures on page 4 130 Store the NVRAM values to the hard drive after calibration Store Engine NVRAM on page 6 150 CAUTION LASER RADIATION I n ii ERDU Tok ERE FORSERVICE Fe p IRD PERL VRE EAY PIi z CF OT RBICMRENS FO HAORBBO RA PINES BC Mt ME YEA T aPEOMTSTE CAUTION LASER RADIATION Invisible Laser Radiation Do not connect the cables when ROS is outside the machine FOR SERVICE Follow replacement instructions in the Service Manual This ROS is a component for Xerox Products and is exempt and does not comply with the requirements of the Federal Laser Product Performance Standard 21 CFR 1040 and IEC 825 There are no field adjustments or replacement items inside This unit is to be opened only at authorized factory repair centres Refer to the Service Manual for replacement instructions Figure 7 44 Laser Unit Label Phaser 7700 Color Laser Printer Service Manual 7 201 RRP 39 Image Processor Board Assembly a NVRAM socketed 87700 454 Figure 7 45 Image Processor Board Assembly Note Turn the printer power Off and unplug the printer Caution The Image Processor Board is susce
252. te Locator Map to identify the sensor m Remove the necessary cover RRP 67 on page 11 325 m Press down on the two locking tabs located at the top of the sensor press up on the two locking tabs at the bottom of the sensor and remove the sensor Phaser 7700 Color Laser Printer Service Manual 11 323 RRP 66 Horizontal Transport Assembly Za 87700 319 Figure 11 8 Horizontal Transport Assembly Removal 1 Unplug the Finisher from the printer 2 Lift the two hooks securing the Horizontal Transport Assembly to the Finisher 3 Remove the Horizontal Transport Assembly 11 324 Phaser 7700 Color Laser Printer Service Manual RRP 67 Horizontal Transport Top Open Front and Rear Cover 87700 452 Figure 11 9 H Transport Top Open Front and Rear Covers Removal 1 2 3 8 Remove the Horizontal Transport Assembly RRP 66 on page 11 324 Remove one screw securing the stopper Remove two screws from the Horizontal Transport Front Cover and remove the cover 4 Remove the hinge screw and remove the Top Open Cover 5 6 7 Remove two screws securing the Horizontal Transport Rear Cover Remove the Horizontal Transport Entrance Upper Cover Assembly Remove the Horizontal Transport Exit Guide by pressing on the tabs on the lower right edge of the Horizontal Transport Frame Remove the Upper Rear Cover Phaser 7700 Color Laser Printer Service Manual 11 325 RRP 68 Horizontal Transport Entrance Upper Co
253. ted on the StartPage in a red box after the system is running A hard fault is any fault discovered by POST that prevents the operating system from initializing successfully A hard fault prevents the system from further execution and is halted with blinking LEDs front panel and health LED The test name of the test that failed is displayed on the front panel Note With the DIP switches in service mode a soft fault is converted to a hard fault Fault Reporting Devices There are four fault presentation devices For hard faults m The health LED flashes according to the fault code m The front panel LED flashes in unison with the health LED m The last posted message to the graphic front panel is present m All soft faults are printed on the StartPage when the DIP switches are in Customer Mode see You can print a service Diagnostics menu map by highlighting Print Service Menu Map using the arrow key and pressing OK on page 2 35 LED Blink Patterns For faults identified as hard faults the POST firmware causes the PS health LED to blink in a particular pattern to identify the fault There are short and long blinks A long blink is worth 5 and a short blink is worth 1 If a fault blink pattern is flashed as long long short short this is fault code 5 5 1 1 12 The exception to the above pattern is a RAM test error The RAM tests have a special blink pattern and the front panel displays RAM Error During power up the
254. ter Service Manual 11 348 Table 11 4 Finisher Stand FRUs List 2 Oo Part Number Qty Description 116 1315 00 1 Front Rack Assembly Item 2 10 Front Cover Knob Screw Screw Bracket Stopper Plate Spring COIN o a A Ol N Rail o Foot CH Front Rack 116 1316 00 1 Rear Rack Assembly Item 3 9 12 14 N Rear Cover wo Rack Cover a D Bracket e a Bottom Plate Phaser 7700 Color Laser Printer Service Manual 11 349 Gate Unit FRUs s 7700 297 Figure 11 29 Gate Unit FRUs 11 350 Phaser 7700 Color Laser Printer Service Manual Table 11 5 Gate Unit FRUs List No Part Number Description 1 116 1292 00 No Gate Cover 2 Bearing 3 116 1293 00 Gate Assembly Item 4 14 4 In Gate 5 In Gate Lever 6 116 1294 00 Gate Bracket 7 Link Assembly 8 Lever Assembly 9 Lever 10 Spring 11 Gate Link 12 13 Bearing 14 Spring 15 Exit Chute 16 Chute Phaser 7700 Color Laser Printer Service Manual 11 351 Horizontal Transport Assembly FRUs 7700 298 Figure 11 30 Horizontal Transport Assembly FRUs 11 352 Phaser 7700 Color Laser Printer Service Manual Table 11 6 Horizontal Transport Assembly FRUs List No Part Number Qty Description 1 116 1290 00 1 ao Open Cover Ass
255. ter displays no error code Note A size prints are processed through the printer with the short edge of the print parallel to the direction of the paper path making print artifacts parallel to the long edge of the print B size prints are processed through the printer with the long edge of the print parallel to the paper path making artifacts parallel to the short axis of the print 3041 43 Inspect the paper that is loaded in the paper tray Is the paper wrinkled dimpled or show any signs of having a high moisture content Does the band repeat at a specific interval If so troubleshoot using the Repeating Defects topic Run the Remove Print Smears routine From the front panel s Support Menu select Improve Print Quality then select Remove Print Smears If the test prints are all okay but prints from an application are not replace the Image Processor Board RRP 39 on page 7 202 Banding Aa 3041 44 Print the Repeating Defects pages From the front panel s Printable Pages Menu select Service Pages then select Print Repeating Defects Pages Swap the Print Cartridges If the defect still appears in the same color the problem is the developer If the banding traveled it is the print cartridge All colors is a problem with the Accumulator Belt Replace the Accumulator Belt Assembly RRP 35 on page 7 196 If the banding frequency is
256. test for a changed state To update the sensor status open and close the Interlock Ambient Temp Temperature is XX C Humidity Humidity is XX Fuser Front Temp is XX C Temperature Back Temp is XX C Phaser 7700 Color Laser Printer Service Manual 2 37 Table 2 2 Service Diagnostics Test Menu Functions cont d Test Front Panel Display Test Operation Results and Function Definition Interlocks Front or Right Door is L H Open A Left Upper Door L L Closed D Duplex Cover is L B Left Lower Door is L C Optional Tray Left Cover L Jam Sensors LH Low Cover Area is H LH Cover Area is H LH Fuser Area is H Duplex Cover Area is H Tray Left Cover Area is H Tray 1 Area is H Tray 2 Area is H Tray 3 Area is H Tray 4 Area is H Tandem Tray 3 Area is H Tandem Tray 4 Area is H MPT Tray Area is H F Fin Compiler Cover Area H G Fin Compiler Safety Area H H J Fin Front Cover Area is H Fin Hor Tran Area is H Fin Docking Area is H H Paper present L Paper not present Engineering use only Engineering use only Engineering use only Engineering use only Engineering use only Engineering use only Engineering use only This is the FIN IN GATE This is the FINHOR TRANS This is the FIN EJECT Engineering use only Engineering use only POB Sensor POB Sensor is L Paper on Belt Sensor L Paper present H Paper not present Registration Registration Sensor is
257. the Finisher rssesrsnorrsvrnrsvenrrnenrrnensrnensrnensrnensrnensrnersrsrrnrnrrsrnnnne 11 317 Internal Assemblies of the Finisher sesnenrsrenrverrsvevrsrerrsrenrrnenrsnrnrssrnrssrnesnnnr 11 318 Horizontal Transport Sensor Interlock and Switch Locator Map ccce 11 319 Finisher Sensor Interlock and Switch Locator Map 11 320 Finisher Sensor Interlock and Switch Locator Map eenerervororvororvororvorornerenn 11 321 Removal and Replacement Procedures 11 323 Horizontal Transport Assembly ou cece ccsccceccsecsceecsscssececsecsseseeseeaens 11 324 Horizontal Transport Top Open Front and Rear Cover 11 325 Horizontal Transport Entrance Upper Cover Assembly 00c00 11 326 Horizontal Transport Belts eniris 11 327 xviii Phaser 7700 Color Laser Printer Service Manual Horizontal Transport Entrance Sensor and Top Tray Full Sensor 11 328 Gate In Solenoid Assembly rasesnavonovrrrvrnvaresvsvarenesrnrsvererenvsreverenesnsnen 11 329 RIIT de d CN 11 330 Stack Height Sensor Assembly svesvovereresvovereresrrrrvererenrsreverenesvenen 11 332 Stacker Paper Sensor Assembly sovervonereresvsvorenesrnrsvererenvsreverenesnenen 11 333 Set Clamp Clutch and Gear seseesrresorseorrvoreserrorerrnssrorersnrsennnn 11 334 Eject Roll Assembly a ssc csscsesecsccscescecacctezdcecassvsseardavcdecteasaveeshchedecheabenesee 11 335 Finisher Control Board Bracket and Shield 11 336 Stacke
258. the Fuser Assembly connector P600 1 and P600 3 see fig ure page 2 47 Does the resistance measure approximately 6 ohms for a 110 VAC Fuser or approximately 20 ohms for a 220 VAC Fuser Yes No Replace the Fuser Assembly Measure the resistance between the Fuser Assembly connector P600 7 see figure page 2 47 and P600 9 see figure page 2 47 Does the resistance measure between 20K and 100K ohms Yes No d Replace the Fuser Assembly einstall Fuser Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 10 on page 7 164 Measure the resistance between P404A 3 see figure page 2 46 and P404A 4 see figure page 2 46 on the Engine Control Board Does the resistance measure between 20K and 100K ohms Yes No Repair or replace the wiring harness between the Engine Control Board and the Fuser einstall the Fuser Switch printer power ON Does the Fuser get warm Yes No Replace the Chassis AC Power Assembly RRP 49 on page 7 214 eplace the Engine Control Board RRP 42 on page 7 206 Phaser 7700 Color Laser Printer Service Manual 2 65 Error Chain Cone Link Front Panel Message 54 10 398 ERROR 54 FAN FAILURE Enter Service Diagnostics Mode Run the Fuser Fan test Does the Fuser Fan operate Yes No Remove the Rear Cover RRP 1 on page 7 154 Rear Shield RRP 9 on page 7 163 and the Rear Shield Bracket RRP 11 on page 7 165 Measure the
259. the main lever down 3 Remove the Waste Cartridge Sensor Holder RRP 23 on page 7 178 7700 013 Figure 7 27 Print Cartridge Plate Assembly 7 182 Phaser 7700 Color Laser Printer Service Manual 87700 167 Figure 7 28 Print Cartridge Plate Assembly cont d 4 Remove the Print Cartridge Plate Cover RRP 24 on page 7 179 5 Remove the Dispense Assemblies RRP 25 on page 7 180 6 Disconnect the wiring harnesses to all four Developer Housing Assemblies and remove them from under their retaining clips and dress the wires so they stick straight out the front of the printer 7 Clear the wire harnesses from the guide located on the lower left side of the assembly 8 Remove the six chrome plated screws that secure the plate to the frame Note Stop here if only replacing developers Complete removal of the Print Cartridge Plate Assembly is not required for removal of the Developer s Tilt the Print Cartridge Plate Assembly forward enough to allow the Developer s to be removed Do not disconnect the Print Cartridge Plate harnesses 9 Remove the screw securing the Left Hand Inner Cover and remove the cover 10 Disconnect the wiring harness from its retaining clip Phaser 7700 Color Laser Printer Service Manual 7 183 11 Disconnect the harness 12 Remove the Print Cartridge Plate Assembly Replacement Note Note Caution Caution Note 7 184 Ensure the developer assemblies are fully and ev
260. tom connector on the three Low voltage Power Supplies 5 Remove the rear cover and the two metal shields Connect AC Input and en the printer On Check for AC voltage at J72 on top of the GFI if not present replace the GFI m Between FS76 and FS77 of the Noise Filter if not present replace the Noise Filter m Into and out of the Power Switch if not present replace the Power Switch m The connector at the bottom of the 3 3 VDC 5 VDC and 24 VDC LVPS if not present replace the AC Drive Board Note The GFI Noise Filter and AC Drive Board are all part of the AC Electrical Chassis see RRP 49 on page 7 214 Troubleshooting the Low voltage Power Supplies 3 3 VDC 5 VDC and 24 VDC voltages are supplied by individual LVPS boards The 24 VDC LVPS requires the presence of a 5 VDC enabling signal to operate Note Before troubleshooting power supply problems disconnect the Lower Tray Deck or Finisher if installed and restart the printer Verify the problem is still present or refer to the appropriate option troubleshooting section Verify the printer is plugged in and the GFI is not tripped Troubleshooting AC Power on page 3 89 Remove the Image Processor Board cover and metal plate Disconnect the Relay Board Power Connector J300 Turn the printer On Check for 3 3 VDC at J300 1 2 3 amp 11 Check for 5 VDC at J300 7 If 5 VDC is present check for 24 VDC at J300 9 If no DC voltages are present
261. tridge Drive Assembly RRP 53 on page 7 219 eplace the Engine Control Board RRP 42 on page 7 206 Replace the Engine Control Board RRP 43 on page 7 207 Phaser 7700 Color Laser Printer Service Manual 2 67 Error Chain Gode Link Front Panel Message 70 09 360 ERROR 70 PRINT CARTRIDGE 1 COMMUNICATIONS 71 09 361 FAILURE 72 09 362 ERROR 70 PRINT CARTRIDGE 2 COMMUNICATIONS 73 09 363 FAILURE ERROR 70 PRINT CARTRIDGE 3 COMMUNICATIONS FAILURE ERROR 70 PRINT CARTRIDGE 4 COMMUNICATIONS FAILURE Swap the suspect print cartridge with any other cartridge Close all doors Does the problem follow the suspect print cartridge Yes Replace the Print Cartridge No Remove the cartridge in problem location and carefully inspect the connector damage Is the connector damaged Yes No frame ground Yes No Yes No Measure the voltage between pin 4 of the suspect print cartridge connector and Does the voltage measure 3 3 VDC Measure the voltage between each of P405A 4 8 see figure page 2 46 P405B 4 8 see figure page 2 46 and frame ground Are all voltages 3 3 VDC Replace the Engine Control Board RRP 42 on page 7 206 eplace the harness between the Engine Control Board and the suspect print cartridge connector Replace the Engine Control Board RRP 42 on page 7 206 Replace the Print Cartridge Plate Assembly RRP 26 on page 7 182 2 68 Phaser 7700 Color Laser Pr
262. trol Board RRP 42 on page 7 206 emove the Print Cartridge Plate Cover RRP 24 on page 7 179 Inspect the wiring harness between the Engine Control Board and the Developer Housing Assembly Is the wiring harness in good condition Yes No i Repair or replace as necessary eplace the Developer Housing Assembly RRP 27 on page 7 185 Replace the Engine Control Board RRP 42 on page 7 206 Note Run approximately 10 pages of solid fill full page prints of this primary color to ensure this error is cleared 2 50 Phaser 7700 Color Laser Printer Service Manual Error Chain code Hink Front Panel Message 14 09 382 ERROR 14 CYAN ATC SENSOR FAILURE Note If this failure reoccurs three times successively an Engine NVRAM value is set preventing further printer use until the NVRAM Access Clear Tech Rep Fault Clear lt 09 380 09 383 gt is run Note If necessary enter Service Diagnostics Mode and run the Clear Tech Rep Fault procedure on page 6 149 Remove the Rear Cover RRP 1 on page 7 154 and Rear Shield RRP 9 on page 7 163 Measure the voltage at P534 8 see figure page 2 46 on the Engine Control Board Does the voltage measure between 1 VDC and 3 VDC Yes No Measure the voltage at P534 9 see figure page 2 46 on the Engine Control Board Does the voltage measure 5 VDC Yes No Replace the Engine Control Board RRP 42 on page 7 206 Measure the voltage at P534 7 see figure page 2 46
263. ts are printed after the customer enters the matching password on the printer s control panel The customer has the option of printing the original number of requested sets or deleting the job Since more than one job may be associated with the same password the customer can print all the jobs delete all the jobs or select or delete individual jobs A proof job that has not been printed is retained on the built in Internal Hard Drive through power cycles Secure Jobs Secure printing allows the customer to defer printing of a job until a matching password is entered from the control panel The customer assigns the password at the client workstation before printing The job is stored and printing is delayed until the password is entered on the printer s control panel Since more than one job can have the same password all secure jobs with the same password are printed A secure job that has not been printed or released is retained on the Internal Hard Drive through power cycles Saved Jobs Saved print allows the user to save print jobs to the internal hard drive of the printer The print job is not deleted after printing it is stored on the hard drive for print on demand This function requires the internal hard drive Note For additional service information refer to the Service CD ROM or the Xerox Service Website http cpidserv opbu xerox com Phaser 7700 Color Laser Printer Service Manual 1 3 Printer RAM and Printer Capabilit
264. tween the following points m From MCU PWB J407 B10 to Tray Module PWB J541 7 m From MCU PWB J407 B9 to Tray Module PWB J541 9 m From MCU PWB J407 B11 to Tray Module PWB J541 5 m From MCU PWB J407 B12 to Tray Module PWB J541 4 Change the following parts in the order of priority as listed 1 Interface Board 2 Tray Module Circuit Board 3 Engine Control Board 4 Image Processor Board Phaser 7700 Color Laser Printer Service Manual 2 85 Error Chain Link Code Front Panel Message 125 009 910 K TRAY COMMUNICATION FAILLURE 009 911 M 009 912 C 009 913 Y 1 Check the installation of the Print Cartridge 2 Clear the Tech Rep Fault for errors 009 910 through 009 913 refer to instructions below 3 Try changing the indicated Print Cartridge 4 Check for an open wire or poor contact between the Print Cartridge and the Engine Control Board m Yellow J 151 to J 405 m Magenta J 152 to J 405 m Cyan J 153 to J 405 m Black J 154 to J 405 5 Replace the Eingine Control Board RRP 42 on page 7 206 Prior to troubleshooting for an open circuit step 4 above or replacing the Engine Control Board step 5 above clear the Tech Rep Fault for any of these codes using the following pro cedure 1 Enter Service Diagnostics 2 Select NVRAM Acces and press OK 3 Select Clear Tech Rep Faults and press OK 4 Select link codes 009 910 through 009 913 and press OK 2 86 Phaser 7700 Color Laser Pri
265. uage Intelligent Ready multi purpose setup tray 1 4 setup Startup Page front panel intensity front panel contrast postscript error information and ENERGY STAR timeout to their default values 1 Enter Service Diagnostics 2 Highlight NVRAM Access and press OK 3 Highlight PostScript NVRAM Reset and press OK 4 Select the specific entry desired and press OK The printer now exits Service Diagnostics and reboots While booting NVRAM is reset Clear Tech Rep Faults The following printer faults can occur during normal operation and the normal procedure is to isolate and repair the problem However with these particular faults an additional step is required value has been written in the engine NVRAM that requires clearing before the printer can be used Some faults require three occurrences before the fault is generated Note To clear a Tech Rep Fault you must disconnect the Finisher option The following functions generate a Tech Rep Fault m Belt Home Too long Error 30 m ATC YMCK Sensor Fail Errors 12 13 14 15 a ADC Sensor Fail Errors Engineering use only m Print Cart YMCK Type Mismatch Engineering use only m Fuser Main Sub Lamp Temp Too High Errors 40 44 1 Enter Service Diagnostics 2 Highlight NVRAM Access and press OK 3 Highlight Clear Tech Rep Faults and press OK 4 Highlight the Link Code to be reset and press OK Reset CRU Life Counters For Engineering use only Phaser 7700
266. undetected by the user These error codes are discussed in this section When an error code first occurs cycle the printer power On to see if the error recurs m For Printer Performance problems see Troubleshooting on page 3 87 m For Print Image Quality problems see Print Image Quality Problems on page 3 108 Troubleshooting Error Codes Chain Link Definitions A chain link number is always represented as a pair with the chain first and the link second Chain A three digit identifier of a major attribute counter or assembly Link A three digit identifier of a specific component within the major attribute counter or assembly Where do they come from The chain link encoding structure is used to identify or address a specific component within the printer The chain points to a high level attribute or counter or component assembly and the link points to a specific item in that assembly Why are they here The printer uses chain links to enumerate printer faults and electronically address printer components or operations Most fatal faults are identified by a number between 10 and 125 but a few faults are identified by the chain link identifier Phaser 7700 Color Laser Printer Service Manual 2 31 System Boot Sequence 1 Om NG OR GO The main power switch is turned On The health LED turns On immediately The boot loader checks for RAM present and functional if not it posts a very large RAM ERRO
267. uxiliary Feeder Paper Feed Motor Assembly srrnrrnrnrrnrrnrnrrnrnrrsrnrnne 7 232 Bracket Assembly Left Hand and Right Hand Gear HCF ssssssssnssa1sn 7 233 FRU Parts List 8 235 PL 8 1 Accumulator Belt FRUS saunassa aa N 8 236 PL 8 2 Left Hand Door FRUS 8 237 PL 8 3 Media Trays FRUS ccccsccssssssssscssescsssssessscssescsseececacseesessssesseesaseeees 8 239 PL 8 4 Duplex Unit FRUS eeernrververevrrvorererrrnsverenesvsvsvenerenrsvenerssesvensveseresnen 8 240 PlL 8 5 Coven FRUS pirinin eaaa aa a aa stelte 8 241 PL 8 6 Cover FRUS cont d secececececeseceeeeeeeeeceeeeeeeeeeeseeeeeeeeseseeeeeeteeees 8 242 PL 8 7 Cover FRUS Cont d iesistie e a 8 243 PL 8 8 Switch and Sensor FRUS ersvrsvsnsvaverenrsnerarevesversveneresvsverevssssvenenenn 8 245 PL 8 9 Switch and Sensor FRUS cont d ececeeseseceeeeeeeeeeeeeeeeteteeeeeeeeeeees 8 247 PL 8 10 Circuit Boards FRUS 8 249 PL 8 11 Power Supplies Fe 8 251 PL 8 12 Power Supplies FRUS cont d ceeceeeseeeseeteesesceeseeteteeetteneeees 8 253 PL 8 13 Motors Drivers FRUS s ernvrrnvrnvoverevrrvsvorenesvsvsvenerenrsnenesssvsvereresnsnener 8 255 PL 8 14 Electrophotographic Components Fills 8 257 PL 8 15 Electrophotographic Components FRUS fcontd 1 8 259 PL 8 16 Multi Purpose Tray FRUS eevrrvererevvrvorovorrsvorovererrsvrverevesrensvenereener 8 261 PL 8 17 Papen Feed Us e EE 8 263 PL 8 18 Paper Feed FRUS contd 1 8 265 Pl 8 19 Fans FRUS sva agns
268. ve ZLZOL AS OF9d 2 oror AUD be 22201 Vv9Z9d agzor Aud ve 22201 Ieceer S gg L RETTET aA ve zzo Aver ovsal 9 oror au ver vocod t VAascor DECKEN vorar AND 82 180 AS seir ii a l egorer TaA 92 1901 UNSHLIVM SELOS orgy ON d D Gs I FACE D ETS vaMmd z over OIA 92 1901 NIHAS SEIT I vozodp Sgaozor Sorser TSA 8 1901 MSENSGO weirs AUS va 220r_ V9Z9d Vlaszor DENK orst OIA 92 ant MA Ser I I I I ER EEE PEER ERR ER ER JE EE HULER ER EEE ER JER NE JER KE E PETITI ASF REISER T ECH N REES MSN3dOF IHT TBA v2 22201 SZIN g veesr NIHAST TAA ve T2ZOL sere I I St gt azggrON I I Za Ke db EE EEN BEE D LI Et azesr LHM e opt NLYAST eroas lt t st eror OIA 92 L901 veeor et gt aeesr LAM ee 1501 Taa iaaanit eroas rer an ee Teor veeor 13A 92 1901 l EH WW azesr LHM 92 L901 vet Ei 9d s FE etr NHO 92 L90L veser NHO 97 ont eter t lt z or or GE Gg azesr IHM 921901 MoOOSTOLUSANI Breas Derer nese so VEEST Ma 92 1901 stark v lt m l e TI Weeer ewen Aver Era Serer nuo s Teor VEEST NHO 92 1901 Treas I I H gt azesr LAM oe 1501 MOSTOLUSANT ereas gt erer mazio seesal e VEEST DKW DCK L O l aceog y Lessor Zen m azesr LHM e opt Aver ELl9d t eror NHO 92 1901 verset H gecor NHO 92 ont LSZd S m D Saeco LUM se IDOL DEET ergi 9 Seppo vessI aeeor Ta 92 1901 Toast L
269. vents a good connection to the interface board 1 Tilt and insert the engine control board assembly under the two loosened screws 2 Carefully lower the assembly onto the engine interface board connector 3 Push lightly into the center of the assembly to ensure the assembly is fully seated If board is reasonably stable the board is properly placed 4 Continue installation by reversing the removal procedures Note Ensure that all connections are firmly seated pay special attention to the laser unit connections on the printers right side Note After replacement of the Engine Control Board perform the Reset Engine NVRAM procedure on page 6 150 Phaser 7700 Color Laser Printer Service Manual 7 205 RRP 42 Engine Control Board Engine Control Board 87700 457 Figure 7 48 Engine Control Board Removal 1 Store the engine board NVRAM values to the hard drive Store Engine NVRAM on page 6 150 2 Remove the Electrical Chassis Card Cage Assembly RRP 41 on page 7 204 3 Disconnect the orange ribbon cable at the engine board connector P460 4 Remove the 8 screws securing the engine control board metal shield and remove the shield 5 Remove the remaining six screws and remove the engine board Note When reinstalling the Engine Control Board be sure to seat connector P460 fully Note Restore engine NVRAM values from the hard drive Reset Engine NVRAM on page 6 150 6 Write the stored NVRAM values
270. ver Assembly 7700 321 Figure 11 10 Horizontal Transport Entrance Upper Cover Removal Remove the Horizontal Transport Assembly RRP 66 on page 11 324 Remove the Front Cover RRP 67 on page 11 325 Remove two screws securing the Rear Cover and remove Remove the Gate In Solenoid Assembly Remove four screws securing the Entrance Upper Cover Assembly TRAN ch 11 326 Phaser 7700 Color Laser Printer Service Manual RRP 69 Horizontal Transport Belts 7700 324 87700 323 Figure 11 11 Horizontal Transport Belts Removal 1 Remove the Horizontal Transport Covers RRP 67 on page 11 325 2 Remove the KL clips from the horizontal transport In and Out 3 4 5 Remove the bearings from the horizontal transport In and Out shafts Remove one end of each horizontal transport belt roller support Remove the belts Replacement Note When reinstalling the belts ensure that the textured side is out Note If necessary remove the KL clip and gear from the out roller to reinstall the belts to help install the bearing Phaser 7700 Color Laser Printer Service Manual 11 327 RRP 70 Horizontal Transport Entrance Sensor and Top Tray Full Sensor Ce Le Figure 11 12 H Tra Entrance and Top Tray Full Sensor 57700 325 Removal 1 Remove the Horizontal Transport Top Open and Front Cover RRP 67 on page 11 325 2 Remove the two screws securing the Horizontal Transport Entrance Upp
271. vice Manual Table 8 20 Lift Components FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1198 00 1 Frame Lift Jack Assembly LH 2 116 1202 00 1 Main Latch Assembly 3 116 1204 00 1 Main Lever Assembly 4 116 1200 00 1 Hinge Lever LH 5 116 1201 00 1 Hinge Lever RH 6 116 1203 00 2 Pin Main 7 116 1199 00 1 Frame Lift Jack Assembly RH Phaser 7700 Color Laser Printer Service Manual 8 269 PL 8 21 Wiring FRUs 7700 059 Leesch e ae Tied V r FAN yr Figure 8 21 Wiring FRUs Phaser 7700 Color Laser Printer Service Manual 8 270 Table 8 21 Wiring FRUs List Parts Part Number Qty Name and Description vendor description 1 116 1223 00 1 Wire Harness Dev Bias Block Assembly In 2 116 1312 00 1 Wire Harness Charge Roller Harness Assembly BCR 3 116 1307 00 1 Wire Harness 1BTR Y M 4 116 1308 00 1 Wire Harness 1BTR C K 5 116 1309 00 1 Wire Harness 2BTR 6 116 1306 00 1 DTS Connector 7 116 1310 00 1 Wire Harness DTS 8 116 1311 00 1 Wire Harness Main HA DC Main P MN Phaser 7700 Color Laser Printer Service Manual 8 271 PL 8 22 Auxiliary Feeder FRUs 7700 409 Figure 8 22 Auxiliary Feeder FRUs 8 272 Phaser 7700 Color Laser Printer Service Manual Table 8 22 Auxiliary Feeders FRUs List Parts Part Number Qty Name and Description vendor description
272. vide several uses in troubleshooting printer problems m Isolating problems to either the print engine or to the Image Processing Board and host software m Locating feed and paper transport problems m Detecting print quality and image registration problems Using Test Prints to Isolate a Problem to the Print Engine or to the Image Processing Board You can use test prints to determine if a problem is caused by a faulty print engine or by a faulty Image Processing Board or host software Note This procedure presumes you have investigated any displayed error code or message If not please do so now Print a sample image from the host computer Enter Printer Diagnostics and generate a test print Compare both prints If the problem occurs when you print from the host computer but does not occur when you print from Diagnostics the problem may be in the Image Processing Board in the print driver software or in the application software on the host computer 5 If the problem occurs when you print a test print then the problem is in the print engine RON ch Note You can also use the above procedure to assist in determining if a print quality problem is caused by a faulty print engine Image Processing board or host software If the print quality problem is an image registration problem refer to Adjustments and Calibration on page 4 123 of this manual for instructions on adjusting image registration Using Tes
273. vrrrsvernrvernsvrsrsnrsrsnrsrsvesvenesvenesvenesvenssnen 8 237 Figure 8 3 Media Trays FRUS secioni ei ias eaaa eaaa ARE E A 8 239 Figure 8 4 Duplex Unit FRUS vroes neria a 8 240 Figure 8 5 Gover FRUS ainiin aag a aoaia en 8 241 Figure 8 6 Cover FRUs cont d cecececececeseseceeeeeseeeeeeeeeseseeeeeeensneteteneneneeeeeteees 8 242 Figure 8 7 Cover FRUS cont d seecececesececeseeeseseeeseeseseeeeeeeesnseeteteneneneeeeeteees 8 243 Figure 8 8 Switch and Sensor FRUS ss snssnsnssnsnsansnsinnnsinsininsnnnnsnsrnnnsnnnrsnnsnseennns 8 245 Figure 8 9 Switch and Sensor FRUS cont d eeseeececeseseeeeeseseseeeeteteneeeeeeeees 8 247 Figure 8 10 Circuit Boards FRUS seorrnererervsvorovererrsvererenrsrererenesverevesesvensvenesnsne 8 249 Figure 8 11 Power Supplies FRUS rorerrnrovvoreronrsvererorvsversvenerrrveverevrsssnessnssvenene 8 251 Figure 8 12 Power Supplies FRUS cont d ererorerrrvsverrvorrrrrvovererrereneserrsvennne 8 253 Figure 8 13 Motors Drivers FRUS ciens naa 8 255 Figure 8 14 Electrophotographic Components FRUS remsvrrrvrrvovorevrsreverenesvenene 8 257 Figure 8 15 Electrophotographic Components FRUSs cont d eorrererenrrvereee 8 259 Figure 8 16 Multi Purpose Tray PRISE 8 261 Figure 8 17 Paper Feed FRUS eisiea niaaa aa eo festene 8 263 Figure 8 18 Paper feed FRUs cont d s sesssessesessiseieiesieresisresrrirrsrisrsrrsresrsrssesrss 8 265 Figure 8 19 Fans ERUS cea Eed Ee 8 267 Figure 8
274. vy Laser Paper Laser Paper 4 Check for paper wrapped around or blocking the fuser roller Inspect the fuser roller for damage Replace the Fuser if necessary RRP 19 on page 7 174 3041 51 3 116 Phaser 7700 Color Laser Printer Service Manual Toner on Back of Print There is toner on the back of the 1 Clean the printer interior 2 Inspect the paper that is loaded in the paper trays Is the paper clean and free of toner 3 Ensure that the loaded media matches the front panel settings TT ag In some cases switching the paper type setting for example from Heavy Laser Paper to Thin cover Index may improve print quality 4 Clean and inspect the Fuser 5 If the Bias Transfer Roller or Belt Cleaner Assembly is near the end of its life replace that part printed sheet of paper pr Mads 3041 52 Phaser 7700 Color Laser Printer Service Manual 3 117 Print is Mottled The printed image has a mottled appearance 1 Ensure that the paper is in good condition and appropriate for a laser printer 2 Ensure that the loaded media matches the front panel settings Also check the media selected in the printer driver 3 For specialty papers experiment with alternate paper type settings such as Heavy Laser Paper Thick Cover Index and others 4 Run the Calibrate for Paper routine From the front panel s Support Menu select Improve Print Quality then select Calibrate for Pa
275. wer cover sensor Waste cartridge Transfer roller interlock switch position sensor behind transfer roller Auxiliary feeder left hand cover interlock switch 7700 390 Figure 1 11 Print Engine and Auxiliary Feeder Interlocks and Sensors Phaser 7700 Color Laser Printer Service Manual 1 15 Image Processor Board Processor Health LED IW J500 SODIMM2 SODIMM1 Hard Drive DIP Switches NVRAM socketed Parallel 7700 258 Figure 1 12 Image Processor Board 1 16 Phaser 7700 Color Laser Printer Service Manual Assemblies of the Print Engine Paper feeder assembly Left Hand lower cover assembly 87700 266 Figure 1 13 Assemblies of the Print Engine Phaser 7700 Color Laser Printer Service Manual 1 17 Assemblies of the Print Engine cont d Toner cartridge 4x Print cartridge plate Developer housing assemblies 4x Dispenser Waste cartridge assembly 4x 7700 312 sensor holder Figure 1 14 Assemblies of the Print Engine cont d 1 18 Phaser 7700 Color Laser Printer Service Manual Assemblies of the Print Engine cont d Exit transport assembly 7700 386 Figure 1 15 Assemblies of the Print Engine cont d Phaser 7700 Color Laser Printer Service Manual 1 19 Auxiliary Feeder Assemblies Paper feeder assembly 3X 87700 368 Figure 1 16 Auxiliary Feeder Assemblies Note The High Capacity Feeder has a Tandem Tray design with three Paper Feeder Assem
276. when you are performing laser related troubleshooting or repair procedures a Never place a mirror or a reflective tool or object in the laser beam path Do not disassemble the printer in such a way that the laser beam can exit the print engine during a print cycle Fuser Components WARNING This printer uses heat to fuse the toner image to a sheet of paper The Fuser Assembly is very hot Turn Off the printer power and wait at least 30 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components Safety Components Make sure covers and panel are in place and that all interlock switches are all functioning correctly after you have completed a printer service call If you bypass or cheat an interlock switch during a service call use extreme caution when working on or around the printer Warning Labels Throughout the printer warning labels are displayed on potentially dangerous components When you service the printer check to make certain that all warning labels are in place Most importantly read and obey all posted warning labels WARNING Turning the power Off using the On Off switch does not de energize the printer You must remove the power cord to disconnect the printer from the main power source Keep the power cord accessible for removal in case of an emergency Phaser 7700 Color Printer Service Manual V Safety Instructions Read all installation instructions carefully be
277. x Nutdriver 5 5 mm magnetic Phaser 7700 Color Laser Printer Service Manual 8 285 8 286 Phaser 7700 Color Laser Printer Service Manual Test Prints A variety of test prints are available to aid in determining the quality of output from the printer and to assist in troubleshooting print image quality problems The topic Troubleshooting on page 3 87 discusses solutions to the problems shown in this section This section illustrates the test prints available through both the Postscript Menu and from the Service Diagnostics Menu The PostScript Menu has two sets of test prints Print Color Test Pages and Print Solid Fill Pages 1 From the main menu scroll to and then select Support Menu gt Improve print quality 2 Select Print Color Test Pages or Print Solid Fill Pages The Service Diagnostics Menu has 4 test print suites Laser Check Halftones Grid 1 dot and Fast Scan 8 Tone There is also a menu selection for Paper Path options This is not a test print but an option for selecting paper output and media size from within the test print mode 1 Turn off the printer 2 Hold down the Back button and the Info button simultaneously while turning the printer back on 3 Continue to hold both keys until the front panel display reads Service Diagnostics V3 60 Initializing then release 4 Select Built in Test Prints Phaser 7700 Color Laser Printer Service Manual 9 287 Analyzing the Test Print Test prints pro
278. y FRUs List No Part Number Qty Description 1 116 1248 00 1 Actuator 2 116 1249 00 1 Clutch Assembly Decurler Cam 3 Cam 4 Shaft 5 Bearing 6 116 1250 00 1 Arm 7 116 1302 00 1 Decurler Roll Assembly REP 17 7 1 8 116 1301 00 1 Gear 40Z 20T 9 116 1301 00 1 Gear 402 10 116 1301 00 1 Gear 18Z 21T 11 Shaft 12 Bearing 13 116 1301 00 1 Gear 23Z 52Z 14 116 1265 00 1 Belt 15 116 1242 00 1 Belt 16 116 1241 00 1 Motor Assembly Main Phaser 7700 Color Laser Printer Service Manual 11 359 Paper Transport Assembly FRUs cont d 17 we i io k Phaser 7700 Color Laser Printer Service Manual Figure 11 34 Paper Transport Assembly FRUs cont d 11 360 Table 11 10 Paper Transport Assembly FRUs List cont d No Part Number Qty Description 1 116 1266 00 1 Cam Bracket Assembly Item 2 12 14 19 2 116 1303 00 1 Pully 3 116 1303 00 1 Gear 152 4 116 1271 00 1 Belt REP 17 8 1 5 116 1303 00 1 Gear 302 6 Collar 7 116 1303 00 1 Gear Pully 8 Eject Motor 9 116 1303 00 1 Cam Gear 10 116 1303 00 1 Gear 427 272 11 Set Clamp Solenoid 12 Bracket 13 Wire Harness 14 116 1234 00 1 Set Clamp Home Sensor 15 Plate 16 116 1234 00 1 Eject Clamp Home Sensor 17 116 1234 00 1 Decurler Cam Home Sensor 18 Bracket 19 Stopper Phaser 7700 Color Laser Printe
279. y operate the Set Clamp Solenoid see illustration in RRP 75 on page 11 334 or RRP 75 on page 11 334 Rotate the Set Clamp Shaft above the solenoid to enable manual operation of the Set Clamp Home Sensor and observe the display for toggling between H and L of the Set Clamp Home Sensor Does the display toggle between H amp L Yes No Remove the Board Cover RRP 72 on page 11 330 Measure the voltage between the Finisher Control Board P849 8 see figure page 2 46 and Finisher frame ground Rotate the Set Clamp Shaft above the solenoid to enable manual operation of the Set Clamp Home Sensor and observe the display for toggling between H and L of the Set Clamp Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at the Set Clamp Sensor pin 2 yellow and Finisher frame ground Rotate the Set Clamp Shaft above the solenoid to enable manual operation of the Set Clamp Home Sensor and observe the display for toggling between H and L of the Set Clamp Home Sensor Does the voltage toggle between 5 VDC and 0 VDC Yes No Measure the voltage at Set Clamp Sensor pin 1 gray Does the voltage measure 5 VDC Yes No Measure the voltage between the Finisher Control Board P849 9 see figure page 2 46 and Finisher frame ground Does the voltage measure 5 VDC Yes No Replace the Finisher Control Board RRP 77 on page 11 336 epair or replace the wiring harness between the

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